Mitsubishi Lancer Evo 6 1999-2001 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo 6) Production Years Covered: 1999-2001 Codes Chassis Code: CP9A 👋 Introduction Market Position Segment: Homologation Special / Performance Rally-Bred...

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标签: 1999 2000 2001 Car Cars Lancer Evo 6 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VI (Evo 6)

Production Years Covered:

1999-2001

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Homologation Special / Performance Rally-Bred Sedan

Reputation:

Iconic status in rallying (WRC) and enthusiast circles for its performance, handling, and raw driving experience.

Competitive Analysis

Key Competitors:

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

Key Features

Performance:

Advanced all-wheel-drive system, powerful turbocharged engine, sophisticated active differentials (AYC).

Design:

Aggressive styling, functional aerodynamics, lightweight construction.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primarily targeting markets where the Evo 6 was officially sold or imported)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

4G63T (2.0L DOHC MIVEC Turbocharged) - including diagnostics, overhaul, tuning, and emissions control

Transmission:

5-speed Manual (W5M51) and optional 6-speed Manual (Getrag 6-speed found in RS models), including clutch, gearbox overhaul, and drivetrain components

Suspension:

Front MacPherson strut with anti-roll bar, Rear multi-link independent suspension with anti-roll bar; includes damper, spring, bushing, and alignment specifications

Brakes:

Front and Rear ventilated disc brakes, ABS (Anti-lock Braking System) and AYC (Active Yaw Control) system diagnostics and repair

Steering:

Power-assisted rack and pinion, steering components, and related hydraulic systems

Electrical:

Full wiring diagrams, ECU (Engine Control Unit) and TCU (Transmission Control Unit) information, lighting, ignition system, charging system, starting system, instrumentation, and accessories

Body And Chassis:

Exterior panels, interior trim, doors, windows, bumpers, body repair, rust prevention, and structural integrity

Cooling System:

Radiator, fan, thermostat, water pump, and coolant specifications

Fuel System:

Fuel pump, injectors, fuel filter, fuel tank, and fuel pressure regulation

Exhaust System:

Manifold, catalytic converter, muffler, and pipework specifications

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair

Procedures Included

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, tune-ups, and inspections

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, error code interpretation

Repair And Overhaul:

Step-by-step procedures for complete engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement, and bodywork

Diagnostics:

Detailed procedures for using diagnostic tools, reading sensor data, and identifying fault sources

Specifications And Tolerances:

Precise measurements, clearances, torque specifications, and material requirements for all components

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and component-level repair.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for workshop use

Print Quality

Quality:

High-resolution scans for clear diagrams and text

Binding Type

Type:

N/A (Digital PDF format)

Paper Type

Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

Inline-4, DOHC, 16-valve, turbocharged, intercooled

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Valve Train:

MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system

Performance

Horsepower Ps Eu:

276 PS (272 bhp; 203 kW) @ 6500 rpm (JDM/European Spec)

Torque Nm Eu:

373 Nm (275 lb-ft) @ 3000 rpm (JDM/European Spec)

Turbocharger:

Mitsubishi TD05H-16G (or similar variant depending on specific market)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Bosch fuel injectors

Fuel Type:

Premium Unleaded (95 RON or higher recommended)

Engine Management

ECU Type:

ECU controlled ignition and fuel systems, specific model ECU part numbers can be found within the manual.

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (W5M51)

Optional

Type:

6-speed Manual Transmission (Getrag - typically on RS models)

Features

All Wheel Drive System:

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

Differentials:

Front Helical Limited-Slip Differential (LSD), Rear Helical Limited-Slip Differential (LSD) on some models, AYC controlled rear differential.

📐 Dimensions

Exterior

Length:

4350 mm (171.3 in)

Width:

1770 mm (69.7 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2635 mm (103.7 in)

Track Width Front:

1515 mm (59.6 in)

Track Width Rear:

1505 mm (59.3 in)

Weights

Curb Weight Kg:

Approx. 1360-1400 kg (2998-3086 lbs), varies by trim and specification.

Gross Weight Limit Kg:

Refer to vehicle VIN plate or manual for exact GVWR.

Interior

Seating Capacity:

Cargo

Trunk Volume Liters:

Approx. 430 liters (15.2 cu ft) - figures may vary.

🛡️ Safety Features

Ratings

Crash Test Data:

Specific official crash test ratings for this era may vary by region. Consult the manual for any chassis or safety structure reinforcement details.

Active Features

Standard Anti-lock Braking System (ABS)

Standard Active Yaw Control (AYC) system for enhanced cornering stability.

Advanced electronically controlled All-Wheel Drive system.

Passive Features

Airbags:

Driver and front passenger airbags standard.

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners for front occupants.

Body Construction:

Reinforced body structure for impact absorption.

💡 Technology Features

Infotainment

Audio System:

Factory fitted AM/FM stereo with cassette player and CD player (optional), typically 4-6 speakers. Aftermarket head unit compatibility is common.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Driver Assistance

Traction Control:

Integrated within the AWD and AYC systems, not a separate traction control button in the conventional sense.

Connectivity

Bluetooth:

Not available in factory specification for this model year.

Not available in factory specification for this model year.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 5,000 km or 6 months, whichever comes first (severe use). Consult manual for specific intervals based on driving conditions.

Air Filter Replacement:

Every 15,000 km or 12 months.

Spark Plug Replacement:

Every 30,000 km (Platinum tipped recommended).

Timing Belt Replacement:

Every 90,000 km or 5 years, whichever comes first. Crucial to follow this interval due to interference engine design.

Fluid Specifications

Engine Oil Type:

API SG, SH, or SJ; ILSAC GF-II or GF-III; Viscosity: 10W-30 or 10W-40 (refer to manual for temperature-specific recommendations).

Engine Oil Capacity Liters:

Approx. 4.5 L (with filter change)

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors).

Transmission Fluid Type 5Mt:

API GL-4 or GL-5; SAE 75W-90 (Manual Transmission fluid, check manual for specific Mitsubishi recommendation).

Transmission Fluid Capacity 5Mt Liters:

Approx. 2.3 L

Transfer Case Fluid Type:

API GL-5; SAE 75W-90 (Gear oil, consult manual for specific Mitsubishi recommendation).

Transfer Case Fluid Capacity Liters:

Approx. 0.7 L

Rear Differential Fluid Type:

API GL-5; SAE 75W-90 (Gear oil, consult manual for specific Mitsubishi recommendation).

Rear Differential Fluid Capacity Liters:

Approx. 1.4 L (standard rear diff), AYC models may differ. Consult manual.

Brake Fluid Type:

DOT 3 or DOT 4 (high-performance synthetic brake fluid recommended).

Power Steering Fluid Type:

ATF (Dexron II/III or equivalent) or specific Mitsubishi power steering fluid.

Known Issues

Engine Reliability:

Generally robust, but prone to issues if maintenance is neglected. Common concerns include head gasket failure (due to high boost), turbocharger wear, and fuel injector clogging.

Ayc System:

AYC pump and sensor failures can occur, leading to warning lights and loss of differential control. Regular fluid changes and system checks are advised.

Rust:

Can be susceptible to rust, particularly in the sills, wheel arches, and floor pans, especially in areas with road salt. Thorough inspections are vital.

Suspension Wear:

Bushings, ball joints, and dampers can wear over time, affecting handling and alignment. Performance-oriented driving can accelerate wear.

Electrical Gremlins:

Older wiring and connectors can develop issues, leading to intermittent problems with various systems.

📚 Vehicle History

Brand Heritage

Rally Success:

Direct lineage from Mitsubishi's highly successful World Rally Championship (WRC) campaigns.

Model Evolution

Previous Generation:

Evolution V (Evo 5)

Next Generation:

Evolution VII (Evo 7)

E6 Updates:

Wider track, improved aerodynamics (larger rear spoiler, front bumper vents), revised suspension geometry, lighter engine components, enhanced AYC system.

Production

Production Period:

1999-2001

Manufacturing Plant:

Mizushima Plant, Kurashiki, Japan

Special Editions:

Tommi Makinen Edition (TME) - a highly sought-after variant with specific mechanical and cosmetic upgrades.

🏆 Awards & Recognition

Recognitions

Rally Titles:

Significant role in Mitsubishi's multiple WRC Manufacturers' and Drivers' Championships.

Enthusiast Awards:

Consistently ranked highly by automotive journalists and enthusiasts for its driving dynamics and performance capabilities.