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Mitsubishi Evo 4 and 5 Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V Generation Generation Name: CN9A (Evo IV) / CP9A (Evo V) Codes Chassis Codes: CN9A (Evo IV), CP9A (Evo...
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斯库: 83932
Mitsubishi Evo 4 and 5 Service ManualMitsubishi Evo 4 and 5 Service ManualMitsubishi Evo 4 and 5 Service ManualMitsubishi Evo 4 and 5 Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV / V
Generation
Generation Name:
CN9A (Evo IV) / CP9A (Evo V)
Codes
Chassis Codes:
CN9A (Evo IV), CP9A (Evo V)
Engine Codes:
4G63 (Evo IV), 4G63 (Evo V)
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally Homologation Special
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale.
Key Features
Performance Focus:
Legendary rally heritage, advanced all-wheel-drive system (AYC), powerful turbocharged engine, high handling capabilities.
Target Audience:
Enthusiasts, motorsport participants, mechanics specializing in performance vehicles.
📋 Manual Details
Coverage Areas
Service Manual Coverage:
Comprehensive repair, maintenance, diagnosis, and specifications for Mitsubishi Lancer Evolution IV and V.
Page Count
Estimated Page Count:
900+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger system.
Drivetrain:
Manual transmission (type TY856WB), transfer case, front differential, rear differential (Active Yaw Control - AYC).
Suspension Steering:
Front suspension (McPherson strut), rear suspension (Multi-link), power steering system, wheel alignment specifications.
Brakes:
Front brakes (Brembo 4-piston calipers), rear brakes (Brembo 2-piston calipers), ABS system, parking brake.
Electrical Electronics:
Engine control unit (ECU), body control module (BCM), lighting, wipers, horn, power windows, audio system, diagnostic connectors (OBD-I/OBD-II).
Body Chassis:
Body construction, interior trim, exterior panels, doors, hood, trunk, glass, chassis components, corrosion protection.
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad replacement.
Diagnostics:
Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams, component testing procedures.
Repair Rebuild:
Engine disassembly and reassembly, transmission overhaul, clutch replacement, suspension component replacement, brake system repair, turbocharger rebuild.
Special Procedures:
AYC system calibration, timing belt replacement, fuel injector cleaning and replacement, ECU reprogramming.
Technical Depth
Depth:
Complete technical information for factory-level repairs and diagnostics, suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Clarity:
High-resolution scans with clear diagrams, text, and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Searchability
Text Search:
Likely text-searchable PDF, allowing quick access to specific information.
⚙️ Engine Specifications
Primary Engine
Engine Family:
4G63
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, Turbocharged
Displacement:
2.0 Liters (1997cc)
Performance
Horsepower Evo4:
276 PS (272 hp) @ 6250 RPM (Japanese Spec, often under-reported)
Torque Evo4:
350 Nm (258 lb-ft) @ 3000 RPM (Japanese Spec)
Horsepower Evo5:
276 PS (272 hp) @ 6250 RPM (Japanese Spec, increased for GSR/RS-Sprint models)
Torque Evo5:
373 Nm (275 lb-ft) @ 3000 RPM (GSR) / 357 Nm (263 lb-ft) (RS)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection.
Fuel Type:
Unleaded Premium (95 RON / 91 AKI recommended)
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant)
Lubrication System
Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change
Recommended Oil Viscosity:
10W-30 or 10W-40 (check manual for specific conditions)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (TY856WB)
Optional
Transmission Options:
N/A (Manual transmission was standard across all Evo IV/V models)
Features
AWD System:
Full-time All-Wheel Drive with Active Yaw Control (AYC) for Evo IV, and AYC Type R for Evo V. Helical front LSD, viscous coupling center diff.
Transfer Case Fluid:
API GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendation)
Rear Differential Fluid:
API GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendation, especially for AYC)
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,405 mm (55.3 in)
Wheelbase:
Approx. 2,625 mm (103.3 in)
Weights
Curb Weight:
Approx. 1,360 kg (2,998 lb) - Varies by model (GSR/RS)
Gross Vehicle Weight Rating:
Varies by specific model and market
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not widely tested by modern NHTSA/Euro NCAP standards due to era of production and homologation focus.
Active Features
Driver Assistance:
AYC (Active Yaw Control) for enhanced stability and traction, ABS (Anti-lock Braking System).
Passive Features
Restraints:
Driver and front passenger airbags, three-point seatbelts with pretensioners.
Body Structure:
Reinforced chassis and safety cage designed for rally conditions.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette/CD player (market dependent), typically 4-6 speaker system.
Climate Control:
Manual or automatic climate control systems (market dependent).
Driver Assistance
AWD Control:
Advanced AYC system electronically controls torque distribution to rear wheels for superior cornering.
Connectivity
Diagnostics:
On-Board Diagnostics (OBD-I in early models, transitioning to OBD-II), with specific proprietary Mitsubishi diagnostic connectors and protocols.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, whichever comes first (severe use may require more frequent changes).
Air Filter Replacement:
Every 15,000-30,000 km (9,000-18,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Refer to manual, typically around 30,000-60,000 km (18,000-36,000 miles) depending on plug type.
Timing Belt Replacement:
100,000 km (60,000 miles) or 7 years, whichever comes first. Critical item!
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for exact specification)
Power Steering Fluid:
Automatic Transmission Fluid (ATF) Dexron II or equivalent (verify with manual)
Known Issues
Common Failures:
Turbocharger failure (oil starvation), AYC pump failure, clutch wear, differential issues, HICAS (if equipped) problems, piston ring wear (higher mileage).
Maintenance Considerations:
Requires diligent adherence to maintenance schedules, especially regarding oil changes and cooling system health, to prevent turbocharger and engine damage.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi's extensive history and success in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution series.
Model Evolution
Evo Iv Introduction:
Introduced in August 1996. Featured a revised engine, new AYC system, and a significantly redesigned exterior with larger spoilers and aggressive styling.
Evo V Introduction:
Introduced in January 1998. Featured wider bodywork, larger intercooler, improved suspension geometry, larger Brembo brakes, and revised AYC for enhanced performance.
Production
Production Period Evo4:
1996 - 1998
Production Period Evo5:
1998 - 1999
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
Multiple WRC Manufacturers' and Drivers' Championships achieved by privateers and factory teams using Lancer Evolution platforms.
Automotive Press:
Consistently praised by automotive journalists for its handling, performance, and rally-bred capabilities.
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