Mitsubishi Evo 5 1998 1999 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo 5) Model Code: CP9A Generation: Fifth Generation Production Years Covered: 1998-1999 👋 Introduction Market Position Vehicle Segment: Performance Compact...

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标签: 1998 1999 Car Cars Evo 5 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution V (Evo 5)

Model Code:

Generation:

Fifth Generation

Production Years Covered:

1998-1999

👋 Introduction

Market Position

Vehicle Segment:

Performance Compact Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, tuners, rally drivers, and owners requiring in-depth service knowledge

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Type:

AWD Turbocharged Performance Sedan

Rally Heritage:

Homologated for Group A rally racing, built for extreme performance and durability

Technical Advancements:

Advanced AYC system, robust powertrain, upgraded chassis and braking compared to earlier Evos

Manual Value

Primary Benefit:

Enables owners and technicians to perform all necessary maintenance, diagnostics, and repairs correctly and efficiently.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service and Repair

Page Count

Estimated Pages:

Hundreds (Exact count varies by compilation, but extensive)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

4G63T DOHC (2.0L Turbocharged)

Powertrain:

Engine, Clutch, Transmission (Manual & Automatic Variants), Differentials (Front, Center, Rear)

Drivetrain:

All-Wheel Drive (AYC - Active Yaw Control), Driveshafts, Axles

Suspension:

Front McPherson Strut, Rear Multi-link, Springs, Dampers, Bushings, Anti-roll Bars

Brakes:

Front Brembo Ventilated Discs, Rear Solid Discs, ABS (Anti-lock Braking System)

Steering:

Power Rack and Pinion

Electrical:

Battery, Charging System, Ignition System, Lighting, Gauges, ECUs, Wiring Diagrams

Fuel System:

Fuel Injection (MPI), Fuel Pump, Injectors, Fuel Pressure Regulator, Fuel Tank

Cooling System:

Radiator, Fan, Water Pump, Thermostat, Coolant Passages

Exhaust System:

Exhaust Manifold, Catalytic Converter, Muffler

Body And Frame:

Chassis, Body Panels, Doors, Hood, Trunk, Bumpers, Glass

Interior:

Seats, Dashboard, Trim, HVAC System (Heating, Ventilation, Air Conditioning)

Diagnostics:

Troubleshooting guides, DTCs (Diagnostic Trouble Codes), Repair procedures

Procedures Included

Maintenance:

Routine service, oil changes, filter replacements, spark plug replacement, timing belt inspection/replacement

Repair:

Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, electrical system repair

Diagnostics And Troubleshooting:

Step-by-step diagnostic flows for various symptoms and fault codes

Specifications:

Torque specifications, clearances, fluid capacities, diagnostic values

Special Tools:

Identification of necessary special tools for specific repairs

Wiring Diagrams:

Detailed electrical schematics for all systems

Technical Depth

Depth:

Comprehensive factory-level repair and maintenance information

Detail Level:

Detailed step-by-step instructions, exploded diagrams, component identification

Diagnostic Capability:

Advanced diagnostics for engine management, AYC system, and other electronic controls

Rebuild Procedures:

Complete engine and transmission overhaul procedures

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content (OCR'd PDF)

Print Quality

Quality:

High-resolution, suitable for printing individual pages or the entire manual

Binding Type

Binding Type For Printed:

N/A (Digital PDF download, user prints and binds)

Paper Type

Paper Type For Printed:

N/A (Digital PDF download, user prints on desired paper)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Ps:

280 PS (JDM Spec), approximately 276 hp (DIN)

Torque Nm:

352 Nm (260 lb-ft) at 3000 RPM (JDM Spec)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (High Octane Recommended)

Engine Management

Engine Control Unit (ECU) with direct ignition

Turbocharger

Turbo Model:

TD05HR-16G

Engine Internals

Piston Type:

Forged

Connecting Rods:

Forged

🔧 Transmission

Standard

Transmission Type:

5-speed Manual (Getrag G5M-R or similar Mitsubishi F5MXX)

Optional

Transmission Type Optional:

4-speed Automatic (Less common for performance variants)

Features

Gear Ratios:

Specific gear ratios provided in manual

Fluid Specifications

Manual Transmission Fluid:

GL-4 or GL-5 SAE 75W-90 Gear Oil (Verify specific Mitsubishi recommendation)

Automatic Transmission Fluid:

Dexron III or equivalent (for automatic variants)

📐 Dimensions

Exterior

Length:

Approx. 4,350 mm (171.3 in)

Width:

Approx. 1,770 mm (69.7 in)

Height:

Approx. 1,415 mm (55.7 in)

Wheelbase:

Approx. 2,600 mm (102.4 in)

Weights

Curb Weight:

Approx. 1,370 kg (3,020 lbs) for GSR model

Gross Vehicle Weight Rating:

Refer to vehicle placard or manual

🛡️ Safety Features

Ratings

Crash Test Ratings:

Limited official crash test data from independent agencies during its era; primarily designed for motorsport homologation.

Active Features

AWD System:

Advanced All-Wheel Drive with Active Yaw Control (AYC) for enhanced stability and cornering

Anti-lock Braking System (ABS) standard

Passive Features

Airbags:

Driver and Passenger Airbags (Standard)

Seatbelts:

3-point seatbelts with pretensioners

Chassis Design:

Reinforced chassis for rally homologation

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM Radio with CD Player or Cassette Player (OEM unit)

Navigation:

N/A (Navigation systems were not standard or widely available in this era for this model)

Driver Assistance

Traction Control:

Limited to AWD system; no electronic traction control in the modern sense beyond ABS.

Connectivity

Bluetooth:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000-7,500 km (3,000-4,500 miles) or 6 months, more frequent under hard driving.

Timing Belt Replacement:

Recommended every 90,000-100,000 km (55,000-60,000 miles) or 7 years, whichever comes first.

Spark Plug Replacement:

Refer to manual for specific type and interval, typically iridium plugs

Fluid Specifications

Engine Oil Specification:

API SG or higher, ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for exact spec based on climate).

Coolant Type:

Ethylene Glycol based antifreeze (50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 (Verify manual for preference)

Known Issues

Engine Wear:

Piston ring wear, connecting rod bearing failure (especially if modified or poorly maintained), head gasket failure

Turbocharger:

Oil seal failure, bearing wear leading to oil consumption or turbo failure

Ayc System:

Pump failure, sensor issues, fluid leaks

Rust:

Common in older vehicles, particularly in areas prone to corrosion (wheel arches, sills, floor pans)

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi has a strong heritage in rallying, including multiple WRC manufacturer and driver championships.

Model Evolution

Evo V Development:

Evo 5 was a significant redesign with wider track, flared arches, improved aerodynamics, and stiffer chassis compared to Evo 4.

Key Changes From Evo 4:

Wider body, larger front bumper vents, improved intercooler, larger spoiler, stiffer suspension, thicker anti-roll bars.

Production

Production Location:

Japan

Market Availability:

Primarily for Japanese Domestic Market (JDM), with limited official exports to select markets; many imported unofficially.

🏆 Awards & Recognition

Recognitions

Rally Accolades:

The Lancer Evolution platform, including the Evo 5's lineage, is widely recognized for its dominance in motorsport, particularly rallying.

Enthusiast Appreciation:

Consistently ranked as one of the most desirable and iconic JDM performance cars of its era.