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Mitsubishi Evolution VI 1999-2001 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Model Designation: Evo VI / Evo 6 Body Style: 4-door Sedan Production Years: 1999-2001 Codes Chassis Code: CP9A Engine Code...
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Mitsubishi Evolution VI 1999-2001 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Model Designation:
Evo VI / Evo 6
Body Style:
4-door Sedan
Production Years:
1999-2001
Codes
Chassis Code:
CP9A
Engine Code Primary:
4G63T
Engine Code Variants:
4G63 (non-turbo variants exist in standard Lancer range, but not relevant to Evo VI)
Transmission Codes:
F5M51 (5-speed manual), V5M31 (4-speed automatic - rare for Evo VI)
👋 Introduction
Market Position
Market Segment:
Performance Compact Sedan / Rally Homologation Special
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Peugeot 206 WRC (in rallying context), but direct road competitors include performance variants of other compact sedans.
Key Features
Driving Dynamics:
Legendary all-wheel-drive system (4WD), advanced Active Yaw Control (AYC) system, powerful turbocharged engine, focused suspension tuning for rallying.
Performance Focus:
Designed with rally homologation in mind, offering exceptional grip, acceleration, and handling capabilities.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service, maintenance, and troubleshooting for all major systems and components.
Page Count
Page Count:
Est. 1500+ pages (typical for full factory service manuals)
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine And Drivetrain:
Engine mechanical, cylinder head, valvetrain, lubrication, cooling, fuel, ignition, emissions control, turbocharging, exhaust, clutch, manual transmission (all-wheel drive system - AYC/ACD).
Chassis And Suspension:
Front suspension, rear suspension, steering system, braking system (ABS), wheel alignment, chassis components.
Electrical And Electronics:
Engine Control Unit (ECU), powertrain control module (PCM), body control module (BCM), wiring diagrams, lighting, instrumentation, audio system, power windows/locks, charging system, starting system.
Body And Interior:
Body exterior panels, doors, hood, trunk, bumpers, interior trim, seats, HVAC system, safety systems (airbags).
Procedures Included
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections and replacement.
Diagnostic Procedures:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical system testing.
Repair Procedures:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, body panel repair, electrical component diagnosis and replacement.
Special Procedures:
Active Yaw Control (AYC) system calibration and service, timing belt replacement, turbocharger service, clutch replacement, differential service.
Technical Depth
Depth:
Detailed torque specifications, tolerances, component testing procedures, wiring schematics, diagnostic flowcharts, component removal and installation sequences, exploded views.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or sections.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchability:
Likely text-searchable if scanned from original factory manual.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, Turbocharged
Engine Code:
4G63T
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
280 PS (JDM) / 276 HP (Export markets, often rated lower for tax purposes)
Torque Nm:
330 Nm (JDM) / 335 Nm (Export)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Fuel Pump
Fuel Type:
Unleaded Premium Gasoline (95 RON or higher recommended)
Turbocharging
Turbocharger Type:
Mitsubishi TD05HR-16G6-10.5T (Twin-Scroll)
Engine Management
ECU Type:
Engine Control Unit (ECU) with advanced ignition and fuel mapping.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual
Transmission Code Standard:
F5M51
Optional
Transmission Type Optional:
4-speed Automatic (Rare for Evo VI models, typically found in standard Lancers or specific markets).
Transmission Code Optional:
V5M31
Features
Drivetrain:
All-Wheel Drive (4WD) with Active Yaw Control (AYC)
Differentials:
Front: Limited Slip Differential (LSD) - Helical. Rear: Active Yaw Control (AYC) unit with Electronic Control Unit.
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Track Width Front:
1515 mm (59.6 in)
Track Width Rear:
1505 mm (59.3 in)
Weights
Curb Weight Kg:
Approx. 1360 kg (2998 lbs)
Gross Vehicle Weight Rating Kg:
Approx. 1700 kg (3748 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Limited official ratings for this era and homologation model; focus was on performance and structural integrity for rallying. Refer to specific country safety standards of the time.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD).
Ayc:
Active Yaw Control (AYC) system for enhanced stability and cornering grip.
Passive Features
Airbags:
Driver and passenger front airbags (standard on most models).
Seatbelts:
3-point inertia reel seatbelts with pre-tensioners.
Body Construction:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette player. Aftermarket upgrades are common.
Instrumentation:
Performance-oriented gauges including boost gauge, oil pressure gauge, tachometer, speedometer.
Driver Assistance
Traction Control:
No explicit electronic traction control beyond the AWD system and AYC.
Connectivity
Connectivity Options:
Limited to factory-installed options like power windows/locks. No modern Bluetooth or USB connectivity from factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 km (4,500 miles) or 6 months, whichever comes first. More frequent under severe driving conditions.
Timing Belt Replacement:
Every 96,000 km (60,000 miles) or 4 years, whichever comes first. Crucial due to interference engine design.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ACEA A2/A3; Viscosity SAE 10W-30 or 10W-40 recommended (refer to manual for specific oil type and capacity).
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Capacity: Approx. 7.5 Liters.
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90. Capacity: Approx. 2.3 Liters.
Differential Fluid Rear:
API GL-5, SAE 75W-90. Capacity: Approx. 1.3 Liters (AYC unit).
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Engine Issues:
Cracked cylinder heads (especially in earlier models or heavily modified cars), turbocharger wear, oil consumption, piston ring wear.
Drivetrain Issues:
AYC pump failure, clutch wear, transmission synchro issues (especially with hard driving).
Body And Chassis Issues:
Rust (especially around wheel arches, sills), suspension bushing wear.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's extensive involvement in World Rally Championship (WRC) with Tommi Mäkinen winning multiple titles.
Model Evolution
Evo Vi Development:
Evolved from Lancer platform, focusing on aerodynamic improvements (e.g., larger front bumper openings, revised rear spoiler), enhanced cooling, stronger engine internals, and refined AYC system.
Special Editions:
Wider availability of RS models (homologation specials) and the highly sought-after Tommi Mäkinen Edition (TME) with unique styling and mechanical enhancements.
Production
Production Location:
Japan
Production Volume:
Relatively limited compared to standard Lancer models, especially for RS and TME variants.
🏆 Awards & Recognition
Recognitions
Rally Dominance:
The Evo VI's engineering and platform were the basis for Mitsubishi's dominant Lancer WRC cars, contributing to multiple manufacturer and driver championships.
Enthusiast Acclaim:
Consistently ranked as one of the greatest performance cars of its era by automotive publications and enthusiasts worldwide.
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