Mitsubishi Lancer Evolution 4 1996-1998 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV (Evo IV) Generation Code: CN9A Codes Chassis Code: CN9A Engine Code: 4G63T (DOHC Turbocharged) 👋 Introduction Market Position Positioning: A...

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类型: Car

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标签: 1996 1997 1998 Car Cars Lancer Evolution 4 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IV (Evo IV)

Generation Code:

Codes

Chassis Code:

Engine Code:

4G63T (DOHC Turbocharged)

👋 Introduction

Market Position

Positioning:

A homologation special built for rally racing, offering exceptional performance and handling in a road-legal package. Known as a driver's car.

Competitive Analysis

Competitors:

Subaru Impreza WRX STi, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione

Key Features

Performance Enhancements:

Aggressive styling, powerful turbocharged engine, advanced all-wheel-drive system with Active Yaw Control (AYC), upgraded suspension and brakes

📋 Manual Details

Coverage Areas

Model Years Covered:

1996, 1997, 1998

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Full Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, searchable)

File Format:

Likely PDF, optimized for digital viewing and printing

Searchability:

Typically features searchable text for quick access to information

Print Quality:

High-resolution for clear diagrams and text

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, component testing, timing belt replacement, turbocharger service, cooling system, lubrication system

Engine Management Electronic:

ECU diagnosis, sensor testing (MAP, TPS, IAT, Knock, O2), fuel injection system, ignition system, emissions control

Transmission Manual:

Clutch system, gearbox overhaul, gear shift mechanism, lubrication, flywheel replacement

Transmission AWD:

Active Yaw Control (AYC) system diagnosis and calibration, transfer case, center differential, rear differential

Drivetrain:

Driveshafts, CV joints, wheel hubs, axle components

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, strut tower braces

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Front and rear brake systems, ABS operation and diagnosis, brake fluid, caliper service, rotor replacement, brake lines

Electrical System:

Battery, charging system, starter, lighting, horn, wipers, power windows, mirrors, fuses, relays, wiring diagrams

Body And Chassis:

Body panel alignment, door mechanisms, interior trim, chassis components, rust prevention, body repair techniques

Climate Control:

HVAC system diagnosis, refrigerant, compressor, heater core, A/C system service

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake inspections, tire rotation

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides for all major systems

Repair Procedures:

Step-by-step instructions for engine, transmission, suspension, brake, electrical, and body component repair and replacement

Diagnostics:

Detailed diagnostic procedures for electronic control units (ECUs), sensors, actuators, and mechanical systems

Wiring Diagrams:

Comprehensive electrical wiring schematics for all vehicle systems

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including complex electronic diagnostics and AYC system calibration

⚙️ Engine Specifications

Primary Engine

Engine Type:

2.0L Inline-4 DOHC 16-valve Turbocharged (4G63T)

Performance

Horsepower:

280 PS (276 hp; 206 kW) at 6,500 rpm (JDM Spec)

Torque:

350 Nm (258 lb-ft) at 3,000 rpm (JDM Spec)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection

Turbocharger:

Mitsubishi TD05HR-16G twin-scroll turbocharger with intercooler

Cooling System

Coolant Type:

Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant, or equivalent)

Lubrication System

Oil Type:

SAE 10W-30 or 10W-40 API SG or higher (e.g., Mitsubishi DiaQueen ECO-Action SAE 10W-30)

Oil Capacity:

Approx. 4.5 Liters (4.8 US Quarts) with filter

Engine Management

Ignition System:

Distributorless ignition system (DIS) with individual ignition coils

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (F5M51)

Optional

Type:

N/A (Manual transmission was standard for Evo IV)

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Yaw Control (AYC)

Ayc System:

Hydraulically controlled differential for torque vectoring to the rear wheels

Lubrication

Gearbox Oil Type:

API GL-4 or GL-5, SAE 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil 75W-90)

Transfer Case Oil Type:

API GL-4 or GL-5, SAE 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil 75W-90)

Ayc Oil Type:

Special AYC fluid, consult manual for specific type (often a high-viscosity hydraulic fluid)

📐 Dimensions

Exterior

Length:

4,350 mm (171.3 in)

Width:

1,770 mm (69.7 in)

Height:

1,415 mm (55.7 in)

Wheelbase:

2,600 mm (102.4 in)

Weights

Curb Weight:

Approx. 1,450 kg (3,197 lbs)

Gross Vehicle Weight:

N/A (Not typically specified in manuals of this era)

Wheels And Tires

Standard Tire Size:

205/50R16

Wheel Bolt Pattern:

5x114.3 (5x4.5 inches)

Standard Wheel Size:

16x7.0 inches

🛡️ Safety Features

Ratings

NHTSA Rating:

N/A (Vehicle not designed to meet modern US safety standards)

Ancap Rating:

N/A (Vehicle not officially tested by ANCAP)

Active Features

Standard Anti-lock Braking System (ABS)

Active Yaw Control (AYC) for enhanced cornering stability

Passive Features

Airbags:

Driver's airbag standard (Passenger airbag optional or unavailable depending on market)

Seatbelts:

3-point front seatbelts with pre-tensioners, 3-point rear seatbelts

Chassis Reinforcement:

Reinforced chassis structure for increased rigidity and crash protection

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM stereo with cassette player and CD compatibility (optional or market dependent). Aftermarket head units are common upgrades.

Driver Assistance

Electronic Features:

ABS, Active Yaw Control (AYC), performance-oriented AWD system.

Connectivity

Connectivity Options:

N/A (No factory Bluetooth or USB connectivity in this era)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under strenuous driving conditions.

Air Filter Replacement:

Every 15,000 km (9,000 miles) or annually.

Spark Plug Replacement:

Every 30,000 km (18,000 miles).

Timing Belt Replacement:

Every 100,000 km (60,000 miles) or 5 years, whichever comes first.

Brake Fluid Change:

Every 2 years or 30,000 km (18,000 miles).

Coolant Flush:

Every 2 years or 40,000 km (24,000 miles).

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

Dexron-II or equivalent automatic transmission fluid (ATF)

Known Issues

Engine Reliability:

Robust 4G63T engine, but prone to ring land failure if consistently overheated or run with poor fuel quality. Regular maintenance is critical.

Ayc System Reliability:

AYC pump and sensors can be prone to failure over time, leading to loss of functionality. Proper fluid changes and diagnostics are key.

Turbocharger:

The TD05HR turbo is robust but requires proper warm-up and cool-down procedures to prevent premature wear. Oil starvation can cause significant damage.

Clutch Wear:

Due to the performance nature of the car, clutches can wear faster than average, especially with spirited driving.

Suspension Bushings:

Rubber suspension bushings can degrade over time, affecting handling and ride quality.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi's strong rally heritage, leading to the development of the Lancer Evolution series for WRC homologation.

Model Evolution

Introduction Of Evo Iv:

Introduced in August 1996, featuring a significant redesign over the Evo III, including a longer wheelbase and the introduction of Active Yaw Control (AYC).

Production

Production Years:

1996 - 1998

Production Location:

Japan

Production Volumes:

Limited production, highly sought after by enthusiasts. Exact figures vary, but generally in the tens of thousands.

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Consistently praised in automotive press for its handling, grip, and rally-bred performance. Considered an icon of the 1990s performance car era.

Ratings

Rally Homologation:

Specifically developed to meet World Rally Championship (WRC) homologation requirements.