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Mitsubishi Evolution X Evo 10 2010 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution X (Evo 10) Year: 2010 Codes Chassis Code: CZ4A Engine Code Prefix: 4B1 👋 Introduction Market Position Vehicle Segment: Compact Sports...
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Mitsubishi Evolution X Evo 10 2010 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution X (Evo 10)
Year:
2010
Codes
Chassis Code:
CZ4A
Engine Code Prefix:
4B1
👋 Introduction
Market Position
Vehicle Segment:
Compact Sports Sedan / Rally Homologation Special
Target Demographic:
Enthusiast drivers, performance car buyers, rally sport fans
Competitive Analysis
Key Competitors:
Subaru WRX STI, Mitsubishi Lancer Ralliart (lesser performance), Ford Focus RS (later generations), VW Golf R
Key Features
Performance Attributes:
All-wheel drive, turbocharged engine, sophisticated suspension and drivetrain management systems (ACD, AYC, S-AYC), powerful braking system
Rally Heritage:
Direct lineage from Mitsubishi's WRC (World Rally Championship) winning Lancer Evolution models
Handling Dynamics:
Renowned for exceptional grip, agility, and driver feedback
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
PDF Download
Page Count Estimate:
2000+ Pages (typical for comprehensive factory manuals)
Target Audience:
Professional Technicians, Advanced DIY Enthusiasts
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Disassembly, inspection, assembly, torque specifications, timing, lubrication, cooling system, turbocharger system
Engine Management And Emissions:
ECM, sensors (O2, MAP, MAF, etc.), actuators, fuel injection, ignition system, evaporative emission control (EVAP), EGR, OBD-II diagnostics
Transmission Manual:
Gears, clutch, synchronizers, shift forks, lubrication, overhaul, troubleshooting (e.g., Getrag 6-speed)
Transmission Automatic Or Dct:
SST (Super-Sport Transmission) details, mechatronics, torque converter, hydraulic control, programming, fluid specifications
Drivetrain And Axles:
Front and rear differentials, ACD (Active Center Differential), AYC (Active Yaw Control) system, driveshafts, CV joints, propeller shaft
Suspension And Steering:
Front struts, rear shocks, springs, control arms, bushings, steering rack, power steering system, wheel alignment specifications
Brakes And Wheel Hub:
Brake system components (calipers, rotors, pads, ABS, EBD, brake booster, master cylinder), parking brake, wheel bearings, hub assemblies, bolt pattern
Body And Exterior:
Body panel removal and installation, doors, hood, trunk, bumpers, fenders, spoilers, glass, seals, weatherstripping, paint codes
Interior And Trim:
Dashboard, seats, door panels, headliner, carpeting, HVAC controls, airbags, seatbelts
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn
Climate Control HVAC:
A/C system components, refrigerant, compressor, condenser, evaporator, heater core, blower motor, controls
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, impact sensors, ABS, traction control, stability control (ASC)
Infotainment And Audio:
Radio, speakers, navigation system (if equipped), amplifier, antenna
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement
Diagnostic Procedures:
Troubleshooting charts, fault code interpretation (DTCs), symptom-based diagnostics, wiring harness testing
Major Component Overhaul:
Engine rebuild, transmission rebuild, differential overhaul, turbocharger replacement
Component Replacement:
Step-by-step instructions for replacing parts like alternators, starters, fuel pumps, radiators, brake calipers, suspension arms, etc.
Calibration And Programming:
ECU re-flashing, transmission control module (TCM) programming, steering angle sensor calibration, throttle body relearn procedures
Structural Repairs:
Frame straightening, body panel replacement, welding procedures (if applicable to the manual's scope)
Electrical Troubleshooting:
Using multimeters, oscilloscopes, interpreting wiring diagrams, diagnosing circuit faults
Technical Depth
Depth Level:
Comprehensive Factory Level - Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Tools References:
Information on necessary diagnostic tools, scan tools, and specialized equipment
Torque Specifications:
Detailed torque values for all fasteners across various systems
Clearances And Tolerances:
Specific measurements for component clearances during assembly and rebuilds
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Searchable text within PDF for quick information retrieval
Print Quality
Image Resolution:
High-resolution for clear diagrams, schematics, and photographic illustrations
Printability:
Optimized for printing individual sections or the entire manual
Binding Type
Binding Type Physical Equivalent:
Digital Download (printable equivalent of a factory service manual binder)
Paper Type
Paper Type Physical Equivalent:
Digital Download (equivalent to high-quality, durable paper)
⚙️ Engine Specifications
Primary Engine
Engine Family:
4B1
Engine Code:
4B11T
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled
Displacement:
2.0 Liters (1998 cc)
Bore X Stroke:
86.0 mm x 86.0 mm
Compression Ratio:
9.0:1
Performance
Horsepower Hp:
291 hp @ 6,500 rpm (US Market GSR/MR)
Torque Lb-Ft:
300 lb-ft @ 3,500 rpm (US Market GSR/MR)
Redline Rpm:
7,000 rpm
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger Type:
MHI TD05H-15G or similar Mitsubishi Heavy Industries turbocharger
Fluid Specifications
Engine Oil Type:
SAE 5W-30 API SN, ILSAC GF-5 (or equivalent ester-based synthetic)
Engine Oil Capacity Liters:
4.5 Liters (4.8 US Quarts) with filter change
Coolant Type:
Long-life coolant, ethylene glycol based (e.g., Mitsubishi DiaQueen Super Long Life Coolant)
🔧 Transmission
Standard
Manual Transmission:
6-speed manual (Getrag MT-340 / MS-A)
Optional
Dct Transmission:
6-speed Twin-Clutch Sportronic Shift Transmission (TC-SST) - Optional on MR and some GSR trims
Features
Acd System:
Active Center Differential (ACD) - electronically controlled for variable torque split between front and rear axles
Ayc System:
Active Yaw Control (AYC) - rear differential system (or S-AYC in later versions) to control torque distribution between rear wheels for improved cornering
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (specific Mitsubishi recommendation often DiaQueen Super Multi Gear Oil)
Dct Transmission Fluid Type:
Specific Mitsubishi DiaQueen SST Fluid (critical for proper operation and longevity)
📐 Dimensions
Exterior
Length:
4,510 mm (177.6 in)
Width:
1,810 mm (71.3 in)
Height:
1,475 mm (58.1 in)
Wheelbase:
2,635 mm (103.7 in)
Front Track:
1,545 mm (60.8 in)
Rear Track:
1,540 mm (60.6 in)
Cargo
Trunk Volume Cu Ft:
Approx. 10.5 cu ft (may vary slightly by trim/region)
Weights
Curb Weight Kg:
Approx. 1,450 kg - 1,550 kg (3,197 - 3,417 lbs) depending on transmission and trim
Gross Vehicle Weight Rating Gvwr Kg:
Approx. 1,945 kg (4,288 lbs)
Wheels And Tires
Wheel Size Standard:
18 x 8.5 inches (GSR)
Wheel Size Optional Performance:
18 x 8.5 inches (MR - often BBS forged wheels)
Wheel Bolt Pattern:
5x114.3mm (5x4.5 inches)
Tire Size Standard:
245/40R18
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
5-Star (2010 model year, specific tests apply)
IIHS Frontal Offset Score:
Good (2010 model year)
Active Features
ABS:
Anti-lock Braking System
Ebd:
Electronic Brakeforce Distribution
Asc:
Active Stability Control (Traction Control System)
Acd:
Active Center Differential
Ayc:
Active Yaw Control
Passive Features
Srs Airbags:
Driver and front passenger airbags, front side impact airbags, full-length side curtain airbags
Seatbelts:
3-point front seatbelts with pre-tensioners and force limiters, rear 3-point seatbelts
Body Structure:
Reinforced Impact Safety Evolution (RISE) body structure
💡 Technology Features
Infotainment
Audio System Standard:
AM/FM/CD/MP3 stereo with 6 speakers, auxiliary input
Audio System Optional:
Rockford Fosgate premium audio system with subwoofer, Bluetooth connectivity (availability varies by trim and market)
Navigation System:
Optional HDD-based navigation system with touch screen (often integrated with Rockford Fosgate system)
Driver Assistance
Active Dynamics Control:
ACD (Active Center Differential) and AYC (Active Yaw Control) are core performance technology features.
Sport Mode:
TC-SST transmission features manual shift mode and sport mode settings for enhanced driver engagement.
Connectivity
Bluetooth:
Available for hands-free calling and audio streaming on higher trims or with optional packages.
Key Tech Features
Keyless Entry And Start:
Standard on MR trims and optional on GSR, featuring a proximity key and push-button start.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions recommended for performance vehicles)
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for iridium-tipped plugs
Transmission Fluid Change Manual:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) - highly recommended to check frequently
Transmission Fluid Change Dct:
Every 24,000 miles (39,000 km) or 24 months for TC-SST fluid change (critical)
Transfer Case Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km)
Rear Differential Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km)
Known Issues
Clutch Wear Manual:
High-performance clutches can wear faster under aggressive driving. Dual-mass flywheel can also be a wear item.
Turbocharger Failure:
Can occur due to oil starvation, improper cooling, or debris ingestion. Regular oil changes are crucial.
Engine Internal Wear:
While robust, sustained high-boost operation without proper maintenance can lead to premature wear of rings and bearings.
Dct Tc Sst Issues:
Mechatronic unit failures, clutch pack wear, and solenoid issues can occur, especially if fluid maintenance is neglected. Requires specialized knowledge for repair.
Acd Ayc System Faults:
Can experience electrical issues or solenoid failures, leading to error codes and loss of functionality. Requires specialized diagnostic tools.
Exhaust Manifold Cracking:
Some early 4B11T engines experienced exhaust manifold cracking due to heat cycling. Aftermarket solutions are available.
Bilstein Strut Leaks:
Performance dampers (e.g., Bilstein on MR models) can develop leaks over time, especially with aggressive use.
📚 Vehicle History
Brand Heritage
Rally Success:
Mitsubishi's extensive history and multiple championships in the World Rally Championship (WRC) directly influenced the Lancer Evolution lineage.
Model Evolution
Evolution Series Origin:
The Evo nameplate dates back to the Group A homologation specials required for WRC competition, starting with the Lancer Evolution I in 1992.
Evolution X Introduction:
The tenth generation (Evolution X) was introduced in 2007 and marked a significant redesign, moving to the new GS platform and featuring a new engine (4B11T) and advanced electronics like ACD and AYC.
Model Year 2010 Updates:
The 2010 model year saw minor updates, often related to trim levels (e.g., GSR, MR) and potentially feature packaging. The core mechanicals remained consistent with the initial Evo X.
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Period For Cz4A:
2007 - 2015 (globally, with regional variations)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
While the Evo X itself didn't consistently make the 10Best list, its predecessors and the performance car segment it represents are often featured or discussed in such awards.
Motortrend Car Of The Year:
The Evo X competed in this segment, and while it may not have won the overall award, it was highly regarded for its performance credentials.
Ratings
Track Performance Reviews:
Consistently praised by automotive journalists for its exceptional handling, braking, and all-weather performance on track and in rally-inspired conditions.
Certifications
Emissions Compliance:
Meets EPA and CARB (California Air Resources Board) emissions standards for the model year, as detailed within the manual.
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