Mitsubishi Lancer EVO 4 & 5 Complete Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation Model Codes: Evo IV (CN9A), Evo V (CP9A) Codes Chassis Codes Evo Iv: CN9A Chassis Codes Evo V: CP9A 👋...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Generation Model Codes:

Evo IV (CN9A), Evo V (CP9A)

Codes

Chassis Codes Evo Iv:

Chassis Codes Evo V:

👋 Introduction

Market Position

Positioning Evo Iv V:

High-performance rally homologation special, potent competitor in affordable sports sedan segment.

Competitive Analysis

Competitors:

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

Key Features Evo Iv

Highlight:

Introduction of Active Yaw Control (AYC), twin-scroll turbocharger, intercooler spray system (optional).

Key Features Evo V

Highlight:

Wider track, revised suspension geometry, larger wheels and brakes, improved engine torque, larger turbocharger.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive workshop service and repair

Supported Models:

Mitsubishi Lancer Evolution IV and Evolution V

Page Count

Estimated Page Count:

Over 1500 pages (typical for complete workshop manuals of this era)

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain.

Engine Electrical:

Ignition system, starting and charging system, fuel injection system (ECI-Multi), emission control systems, ECU diagnostics.

Transmission Manual:

Gearbox overhaul, clutch operation, synchronizers, shift mechanisms, gear ratios.

Transmission AWD System:

Active Yaw Control (AYC) system, viscous coupling unit (VCU), front differential, rear differential, driveshafts.

Suspension:

Front and rear suspension components, struts, springs, control arms, bushings, wheel bearings, alignment specifications.

Brakes:

Brake system hydraulic components, ABS, disc brake servicing (pads, rotors), parking brake.

Steering:

Power steering system, steering rack, tie rods, steering column.

Electrical System:

Wiring diagrams, lighting, power windows, central locking, instrumentation, fuses, relays, battery.

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, rust repair, chassis specifications.

Heating Ventilation Air Conditioning:

HVAC system components, refrigerant, cabin filter replacement.

Procedures Included

Maintenance:

Routine maintenance tasks, oil changes, filter replacements, spark plug replacement, coolant flush, brake fluid change.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for various systems.

Repair:

Detailed step-by-step repair instructions for all major vehicle components.

Overhaul:

Complete engine and transmission rebuild procedures.

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical values, wheel alignment settings.

Technical Depth

Depth:

Expert level, covering from basic maintenance to complete engine/transmission rebuilds and advanced diagnostics.

Diagnostic Tools:

Information relevant to using OBD-II scanners and specific Mitsubishi diagnostic tools (if applicable to the era).

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchable Text:

Yes, typically searchable text for easy navigation.

Print Quality

Resolution:

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

Binding Type

Binding Type:

N/A (Downloadable Digital Format)

Paper Type

Paper Type:

N/A (Downloadable Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Evo Iv:

Engine Code Evo V:

4G63T

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled

Displacement Liters:

Bore X Stroke Mm:

85.0 x 88.0

Performance

Horsepower Ps Evo Iv:

280 PS @ 6,500 rpm

Torque Kgfm Evo Iv:

34.0 kgfm @ 3,000 rpm

Horsepower Ps Evo V:

280 PS @ 6,500 rpm

Torque Kgfm Evo V:

38.0 kgfm @ 3,000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (ECI-Multi), multi-point injection

Fuel Type:

Unleaded gasoline, high octane (95 RON or higher recommended)

Turbocharger:

Mitsubishi TD05H-16G (Evo IV), Mitsubishi TD05HR-16G6-10.5cm² (Evo V) twin-scroll

🔧 Transmission

Standard

Type Evo Iv:

5-speed manual

Type Evo V:

5-speed manual

Optional

Type:

N/A (Manual transmission only for these performance variants)

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Helical front LSD, Viscous coupling rear differential.

Ayc System:

Electronically controlled torque vectoring to the rear wheels for enhanced cornering stability.

📐 Dimensions

Exterior

Length Mm Evo Iv:

Width Mm Evo Iv:

Height Mm Evo Iv:

Length Mm Evo V:

Width Mm Evo V:

Height Mm Evo V:

Wheelbase Mm:

Track Front Mm Evo Iv:

Track Rear Mm Evo Iv:

Track Front Mm Evo V:

Track Rear Mm Evo V:

Weights

Curb Weight Kg Approx:

Gross Vehicle Weight Kg:

Fuel Tank Capacity Liters:

🛡️ Safety Features

Ratings

Crash Test Ratings:

Era-specific safety ratings, generally not comparable to modern standards. Focus on structural integrity.

Active Features

Standard Anti-lock Braking System

Active Yaw Control (enhances stability and handling)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners

Chassis Design:

Reinforced chassis for rally homologation standards.

💡 Technology Features

Infotainment

Head Unit:

Factory fitted radio/cassette or CD player, often with basic speaker systems. Aftermarket upgrades common.

Driver Assistance

Ayc System:

The primary electronic driver assistance feature, significantly enhancing handling dynamics.

Connectivity

Connectivity Features:

Limited to basic vehicle functions. No advanced Bluetooth or smartphone integration from factory.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 7,500 km or 6 months (whichever comes first, depending on driving conditions).

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 - 20,000 km or as needed based on inspection.

Spark Plug Replacement:

Every 30,000 - 40,000 km for standard plugs, potentially longer for performance plugs.

Coolant Flush:

Every 2-3 years or 40,000 - 60,000 km.

Transmission Fluid Change:

Every 40,000 - 60,000 km (manual transmission).

AWD Fluid Change:

Refer to manual for specific AYC, front/rear diff fluid change intervals (typically 40,000-60,000 km).

Fluid Specifications

Engine Oil:

API SG/SH, ACEA A2/A3, SAE 10W-40 or 10W-30 (check manual for precise viscosity based on climate).

Coolant:

Ethylene glycol-based, Mitsubishi Super Long Life Coolant (or equivalent) with a 50/50 mix of coolant and distilled water.

Transmission Fluid:

API GL-4 SAE 75W-90 synthetic gear oil (manual transmission).

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Timing Belt Failure:

Critical to follow replacement intervals to prevent catastrophic engine damage. Often cited as a potential failure point if neglected.

Ayc Pump Failure:

The AYC hydraulic pump can be a failure point, leading to loss of AYC functionality. Requires specialized diagnosis and repair.

Turbocharger Wear:

With high mileage, turbocharger seals can degrade, leading to oil consumption or reduced boost.

Suspension Bushings:

Wear on suspension bushings can lead to a less precise feel and affect alignment.

📚 Vehicle History

Brand Heritage

Rally Legacy:

Mitsubishi has a long and successful history in World Rally Championship (WRC), with the Lancer Evolution being its flagship rally car.

Model Evolution

Evo Iv Introduction:

Introduced in August 1996. Based on the Lancer Cedia platform.

Evo V Introduction:

Introduced in January 1998. Significant revisions over the Evo IV, focusing on chassis and powertrain enhancements.

Rally Homologation:

These models were crucial for homologating Mitsubishi's rally cars for WRC Group A regulations.

Production

Production Years Evo Iv:

1996-1998

Production Years Evo V:

1998-1999

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Rally Titles:

These road-going models were the homologation basis for numerous WRC championships won by Mitsubishi Ralliart drivers.

Performance Reviews:

Consistently praised by automotive media for their driving dynamics, handling, and all-wheel-drive capabilities.

Certifications

Homologation Standards:

Built to meet FIA Group A homologation requirements for rally competition.