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Mitsubishi Lancer Evo 4 and Evo 5 1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo 5) Year: 1998 Codes Chassis Code Evo4: CN9A Chassis Code Evo5: CP9A 👋 Introduction Market Position Segment: Compact Performance...
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Mitsubishi Lancer Evo 4 and Evo 5 1998 Service Repair ManualMitsubishi Lancer Evo 4 and Evo 5 1998 Service Repair ManualMitsubishi Lancer Evo 4 and Evo 5 1998 Service Repair ManualMitsubishi Lancer Evo 4 and Evo 5 1998 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution V (Evo 5)
Year:
1998
Codes
Chassis Code Evo4:
CN9A
Chassis Code Evo5:
CP9A
👋 Introduction
Market Position
Segment:
Compact Performance Sedan / Rally Homologation Special
Competitors Era:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four
Competitive Analysis
Key Selling Points Evo4:
Advanced AWD system (AWC), Active Yaw Control (AYC), potent turbocharged engine, aggressive styling, rally heritage
Key Selling Points Evo5:
Refined styling, improved engine output, enhanced AYC, larger wheels and brakes, wider track, better aerodynamics compared to Evo 4.
Key Features
Performance Focus:
Designed for high-performance driving and motorsport homologation, prioritizing handling, power, and driver control.
Technology Integration:
Early adoption of advanced electronic aids like AYC for enhanced dynamic performance.
Manual Value Proposition
Target Audience:
Enthusiast owners, DIY mechanics, independent workshops specializing in performance Mitsubishi vehicles.
📋 Manual Details
Coverage Areas
Market:
Global (with specific regional variations noted where applicable)
Regions:
Japan, Europe, North America (specific to Lancer platform with Evo enhancements)
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (4G63T), fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
All-Wheel Drive (AWC) system, Active Yaw Control (AYC) system, differential systems (front, rear, center), transmission (manual gearbox)
Chassis:
Suspension (front MacPherson strut, rear multi-link), steering system, braking system (ABS, performance braking components)
Electrical:
Engine control unit (ECU) and related sensors, body control module, lighting systems, instrumentation, audio system, power accessories
Body:
Exterior body panels, interior trim, structural components, body sealing, glass replacement
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, belt inspection/replacement
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation, circuit testing
Repair:
Component disassembly and reassembly, component repair and replacement, major overhaul procedures
Installation:
New component installation, replacement parts installation, accessory fitting
Calibration:
AYC system calibration, sensor recalibration
Technical Depth
Depth:
Comprehensive: from basic fluid checks and adjustments to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
PDF Version:
Likely PDF 1.4 or higher, supporting searchable text and high-resolution images.
Print Quality
Image Resolution:
High-resolution (estimated 300 DPI or higher) for clear diagrams and illustrations.
Text Clarity:
Sharp and legible text, optimized for on-screen reading and printing.
Binding Type
Digital Binding:
N/A (Digital format)
Paper Type
Digital Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
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:
8.5:1 (typical)
Performance
Horsepower Evo4 Jdm:
280 PS (276 hp) @ 6500 rpm (JDM spec, often underestimated)
Torque Evo4 Jdm:
35.0 kg-m (253 lb-ft) @ 3000 rpm (JDM spec)
Horsepower Evo5:
280 PS (276 hp) @ 6500 rpm (JDM spec, slightly higher output through tuning/turbo)
Torque Evo5:
37.5 kg-m (271 lb-ft) @ 3000 rpm (JDM spec)
Fuel System
Fuel Type:
Unleaded Gasoline (premium/high octane recommended, 95 RON minimum)
Injection System:
Electronic Fuel Injection (EFI), Sequential Multi-Point Fuel Injection (MPI)
Turbocharger:
Mitsubishi TD05H-16G (common, variations exist)
Cooling System
Coolant Capacity:
Approximately 7.5 Liters
Lubrication System
Oil Capacity:
Approximately 4.5 Liters (with filter)
Recommended Oil Viscosity:
10W-30 or 10W-40 (refer to manual for specific climate and usage)
🔧 Transmission
Standard
Type Evo4:
5-Speed Manual Transaxle (F5M51-2)
Type Evo5:
5-Speed Manual Transaxle (F5M51-2, revised ratios/internals)
Optional
Automatic Availability:
Not available for Lancer Evolution models.
Features
All Wheel Drive:
Yes, advanced AWC (All-Wheel Control) system.
Center Differential:
Mechanical Limited-Slip Center Differential (Evo 4) / Active-lock Center Differential (Evo 5, computer controlled)
Rear Differential:
Mechanical Limited-Slip Differential (LSD)
Active Yaw Control:
Yes (AYC), a hydraulic differential system in the rear that can vector torque for improved cornering stability and turn-in.
Fluid Capacity
Manual Transmission Fluid Capacity:
Approximately 2.6 Liters
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 or GL-5 SAE 75W-90 Gear Oil (refer to manual for specific Mitsubishi recommendation)
Ayc Fluid Type:
Specific hydraulic fluid (refer to manual for part number/specification)
📐 Dimensions
Exterior
Length Evo4:
4350 mm
Length Evo5:
4375 mm
Width Evo4:
1770 mm
Width Evo5:
1770 mm
Height Evo4:
1415 mm
Height Evo5:
1415 mm
Wheelbase:
2600 mm
Track Width Front Evo4:
1500 mm
Track Width Front Evo5:
1515 mm
Track Width Rear Evo4:
1505 mm
Track Width Rear Evo5:
1510 mm
Weights
Curb Weight Evo4:
Approximately 1400 kg
Curb Weight Evo5:
Approximately 1410 kg
Gross Vehicle Weight:
Refer to vehicle placard
Towing Capacity:
Not specified/recommended
Wheels And Tires
Wheel Size Evo4:
16-inch (standard), 17-inch (optional/performance)
Wheel Size Evo5:
17-inch
Tire Size Evo4 Standard:
205/50R16
Tire Size Evo5:
215/45R17
Bolt Pattern:
5x114.3
🛡️ Safety Features
Ratings
Crash Test Ratings Era:
Limited official ratings available for this era and performance focus; JNCAP and Euro NCAP data may be sparse.
Active Features
All Wheel Drive:
Standard on all models, significantly enhancing traction and stability.
Active Yaw Control:
Standard on Evo 4 GSR and Evo 5, actively managing torque distribution to improve cornering grip and reduce understeer/oversteer.
Anti Lock Braking System:
ABS standard on most models, with performance-tuned calibration.
Limited Slip Differentials:
Front and Rear LSDs contribute to traction and controlled power delivery.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
3-point front and rear seatbelts with pre-tensioners (front).
Body Structure:
Reinforced chassis and safety cell designed for high-speed and rally conditions.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD player (model dependent), often with 4-6 speakers.
Display:
Basic digital or analog instrument cluster, possibly a small LCD for trip computer or warning lights.
Driver Assistance
Traction Control:
No dedicated electronic traction control system in the modern sense; AWC and LSDs provide the primary traction management.
Cruise Control:
Available on some models, but often omitted on pure performance variants.
Connectivity
Auxiliary Input:
Not present from the factory; aftermarket solutions are common.
Bluetooth:
Not available from the factory.
Performance Tech
Ayc Control:
Driver-selectable modes for AYC (e.g., Normal, Snow) might be present in some JDM variants, controlled via dash switch.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 5,000 - 7,500 km or 6 months (whichever comes first) for severe/performance use. Every 10,000 km or 12 months for normal use.
Air Filter Replacement:
Every 15,000 - 20,000 km or annually.
Fuel Filter Replacement:
Every 30,000 - 40,000 km.
Spark Plug Replacement:
Every 30,000 - 40,000 km (performance plugs). Inspect iridium plugs at 60,000 km.
Timing Belt Replacement:
Every 90,000 - 100,000 km or 5-7 years. Crucial due to interference engine design. Also replace tensioner and idler pulleys.
Coolant Flush And Replacement:
Every 2-3 years or 40,000 - 60,000 km.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (high-performance fluid recommended for spirited driving).
Power Steering Fluid:
Dexron II/III compatible ATF or specific Mitsubishi power steering fluid.
Clutch Fluid:
DOT 3 or DOT 4 (shared with brake system).
Known Issues
Engine Wear:
Piston ring wear, cylinder wall honing deterioration, rod bearing wear (especially with aggressive tuning or poor maintenance)."Sludge" buildup from infrequent oil changes.
Turbocharger:
Oil seal failure, bearing wear leading to smoking and reduced boost.
Ayc System:
Pump motor failure, leaks in hydraulic lines, sensor issues, control unit faults.
Suspension Components:
Wear in bushings, ball joints, and shock absorbers, particularly if driven hard.
Clutch:
Wear on clutch disc and pressure plate, especially under aggressive driving conditions.
Maintenance Tips
Engine Warm-Up:
Allow engine to warm up properly before applying significant throttle, especially in colder conditions.
Monitoring Fluids:
Regularly check and maintain all fluid levels (oil, coolant, brake, power steering, AYC). Use high-quality fluids.
Ignition System:
Ensure spark plugs, coils, and wires are in good condition for optimal performance and fuel economy.
📚 Vehicle History
Brand Heritage
Motorsport Foundation:
Mitsubishi's extensive success in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution series.
Model Evolution
Evo4 Introduction:
Introduced in August 1996, marked a significant leap in technology and performance over the Evo III, featuring a new chassis and the introduction of AYC.
Evo5 Introduction:
Launched in January 1998, the Evo V was a substantial update with a larger turbocharger, upgraded brakes, revised AYC, a wider body kit, and improved aerodynamics, directly homologating for WRC regulations.
Platform:
Based on the Mitsubishi Lancer (Cedia platform).
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Period Evo4:
August 1996 – August 1997
Production Period Evo5:
January 1998 – January 1999
🏆 Awards & Recognition
Recognitions
Rally Performance:
Numerous WRC class wins and championships during the era, cementing its 'legend' status.
Automotive Press Reviews:
Consistently praised by automotive journalists for its handling, grip, and raw performance, often outperforming cars with significantly higher price tags or engine power.
Ratings
Enthusiast Popularity:
Highly regarded within the automotive enthusiast community, considered a modern classic and a benchmark for performance sedans.
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