Mitsubishi Lancer Evolution 4 1996-1998 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Generation Designation: CN9A / CP9A Years Covered: 1996, 1997, 1998 Codes Chassis Code: CN9A (Sedan), CP9A (RS) Engine Code Primary:...

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类型: Car

斯库: 466204

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

Generation Designation:

CN9A / CP9A

Years Covered:

1996, 1997, 1998

Codes

Chassis Code:

CN9A (Sedan), CP9A (RS)

Engine Code Primary:

4G63T

👋 Introduction

Market Position

Vehicle Segment:

Performance Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, tuners, motorsport competitors, and owners seeking in-depth maintenance knowledge.

Competitive Analysis

Key Rivals:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Audi S2 Quattro.

Key Features

Performance Focus:

The Evo IV is renowned for its rally heritage and advanced performance technologies.

Technological Advancement:

Introduction of Active Yaw Control (AYC) significantly enhanced handling dynamics.

Manual Value Proposition

Dealership Alternative:

Provides comprehensive information typically only available to authorized service centers.

Enthusiast Resource:

Indispensable for owners looking to maintain, modify, or restore their vehicles.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Over 1000 pages (typical for this era of comprehensive manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Yes, full overhaul, component diagnostics, timing belt, piston/ring/valve service, lubrication system.

Engine Management:

Yes, ECU diagnosis, sensor testing, fuel injection, ignition system, emissions controls.

Transmission Manual:

Yes, servicing, clutch replacement, gearbox overhaul, component specifications.

Transmission Automatic:

Not applicable for standard Evo IV models, but if an automatic was an option, it would be covered.

Drivetrain Awc:

Yes, Active Yaw Control (AYC) system diagnostics, servicing, and calibration.

Suspension:

Yes, front and rear suspension components, geometry, component replacement, shock absorber/strut service.

Steering:

Yes, power steering system diagnosis and repair, steering rack service.

Brakes:

Yes, front and rear brake systems, ABS operation and diagnosis, hydraulic components, pad/rotor replacement.

Electrical System:

Yes, complete wiring diagrams, component testing, battery, charging system, lighting, accessories.

Body And Chassis:

Yes, body panel alignment, door/hood/trunk servicing, interior trim removal, chassis integrity.

Climate Control:

Yes, HVAC system diagnosis and repair, refrigerant handling, component replacement.

Procedures Included

Scheduled Maintenance:

Yes, detailed maintenance intervals and procedures.

Troubleshooting:

Yes, extensive diagnostic flowcharts and symptom-based troubleshooting.

Component Replacement:

Yes, step-by-step guides for all major components.

Engine Rebuild:

Yes, complete engine overhaul procedures, torque specifications, assembly sequences.

Transmission Rebuild:

Yes, detailed steps for manual gearbox disassembly and reassembly.

Body Repair:

Yes, basic bodywork procedures, panel removal and installation.

Electrical Diagnostics:

Yes, using wiring diagrams for fault finding.

Specifications Data:

Yes, all necessary technical data, torque values, clearances, etc.

Technical Depth

Depth Level:

Comprehensive - from basic maintenance to full engine/transmission rebuilds and advanced diagnostics.

Diagnostic Tools:

Covers procedures that may require specialized tools like timing gauges, compression testers, and diagnostic scan tools (though OBD-I/II specifics may vary).

Esoteric Procedures:

Includes specialized procedures for AYC system, performance tuning considerations, and specific Evo IV upgrades.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Typically searchable text within the PDF, allowing for quick keyword lookup.

Printability:

Designed to be printable for workshop use.

Print Quality

Image Resolution:

High-resolution scans ensuring clear diagrams and illustrations.

Binding Type

Physical Equivalent:

Likely spiral-bound or similar for lay-flat workshop use if it were a physical copy.

Paper Type

Physical Equivalent:

Heavy-duty, durable paper stock suitable for workshop environments if printed.

⚙️ Engine Specifications

Primary Engine

Engine Family:

4G63T (DOHC Turbocharged Inline-4)

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Ps:

280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese domestic market) - often underrated.

Torque Nm:

350 Nm (258 lb-ft) at 3,000 rpm (Japanese domestic market)

Turbocharger:

Mitsubishi TD05HR-16G (upgraded from previous generations)

Compression Ratio:

8.8:1

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI), Electronic Fuel Control System (EFIC)

Fuel Type:

Unleaded Gasoline (RON 98 recommended for optimal performance)

Engine Oil Specification:

API SG/SH or ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for specific viscosity by climate).

Engine Oil Capacity:

4.5 Liters (4.8 US quarts) with filter change.

Valvetrain

Timing Belt Part Number:

MB961764 (example, verify with specific VIN)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Type-R 'R' variant likely had specific gearbox codes)

Optional

Automatic Option:

Not available for Evolution models.

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Yaw Control (AYC) and viscous coupling center differential.

Front Differential:

Helical Limited-Slip Differential (LSD)

Rear Differential:

Active Yaw Control (AYC) electronically controlled differential.

Manual Transmission Fluid Spec:

API GL-4 or GL-5, SAE 75W-90 (verify specific requirements for AYC differential if separate fluid).

Clutch Type:

Hydraulically operated, single dry plate clutch.

📐 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)

Track Width Front:

1,495 mm (58.9 in)

Track Width Rear:

1,490 mm (58.7 in)

Ground Clearance:

145 mm (5.7 in)

Wheel Bolt Pattern:

5x114.3 (5x4.5 inches)

Wheel Size Standard:

17 x 7.5 inches

Tire Size Standard:

225/45R17

Weights

Curb Weight:

Approx. 1,360 kg (2,998 lbs) - varies by trim (RS lighter)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not extensively tested by modern agencies like NHTSA/Euro NCAP; relied on robust chassis design and driver skill.

Active Features

AWD System:

Advanced All-Wheel Drive with AYC for enhanced traction and cornering stability.

Standard Anti-lock Braking System (ABS) with electronic brake-force distribution (EBD).

Brakes Front:

Ventilated Disc Brakes (larger on RS model)

Brakes Rear:

Solid Disc Brakes

Passive Features

Airbags:

Driver's airbag standard; passenger airbag optional or standard depending on market and year.

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners.

Chassis Structure:

Reinforced chassis and body structure for rigidity and impact protection, derived from rally car design.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM Radio with CD player or Cassette deck, 4-6 speaker system.

Gauges:

Comprehensive gauge cluster including boost gauge, oil pressure gauge, and AYC status indicator.

Driver Assistance

Ayc System:

Active Yaw Control is the primary driver assistance system, actively managing torque distribution to rear wheels for improved cornering. This is a key technological differentiator.

Connectivity

Connectivity Options:

Limited to basic audio system connectivity; no modern Bluetooth or USB integration natively.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Timing Belt Replacement:

Every 100,000 km (60,000 miles) or 5 years. Crucial for 4G63T engines to prevent catastrophic failure.

Spark Plug Replacement:

Typically every 30,000 - 40,000 km (20,000 - 25,000 miles), depending on plug type (e.g., iridium recommended).

Transmission Fluid Change:

Every 40,000 - 60,000 km (25,000 - 40,000 miles), or more frequently if used for track or spirited driving.

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant) mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (DOT 4 recommended for better performance).

Power Steering Fluid:

Dexron-III ATF or equivalent power steering fluid.

Known Issues

Engine Oil Sludge:

Risk of oil sludge buildup due to high operating temperatures and oil degradation if maintenance is neglected.

Ayc Pump Failure:

The AYC hydraulic pump can be a point of failure over time, leading to loss of AYC functionality. Requires specialized diagnosis and potentially replacement.

Turbocharger Wear:

Wear and tear on the turbocharger seals and bearings is common with age and high-performance use.

Clutch Wear:

Clutch wear is accelerated by aggressive driving; replacement is a common maintenance item.

Rust Corrosion:

Typical for vehicles of this age, particularly in areas prone to road salt and moisture. Check wheel wells, sills, and underbody.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi's extensive WRC (World Rally Championship) success directly informed the development of the Lancer Evolution series.

Model Evolution

Evolution Series Origin:

The Lancer Evolution IV built upon the foundation of its predecessors, further refining the performance, handling, and technological integration.

Key Innovations In Iv:

Introduction of Active Yaw Control (AYC) and a significantly revised chassis (CN9A platform).

Evolution Iv Variants:

GSR (standard road version) and RS (rally-focused, lighter, basic interior).

Production

Production Period:

August 1996 - December 1997

Manufacturing Location:

Mizushima, Kurashiki, Okayama, Japan

Total Units Produced:

Approximately 6,000 units (GSR and RS combined).

🏆 Awards & Recognition

Recognitions

Motorsport Dominance:

While specific 'awards' are less applicable to a workshop manual, the vehicle itself was a dominant force in rally championships during its era.

Performance Acclaim:

Consistently lauded by automotive publications for its handling, performance, and driver engagement.