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Mitsubishi Evo 5 1998 1999 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo 5) Model Code: CP9A Years Covered: 1998-1999 👋 Introduction Market Position Market Position: The Mitsubishi Lancer Evolution V (Evo...
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Mitsubishi Evo 5 1998 1999 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution V (Evo 5)
Model Code:
CP9A
Years Covered:
1998-1999
👋 Introduction
Market Position
Market Position:
The Mitsubishi Lancer Evolution V (Evo 5) was a highly acclaimed homologation special, built for rallying. It represented a significant evolution in performance and technology from its predecessors, positioning it as a dominant force in the rally-inspired performance car segment.
Competitive Analysis
Competitive Analysis:
Competed directly with cars like the Subaru Impreza WRX STi, Ford Escort RS Cosworth, and other high-performance, turbocharged, all-wheel-drive sedans. Its advanced AYC (Active Yaw Control) system and robust chassis set it apart.
Key Features
Key Features:
Aggressive styling with wider fenders, improved aerodynamics, enhanced engine tuning, advanced AYC system, larger intercooler, stiffer chassis, and upgraded braking system.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Repair Service Manual
Language:
English
Format:
PDF Download
Coverage Scope:
All Models/Engines/Trim/Transmission Variants
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (Transfer Case, Differentials)
Chassis:
Suspension (Front & Rear), Steering System, Brake System (Hydraulic, ABS), Wheels & Tires
Electrical:
Engine Control Unit (ECU), Body Control Module (BCM), Lighting, Instrumentation, Power Accessories, Audio System, Airbag System
Body:
Exterior Body Panels, Interior Trim, Doors, Windows, Seats, HVAC System
Procedures Included
Maintenance:
Scheduled Maintenance, Oil & Filter Changes, Spark Plug Replacement, Belt Replacement, Fluid Checks & Changes
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs) and Procedures
Repair:
Component Removal & Installation, Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul
Adjustments:
Wheel Alignment, Clutch Adjustment, Handbrake Adjustment
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Searchability:
Text-searchable for quick access to specific topics and procedures.
Version:
Likely contains all technical updates and revisions released during the 1998-1999 model years.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
1997cc, 16-valve, DOHC, Inline 4-Cylinder, Turbocharged
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Ps:
280 PS @ 6500 rpm (Often underestimated, actual output higher)
Horsepower Hp:
276 hp @ 6500 rpm
Torque Lb-Ft:
275 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Ignition
Fuel Type:
Unleaded Premium Gasoline (95-98 RON)
Turbocharger:
Mitsubishi TD05H-16G (or similar, specific variant may apply)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transaxle
Optional
Transmission Type:
No automatic transmission was offered for the Evo V.
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC)
Gear Ratios Example:
Specific ratios vary but optimized for performance driving and rallying.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (Specific Mitsubishi fluid recommended)
Transfer Case Fluid:
API GL-4, SAE 75W-90 (Specific Mitsubishi fluid recommended)
Rear Differential Fluid:
API GL-5, SAE 80W-90 or 75W-90 (Specific Mitsubishi fluid recommended)
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,420 mm (55.9 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Track Width Front:
Approx. 1,515 mm (59.6 in)
Track Width Rear:
Approx. 1,505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1,350 kg (2,976 lbs) - varies slightly by spec
Gross Vehicle Weight Rating:
Not typically specified for performance models, but generally around 1700-1800 kg.
Towing Capacity:
Not designed or rated for towing.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Vehicle safety standards of the late 1990s applied; specific official ratings like NHTSA/Euro NCAP may not be directly comparable or widely published for this specialized model.
Active Features
Active Features:
ABS (Anti-lock Braking System), AYC (Active Yaw Control), ACD (Active Center Differential), Limited-Slip Rear Differential (Mechanical)
Passive Features
Passive Features:
Driver and Passenger Airbags, Reinforced Safety Cell, Three-Point Seatbelts with Pretensioners
Chassis Enhancements
Chassis Enhancements:
Stiffened chassis with increased torsional rigidity compared to standard Lancer models.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM Stereo with Cassette Player and CD Player (optional). Factory speaker systems were typically modest.
Instrumentation:
Comprehensive gauge cluster including speedometer, tachometer, oil pressure, coolant temperature, boost gauge, and warning lights.
Driver Assistance
Driver Assistance:
Advanced AWD system with ACD and AYC for enhanced traction and cornering stability. ABS is standard.
Connectivity
Connectivity:
Limited connectivity by modern standards; typically only power antenna operation and basic audio input.
Engine Management
Engine Management System:
ECU (Engine Control Unit) with integrated ignition and fuel control, managing turbo boost and engine parameters.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first (more frequent recommended for spirited driving).
Air Filter Replacement:
Every 20,000 km (12,000 miles) or as needed based on driving conditions.
Spark Plug Replacement:
Every 40,000 km (24,000 miles) or as recommended by the manual (specific plug type critical).
Timing Belt Replacement:
Every 80,000 km (50,000 miles) or 5 years. Crucial for the 4G63T engine; failure is catastrophic.
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 10W-40 or 10W-50 recommended for performance. Consult manual for exact specifications.
Coolant Specification:
Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 (high-performance fluid recommended for spirited driving).
Power Steering Fluid:
Specific Mitsubishi power steering fluid or Dexron II/III ATF.
Known Issues
Known Issues:
Potential for cracked cylinder heads under extreme heat, turbocharger wear, oil consumption, AYC pump failure, fuel pump failure, and clutch wear.
Common Repairs
Common Repairs:
Timing belt replacement, turbocharger rebuild/replacement, clutch replacement, AYC system servicing, engine mount replacement.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long history in motorsport, particularly in rallying, with the Lancer Evolution lineage being a direct product of this heritage.
Model Evolution
Model Evolution:
The Evo V was the fifth iteration of the performance Lancer, building upon the success of previous generations. It featured significant chassis and aerodynamic improvements, wider track, and enhanced electronics for superior handling.
Production
Production Period:
1998-1999
Production Location:
Japan
Homologation:
Built as a homologation special for Group A rallying regulations.
🏆 Awards & Recognition
Recognitions
Recognitions:
The Lancer Evolution series, including the Evo V, is widely recognized as one of the greatest performance sedans ever produced, particularly for its rally prowess and driving dynamics.
Ratings
Car And Driver Rating:
Car and Driver magazine often lauded the Evo series for its exceptional handling and performance, though the Evo V was not officially imported to the US market at the time of its release.
Certifications
Certifications:
None specific beyond standard Japanese vehicle manufacturing certifications.
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