Mitsubishi Lancer Evo 4 & 5 1996-1999 Factory Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation Codes: Evo IV (CN9A), Evo V (CP9A) Model Years Covered: 1996, 1997, 1998, 1999 👋 Introduction Market Position Segment: Performance...

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类型: Car

斯库: 69859

标签: 1996 1997 1998 1999 Car Cars Lancer Evo 4 Lancer Evo 5 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Generation Codes:

Evo IV (CN9A), Evo V (CP9A)

Model Years Covered:

1996, 1997, 1998, 1999

👋 Introduction

Market Position

Segment:

Performance Sedan / Rally homologation special

Reputation:

Legendary for its rally-bred performance, advanced all-wheel-drive systems, and potent turbocharged engines

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four

Key Features

Drivetrain Technology:

Advanced four-wheel-drive systems (AYC/ACD) for exceptional traction and handling

Engine Technology:

High-performance turbocharged and intercooled inline-4 engines

Aerodynamics:

Aggressive styling with functional aerodynamic aids like large rear spoilers and front splitters

Interior Features:

Driver-focused cockpit with performance-oriented seating and instrumentation

📋 Manual Details

Coverage Areas

Primary Focus:

Comprehensive service, repair, and maintenance

Target Audience:

Professional technicians and experienced DIY enthusiasts

Page Count

Estimated Pages:

Hundreds (exact count varies by specific version, typically 1000+ pages for complete factory manuals)

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, engine fuel system, engine cooling, engine lubrication, ignition system, emissions control, engine electrical (ECU, sensors)

Drivetrain:

Manual transmission, transfer case, front axle, rear axle, drive shafts, differentials (front, center, rear AYC/ACD)

Suspension Steering:

Front suspension, rear suspension, steering system, power steering

Brakes:

Front brakes (calipers, discs), rear brakes (calipers, discs), ABS system, parking brake

Electrical:

Battery, charging system, starting system, lighting, instruments, gauges, horn, wipers, washers, power windows, power locks, audio system, climate control, body control modules (BCM)

Body Chassis:

Body panels, doors, hoods, trunk, interior trim, chassis components, frame

HVAC:

Heating, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant system)

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt inspections/replacement

Repair Rebuild:

Engine overhaul, transmission rebuild, differential service, suspension component replacement, brake caliper/rotor replacement, electrical component diagnosis and repair

Diagnostics:

Troubleshooting guides, symptom-based diagnosis, diagnostic trouble codes (DTCs), wiring diagrams, electrical schematics

Adjustments:

Valve clearance adjustment, ignition timing, clutch adjustment, brake adjustments

Specifications:

Torque specifications, clearances, tolerances, fluid capacities, electrical specifications

Technical Depth

Depth:

Complete factory-level repair and overhaul procedures, including detailed disassembly, assembly, and testing

Diagnostic Tools:

Information on using specialized diagnostic tools and scan tools for electronic systems

📊 Manual Specifications

File Format

Format:

Portable Document Format (PDF)

Searchability:

Likely text-searchable PDF for efficient information retrieval

Print Quality

Quality:

Designed for clear reproduction, including detailed diagrams and schematics

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Evo4:

4G63T (DOHC, 16-valve, Turbocharged Inline-4)

Engine Code Evo5:

4G63T (DOHC, 16-valve, Turbocharged Inline-4, often with larger turbo and improved intercooler over Evo IV)

Performance Evo4

Displacement Evo4:

1997 cc (2.0 Liters)

Horsepower Evo4 Jdm:

280 PS (276 hp) @ 6500 rpm (Often underestimated, real output higher)

Torque Evo4 Jdm:

352 Nm (260 lb-ft) @ 3000 rpm

Performance Evo5

Displacement Evo5:

1997 cc (2.0 Liters)

Horsepower Evo5 Jdm:

280 PS (276 hp) @ 6500 rpm (Often underestimated, real output higher)

Torque Evo5 Jdm:

373 Nm (275 lb-ft) @ 3000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Turbocharger:

Mitsubishi TD05HR-16G twin-scroll turbocharger with intercooler

Engine Management

Electronic Control Unit (ECU) with specific tuning for performance

🔧 Transmission

Standard

Type:

5-speed manual transmission

Optional

Type:

No automatic transmission offered for these performance models

Features

Drivetrain Type:

All-Wheel Drive (AWD)

Active Center Differential:

Active Center Differential (ACD) - Evo V standard, Evo IV optional/later production

Active Yaw Control (AYC) - Standard on Evo V, optional on Evo IV

Gear Ratios

Gear Ratios:

Specific gear ratios for performance driving (details in manual)

📐 Dimensions

Exterior Evo4

Length Evo4:

4345 mm (171.1 in)

Width Evo4:

1770 mm (69.7 in)

Height Evo4:

1415 mm (55.7 in)

Exterior Evo5

Length Evo5:

4350 mm (171.3 in)

Width Evo5:

1770 mm (69.7 in)

Height Evo5:

1415 mm (55.7 in)

Weights

Curb Weight:

Approx. 1370-1400 kg (3020-3086 lbs) depending on trim and options

Wheelbase

Wheelbase:

2600 mm (102.4 in)

Track Width

Front Track Evo5:

1500 mm (59.1 in)

Rear Track Evo5:

1490 mm (58.7 in)

Wheels Tires

Wheel Size Evo4:

15-inch (standard), 16-inch (optional/GSR)

Wheel Size Evo5:

17-inch

Tire Size Evo5:

215/45R17

Bolt Pattern:

5x114.3 (5x4.5 inch)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited specific safety rating data publicly available for these homologation specials from that era, focus on structural integrity for motorsport.

Active Features

Anti-lock Braking System (ABS) - Standard

AWD Traction Control:

Advanced AWD system with ACD and AYC for enhanced traction and stability

Passive Features

Airbags:

Driver and front passenger airbags (standard)

Seatbelts:

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

Chassis Structure:

Reinforced chassis and safety cage design for structural rigidity and occupant protection

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette player with speakers (CD players became more common later)

Climate Control:

Manual or automatic climate control systems depending on trim level

Driver Assistance

Traction Control:

Not typically electronic traction control in the modern sense, but the AWD, AYC, and ACD systems are key electronic driver aids for performance.

Connectivity

Connectivity Options:

No modern connectivity features like Bluetooth or USB ports

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 km (4,660 miles) or 6 months, whichever comes first (severe driving conditions may require more frequent changes)

Air Filter:

Inspect every 15,000 km (9,320 miles), replace as needed or every 30,000 km (18,640 miles)

Spark Plugs:

Replace every 60,000 km (37,280 miles) (use recommended iridium or platinum plugs)

Coolant Flush:

Every 45,000 km (27,960 miles) or 2 years

Timing Belt:

Replace every 90,000 km (55,920 miles) or 5 years. Crucial for the 4G63 engine.

Fluid Specifications

Engine Oil:

API SG or SH, SAE 10W-30 or 10W-40 (synthetic recommended for high performance)

Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (manual transmission, specific Mitsubishi fluid recommended for ACD/AYC units)

Coolant:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent (Ethylene Glycol based with de-ionized water, 50/50 mix)

Brake Fluid:

DOT 3 or DOT 4

Known Issues

Engine Wear:

Piston ring wear, connecting rod issues (especially with aggressive tuning or abuse), turbocharger wear, head gasket failures under high boost.

AWD System:

AYC/ACD pump failure, differential wear if fluid maintenance is neglected.

Suspect Area:

Radiator failure, exhaust system corrosion, front suspension bushings.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi has a rich heritage in rallying, with the Lancer Evolution series being a direct descendant of their WRC (World Rally Championship) efforts.

Model Evolution

Evolution Iv Introduction:

Introduced in August 1996, featuring a revised ECU, improved turbocharger, and a more advanced AYC system.

Evolution V Introduction:

Introduced in January 1998, with significant mechanical updates including wider track, larger brakes, new wheels, improved ACD, and a redesigned front bumper for better airflow.

Production

Production Period:

1996-1999

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Rally Homologation:

Developed specifically to meet World Rally Championship (WRC) homologation requirements, earning it a legendary status.

Performance Acclaim:

Widely praised by automotive journalists and enthusiasts for its driving dynamics, acceleration, and handling capabilities.