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Mitsubishi Evolution IV 1996-1998 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Model Code: CN9A Year: 1996-1998 Codes Chassis Code: CN9A Engine Code: 4G63 👋 Introduction Market Position Category: Performance Rally Homologation...
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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV
Model Code:
CN9A
Year:
1996-1998
Codes
Chassis Code:
CN9A
Engine Code:
4G63
👋 Introduction
Market Position
Category:
Performance Rally Homologation Special
Reputation:
Legendary status in rallying and enthusiast communities
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Performance Focus:
All-wheel drive, turbocharged engine, advanced suspension and differential systems
Rally Heritage:
Developed for World Rally Championship (WRC) homologation, directly translating motorsport technology to road cars
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair, Overhaul, Maintenance, Troubleshooting
Specific Sections:
Engine, Transmission, Drivetrain, Suspension, Brakes, Steering, Electrical System, Bodywork, HVAC, Fuel System, Cooling System
Page Count
Estimated Page Count:
1500-2500 (estimated based on typical comprehensive workshop manuals of the era)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, reassembly of 4G63 engine components (pistons, rings, rods, crankshaft, cylinder head, valvetrain, oil pump, etc.)
Engine Electrical:
Ignition system, starting system, charging system, ECU diagnosis, wiring diagrams, sensor functions
Transmission Manual:
Disassembly, inspection, repair of the 5-speed manual gearbox, clutch operation, drivetrain components (driveshafts, differentials)
Transmission Awc:
Active Yaw Control (AYC) system diagnosis, operation, troubleshooting, and calibration procedures
Suspension Front:
MacPherson strut assembly, control arms, anti-roll bar, bushings, wheel bearings, alignment specifications
Suspension Rear:
Multi-link independent suspension, shock absorbers, springs, control arms, bushings, alignment specifications
Brakes:
Front Brembo 4-piston calipers, rear 2-piston calipers, vented discs, ABS system diagnosis and components, brake fluid specifications
Steering:
Power steering system, steering rack, tie rods, steering column, alignment specifications
Bodywork:
Panel removal and installation, door mechanisms, trim components, glass replacement, structural repair guidelines
Electrical System Major:
Lighting systems, power windows, central locking, mirrors, dashboard instrumentation, audio system wiring
HVAC:
Air conditioning system diagnosis, recharge procedures, heater core, blower motor, climate control panel
Fuel System:
Fuel pump, injectors, fuel pressure regulator, fuel filter replacement, EVAP system
Cooling System:
Radiator, thermostat, water pump, cooling fan operation, coolant type and capacity
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, transmission fluid change
Major Repairs:
Engine rebuild, transmission overhaul, clutch replacement, turbocharger servicing, differential overhaul
Diagnostics Troubleshooting:
Fault code retrieval and interpretation, symptom-based troubleshooting guides for all major systems
Specifications Torque:
Detailed torque specifications for all critical fasteners
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems
Alignment Procedures:
Front and rear wheel alignment angles and adjustment procedures
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Diagnostic Level:
Advanced, including ECU diagnostics and component testing
Component Rebuilds:
Detailed instructions for rebuilding major mechanical and electrical components
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (depending on original scan quality)
Print Quality
Quality:
Dependent on source scan, typically clear and readable for technical diagrams and text
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Engine Code:
4G63T
Displacement:
1997 cc (2.0 L)
Bore X Stroke:
85.0 mm x 88.0 mm
Performance
Horsepower Ps Jdm:
280 PS (276 hp) @ 6500 rpm (JDM spec, often underestimated)
Torque Nm Jdm:
352 Nm (260 lb-ft) @ 5500 rpm (JDM spec)
Boost Pressure Psi:
Approx. 1.3 bar (18.9 psi) (stock)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (95 RON or higher)
Ignition System:
Electronic ignition with distributorless ignition system (DIS)
🔧 Transmission
Standard
Type:
5-speed Manual Transaxle
Optional
Type:
None offered (manual only)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Transfer Case:
Mechanical, with viscous coupling center differential
Rear Differential:
Active Yaw Control (AYC) system with electronically controlled hydraulic clutch pack
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1405 mm (55.3 in)
Wheelbase:
2600 mm (102.4 in)
Front Track:
1515 mm (59.6 in)
Rear Track:
1505 mm (59.3 in)
Weights
Curb Weight Kg:
1420 kg (3131 lbs)
Gross Vehicle Weight Rating Kg:
1645 kg (3627 lbs)
Fuel Tank Capacity Liters:
50 L (13.2 US gal)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Vehicle not subjected to formal government crash testing in most markets due to homologation nature)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC) system enhances stability and traction
AWD:
Advanced All-Wheel Drive system provides superior grip
Passive Features
Airbags:
Driver and front passenger airbags (standard)
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners
Body Structure:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player, cassette tape, and 6 speakers (typically)
Instrument Cluster:
Digital odometer, analog tachometer, speedometer, fuel gauge, temperature gauge, boost gauge (on some models/trims)
Driver Assistance
Traction Control:
Limited slip differential (front), Active Yaw Control (rear) for enhanced traction
Connectivity
Connectivity Features:
None beyond basic audio system connectivity (no Bluetooth, USB, etc.)
🔧 Maintenance
Service Intervals
Engine Oil Filter Change:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months
Air Filter Replacement:
Every 15,000-20,000 km (9,000-12,000 miles)
Spark Plug Replacement:
Every 30,000-40,000 km (18,000-24,000 miles) (depending on plug type)
Timing Belt Replacement:
Every 80,000-100,000 km (50,000-60,000 miles) or 5-7 years
Transmission Fluid Change:
Every 30,000-50,000 km (18,000-30,000 miles)
Fluid Specifications
Engine Oil:
API SG/SH, SAE 10W-30 or 10W-40 (synthetic recommended for performance driving)
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant, pink/red color)
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 (synthetic recommended)
Known Issues
Engine Wear:
Ringland failure on early 4G63 engines due to detonation; piston slap; valve stem seal wear
Ayc System:
Failure of AYC pump or sensors leading to warning lights and system malfunction; fluid leaks
Turbocharger:
Oil seal failure leading to smoking, bearing wear, wastegate issues
Suspect Component Reliability:
Clutch wear (performance driving), synchronizer wear in transmission, turbo hoses
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's extensive success in World Rally Championship (WRC) with the Lancer Evolution series
Model Evolution
Generation:
Fourth generation of the Lancer Evolution
Introduction Year:
1996
Key Advancements:
Introduction of Active Yaw Control (AYC) system, revised chassis and suspension geometry, larger twin-scroll turbocharger
Production
Manufacturing Location:
Japan
Production Volume:
Limited production runs, highly sought after by collectors and enthusiasts
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
Numerous WRC rally victories and championships contributed to the model's legendary status
Ratings
Enthusiast Reviews:
Consistently highly rated by automotive journalists and enthusiasts for performance, handling, and driver engagement