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Mitsubishi Evo 6 1999-2001 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo 6) Model Code: CP9A Production Years Covered: 1999-2001 Codes Chassis Code: CP9A Engine Code Primary: 4G63T 👋 Introduction Market...
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Mitsubishi Evo 6 1999-2001 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI (Evo 6)
Model Code:
CP9A
Production Years Covered:
1999-2001
Codes
Chassis Code:
CP9A
Engine Code Primary:
4G63T
👋 Introduction
Market Position
Vehicle Class:
Compact Sports Sedan / Rally Homologation Special
Positioning Statement:
The Mitsubishi Lancer Evolution VI (Evo 6) represented the pinnacle of performance and rallying technology for its era, offering a potent blend of turbocharged power, advanced all-wheel-drive grip, and sophisticated mechanicals. This manual provides the essential technical documentation for maintaining and repairing this iconic performance machine.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Audi S3 (8L), Lancia Delta Integrale Evoluzione
Key Features
Performance Enhancements:
Wider bodywork, larger intercooler, revised turbocharger (larger compressor wheel), improved cooling system, revised suspension geometry compared to Evo V.
Rally Heritage:
Developed for World Rally Championship (WRC) homologation, benefiting from extensive motorsport experience.
All Wheel Drive System:
Advanced Mitsubishi All-Wheel Control (AWC) system, including Active Yaw Control (AYC) and Super Active Yaw Control (S-AYC) on some variants, providing exceptional traction and handling.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
PDF
Primary Focus:
Repair and Overhaul
Target Audience:
Professional Technicians and Advanced DIY Enthusiasts
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (Transfer Case, Differentials)
Chassis:
Suspension (Front & Rear), Steering, Brakes (Hydraulic, ABS), Wheels & Tires
Electrical:
Battery, Charging System, Starting System, Lighting, Instrumentation, Wiper/Washer, Audio, Air Conditioning Controls, ECU/ECM and associated sensors/actuators
Body:
Exterior Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Seats
Procedures Included
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication
Diagnostics:
Troubleshooting guides, fault code interpretation, symptom-based diagnostics
Repair:
Component removal, installation, overhaul, adjustment, replacement
Rebuilding:
Engine rebuild procedures, transmission overhaul, differential rebuild
Specifications:
Torque specifications, clearances, fluid capacities, electrical schematics
Technical Depth
Depth Level:
Comprehensive: Covers everything from basic fluid changes to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality:
High-resolution scans, suitable for printing individual pages or sections
Binding Type
Digital Binding:
N/A (Digital File)
Paper Type
Digital Paper Type:
N/A (Digital File)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Ps:
280 PS (276 bhp / 206 kW) at 6500 rpm (JDM Spec), higher in some export markets
Torque Nm:
373 Nm (275 lb-ft) at 3000 rpm (JDM Spec)
Redline:
7500 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Premium Unleaded Gasoline (95 RON or higher recommended)
Turbocharger:
Mitsubishi TD05H-16G or similar variant with larger compressor wheel than Evo V
Intercooler:
Large Front-Mount Intercooler (FMIC)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (Getrag-derived, specific Mitsubishi version)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (less common, not performance-oriented)
Features
Clutch Type:
Hydraulic, single-plate, dry
Gear Ratios Manual:
Specific ratios detailed in manual, typically close-ratio for sporty driving.
All Wheel Drive System:
Mitsubishi All-Wheel Control (AWC): Full-time 4WD with Active Yaw Control (AYC) and driver-selectable modes (Tarmac, Gravel, Snow).
Center Differential:
Helical gear type LSD
Front Differential:
Helical gear type LSD
Rear Differential:
Active Yaw Control (AYC) integrated, electronically controlled viscous coupling LSD on earlier versions, hydraulic AYC on later/specific models.
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Front Track:
1510 mm (59.4 in)
Rear Track:
1500 mm (59.1 in)
Weights
Curb Weight:
Approx. 1400 kg (3086 lbs) depending on specification
Gross Vehicle Weight Rating:
Information typically found in VIN plate or owners manual, not standard spec.
Cargo
Trunk Volume:
Limited due to drivetrain components, specific capacity not widely published but approximately 0.3 cubic meters.
🛡️ Safety Features
Ratings
Jnc Ap Safety Rating:
Not officially tested or rated by major agencies like NHTSA or Euro NCAP during its production era for most markets.
Active Features
ABS:
Standard, often with electronic brake-force distribution (EBD)
Traction Control:
Integrated with AWC system and engine management
Awc System:
Active Yaw Control (AYC) / Super Active Yaw Control (S-AYC) for enhanced stability and cornering.
Passive Features
Airbags:
Driver and front passenger airbags standard
Seatbelts:
3-point ELR seatbelts with pretensioners
Chassis Reinforcement:
Rigid body structure with integrated roll cage elements for rally homologation.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM/CD player or cassette player with basic speaker system. Often upgraded by owners.
Display:
Basic digital or analog displays for climate control, clock, and trip computer.
Driver Assistance
ABS:
Standard Anti-lock Braking System.
Ayc S Ayc:
Active Yaw Control (AYC) and Super Active Yaw Control (S-AYC) systems for dynamic torque vectoring and enhanced handling.
Connectivity
Original Connectivity:
Limited to basic audio and communication features. No factory integrated smartphone connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 4,500 miles) or 6 months, whichever comes first, depending on driving conditions. Frequent hard driving may require shorter intervals.
Air Filter Replacement:
Every 15,000 - 30,000 km (9,000 - 18,000 miles)
Spark Plug Replacement:
Every 30,000 - 60,000 km (18,000 - 36,000 miles) depending on plug type (e.g., iridium recommended).
Timing Belt Replacement:
Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 7 years. Critical component; failure leads to severe engine damage.
Transmission Fluid Change:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) for manual and automatic transmissions.
Coolant Replacement:
Every 2 years or 40,000 km (25,000 miles)
Fluid Specifications
Engine Oil Type:
API SG, SH, or SJ; SAE 10W-40 or 15W-40 recommended for general use. Consider synthetic 5W-40 or 10W-50 for high-performance driving.
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change.
Transmission Fluid Type Manual:
API GL-4 SAE 75W-90 or 75W-85 Synthetic Gear Oil.
Transmission Fluid Type Automatic:
DIAQueen ATF-SP II M or equivalent.
Transfer Case Fluid Type:
API GL-5 SAE 75W-90 Hypoid Gear Oil.
Rear Differential Fluid Type:
API GL-5 SAE 75W-90 Hypoid Gear Oil (for standard LSD). Specific fluid for AYC system needs to be confirmed in manual.
Coolant Type:
Mitsubishi Super Long Life Coolant (Green) or equivalent ethylene glycol based coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4, high-temperature brake fluid.
Known Issues
Engine Issues:
Rod bearing failure at high mileage or under abuse, turbocharger wear, coolant hose degradation, piston ring wear leading to oil consumption.
Transmission Issues:
Wear in synchros, clutch wear, differential issues (especially AYC system reliability over time).
Electrical Issues:
Corrosion on connectors, sensor failures (e.g., crank/cam sensors), intermittent issues with power windows or central locking due to age.
Body Issues:
Rust formation in common areas (wheel arches, sills), paint delamination, interior trim wear.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Rally History:
Mitsubishi has a rich history in motorsports, particularly in the World Rally Championship (WRC), where the Lancer Evolution series achieved significant success.
Model Evolution
Evolution Series Origin:
The Lancer Evolution was conceived to homologate Mitsubishi's rally cars for WRC competition, beginning with the Evo I in 1992.
Evo 6 Development:
The Evo VI (CP9A) was introduced in October 1999, building upon the foundation of the Evo V with numerous enhancements focused on cooling, engine durability, and improved aerodynamics, particularly for rally use.
Special Editions:
Notably includes the Tommi Makinen Edition (Evo VI TME), commemorating Tommi Makinen's WRC titles, featuring unique styling, suspension, and engine tuning.
Production
Production Period:
1999-2001
Manufacturing Location:
Japan
Global Availability:
Primarily Japan, but officially and unofficially exported to various markets worldwide (e.g., UK, Australia, Europe).
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
The Evo VI and its variants achieved significant success in WRC, including multiple driver and manufacturer championships, solidifying its legendary status.
Performance Reviews:
Consistently praised by automotive journalists for its exceptional handling, braking, and all-wheel-drive capabilities.
Ratings
Enthusiast Recognition:
Widely considered one of the greatest performance cars of its era by enthusiasts and tuners.
Certifications
Homologation:
Built to meet FIA homologation standards for Group A rallying.
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