Mitsubishi Evo 4 1996-1998 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Common Name: Evo 4 Chassis Code: CN9A Production Years Covered: 1996-1998 Codes Engine Code Primary: 4G63 👋 Introduction Market Position...

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类型: Car

斯库: 68870

标签: 1996 1997 1998 Car Cars Evo 4 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IV

Common Name:

Evo 4

Chassis Code:

Production Years Covered:

1996-1998

Codes

Engine Code Primary:

👋 Introduction

Market Position

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Competitive Analysis

Competitors:

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

Key Features

Performance Focus:

Engineered for rally racing, emphasizing power, handling, and all-wheel-drive traction.

Technology:

Introduction of Active Yaw Control (AYC) for enhanced cornering stability.

Design:

Aggressive styling, large rear spoiler, functional aerodynamic aids.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

Coverage Scope:

Complete Official Full Factory Service Repair Manual

Page Count

Estimated Page Count:

Hundreds of pages (Exact number not specified, implying comprehensive)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostic, repair, and overhaul procedures for the 4G63 engine, including turbocharger, cooling, lubrication, and fuel systems.

Transmission:

Service and repair information for the F5M33 5-speed manual transmission, including clutch, gearbox, and drivetrain components.

Drivetrain:

Covers front and rear differentials, driveshafts, transfer cases, and the Active Yaw Control (AYC) system.

Suspension:

Front MacPherson strut and multi-link rear suspension, including alignment specifications, shock absorbers, springs, and bushings.

Brakes:

Front and rear disc brakes, including ABS system, brake fluid specifications, caliper overhaul, and pad replacement procedures.

Steering:

Power steering system diagnosis and repair, including pump, rack, and fluid specifications.

Electrical:

Wiring diagrams, ECU pinouts, starter, alternator, ignition system, lighting, and accessory circuits.

Body And Chassis:

Body panel removal/installation, interior trim, glass replacement, structural components, and chassis repair.

Heating And Air Conditioning:

AC system diagnosis, refrigerant types, component replacement, and heater core service.

Safety Systems:

Airbag system (SRS) diagnosis and repair, seatbelt mechanisms.

Procedures Included

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, belt inspections.

Diagnostics:

Troubleshooting charts for common problems, fault code interpretation, component testing procedures.

Repair:

Step-by-step instructions for component removal, installation, and overhaul across all major vehicle systems.

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, engine timing settings.

Alignment:

Detailed suspension alignment parameters (camber, caster, toe) for optimal handling.

Rebuilds:

Comprehensive instructions for engine, transmission, and differential rebuilds.

Technical Depth

Depth:

Factory-level technical depth covering everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text (standard for well-digitized manuals).

Print Quality

Printability:

Designed to be printable, allowing users to create a physical copy.

Binding Type

Binding Type:

N/A (Digital Download - user dependent)

Paper Type

Paper Type:

N/A (Digital Download - user dependent)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2.0L Inline 4-cylinder DOHC 16-valve turbocharged

Engine Code:

4G63 (Revised for Evo IV)

Performance

Horsepower Ps:

280 PS (276 hp) - Officially rated due to the 'gentleman's agreement' among Japanese manufacturers.

Torque Nm:

352 Nm (260 lb-ft)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Multi-Point Injection

Fuel Type:

Unleaded Premium Gasoline (95 RON or higher recommended)

Engine Management

Engine Control Unit (ECU) with ignition timing and fuel mapping adjustments.

Cooling System

Cooling Type:

Water-cooled, pressurized system

Lubrication System

Oil Capacity Liters:

4.5 liters (with filter change)

Oil Type Recommendation:

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

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (F5M33)

Optional

Type:

None (All Evo IV models featured a manual transmission)

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Yaw Control (AYC)

Gear Ratios 1St:

3.071

Gear Ratios 2Nd:

1.777

Gear Ratios 3Rd:

1.307

Gear Ratios 4Th:

1.000

Gear Ratios 5Th:

0.742

Final Drive Ratio:

4.529

Transmission Fluid

Fluid Type Recommendation:

API GL-3 or GL-4, SAE 75W-90 (Manual Transmission Fluid)

Capacity Liters:

2.7 liters (Manual Transmission)

📐 Dimensions

Exterior

Length Mm:

Width Mm:

Height Mm:

Wheelbase Mm:

Front Track Mm:

Rear Track Mm:

Weights

Curb Weight Kg:

1400 - 1450 kg (depending on specification)

Gross Vehicle Weight Rating Kg:

Approx. 1800 kg

Towing Capacity Kg:

Not Recommended/Specified

Wheels And Tires

Wheel Size:

17 inches

Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Tire Size Front:

225/45R17

Tire Size Rear:

225/45R17

🛡️ Safety Features

Ratings

NHTSA Crash Test Ratings:

Not officially tested by NHTSA in the US market during its production years as it was primarily a Japanese Domestic Market (JDM) vehicle.

Active Features

Traction Control:

Yes (AYC - Active Yaw Control)

Anti Lock Brakes:

Yes (ABS)

Electronic Brakeforce Distribution:

Integrated with ABS system.

Passive Features

Airbags:

Driver and Passenger Airbags (standard on most trims)

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners

Crumple Zones:

Designed with front and rear crumple zones for energy absorption.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player (often optional) and cassette tape player. Speaker configuration typically 4-6 speakers.

Display:

Basic digital climate control display and analog gauge cluster.

Driver Assistance

Active Yaw Control:

The signature technological feature, actively distributing torque between the rear wheels to enhance cornering performance and stability.

Anti Lock Braking System:

Standard ABS system to prevent wheel lock-up during heavy braking.

Connectivity

Bluetooth:

Not available from the factory.

Usb Ports:

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Km Miles:

Every 5,000-7,500 km (3,000-4,500 miles) or 6 months, whichever comes first (severe duty).

Air Filter Replacement Km Miles:

Every 15,000-20,000 km (9,000-12,000 miles).

Spark Plug Replacement Km Miles:

Every 40,000-60,000 km (24,000-36,000 miles), depending on spark plug type (iridium recommended).

Timing Belt Replacement Km Miles:

Every 90,000-100,000 km (56,000-62,000 miles) or 5 years.

Fluid Specifications

Coolant Type:

Ethylene Glycol based, 50/50 mix with distilled water (typically green coolant).

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

Dexron II or equivalent ATF

Known Issues

Engine Reliability:

Known for robust 4G63 engine, but requires diligent maintenance. Common issues include turbocharger wear, head gasket failures under extreme stress, and oil starvation if not properly maintained.

Ayc System:

The AYC hydraulic pump and solenoids can be prone to failure over time due to age and heat cycles. Fluid leaks can also occur.

Rust:

As with many Japanese performance cars of this era, rust can be a concern, particularly in the wheel arches, sills, and undercarriage, depending on climate and previous care.

Suspension Wear:

Bushings and ball joints can wear out, affecting handling and alignment. Shock absorbers may also lose damping effectiveness.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi has a long and successful history in rally racing, starting with the Pajero and then transitioning to the Lancer platform for WRC homologation.

Model Evolution

Generation:

Fourth generation of the Lancer Evolution, succeeding the Evo III.

Key Advancements Over Evo Iii:

Introduction of AYC, revised chassis with increased rigidity, improved aerodynamics, and enlarged intercooler.

Production

Manufacturing Location:

Japan

Production Volume:

Significant production numbers, but exact figures for Evo IV are not widely publicized; tens of thousands are estimated.

Market Availability:

Primarily Japan Domestic Market (JDM), with limited imports to other countries.

🏆 Awards & Recognition

Recognitions

Rally Championships:

While the Evo IV itself wasn't a direct WRC homologation for a specific year's championship, it cemented Mitsubishi's reputation built on rally success.

Enthusiast Following:

Highly regarded by automotive enthusiasts and considered a legendary performance car icon.

Ratings

Performance Car Rankings:

Consistently ranked highly in performance driving publications for its handling and acceleration capabilities in its era.