Mitsubishi Lancer Evo 5 1998 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo 5) Chassis Code: CP9A Production Years: 1998-1999 Codes Engine Code: 4G63 Transmission Codes: W5M51 (Manual), F5A51 (Automatic - rare...

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类型: Car

斯库: 500489

标签: 1998 1999 Car Cars Lancer Evo 5 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution V (Evo 5)

Chassis Code:

Production Years:

1998-1999

Codes

Engine Code:

Transmission Codes:

W5M51 (Manual), F5A51 (Automatic - rare for Evo 5)

👋 Introduction

Market Position

Segment:

Performance Sedan, Rally Homologation Special

Target Audience:

Enthusiasts, performance drivers, rally fans, owners requiring in-depth technical knowledge.

Competitive Analysis

Competitors:

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

Key Features

Vehicle Legacy:

Iconic rally car, renowned for its 4WD system and potent turbocharged engine.

Manual Value Proposition:

Provides essential technical data for maintaining and repairing a highly specialized performance vehicle, crucial for preserving its value and performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Body, Diagnostics, Maintenance, Repair

Specific Systems:

Engine, Drivetrain, Suspension, Steering, Brakes, HVAC, Fuel System, Cooling System, Electrical System, Body Panels, Interior Components

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, oil pump, oil cooler.

Engine Management:

ECU diagnostics, sensor testing (MAP, TPS, O2, crank, cam), fuel injection system, ignition system, turbocharger operation and testing.

Drivetrain:

Manual transmission (W5M51) overhaul, clutch system, transfer case, Super AYC (Active Yaw Control) system diagnostics and repair, front and rear differentials.

Suspension:

Front and rear suspension component identification, diagnosis, replacement (struts, springs, control arms, bushings), alignment specifications.

Steering:

Power steering system diagnosis and repair, steering rack, tie rods, steering column.

Brakes:

Brake system overhaul, ABS (Anti-lock Braking System) diagnostics, brake fluid specifications, pad/rotor replacement procedures, caliper rebuilding.

Electrical System:

Wiring diagrams for all circuits, starter, alternator, battery, lighting systems, power windows, central locking, ECU pinouts, fuse and relay locations.

HVAC:

Air conditioning system diagnosis, refrigerant types, blower motor, evaporator, condenser, climate control unit.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, fuel tank, fuel lines, EVAP system.

Cooling System:

Radiator, water pump, thermostat, cooling fan operation, coolant specifications.

Bodywork:

Exterior panel removal/installation (fenders, bumpers, hood, trunk), door mechanisms, glass replacement, interior trim removal.

Procedures Included

Maintenance Routine:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, belt inspections/replacements.

Troubleshooting:

Diagnostic flowcharts for common drivability issues, electrical faults, starting problems, and system failures.

Repair Major:

Engine rebuilding, transmission overhaul, turbocharger replacement, clutch replacement, suspension component replacement, differential rebuilds.

Diagnostics:

OBD-II code interpretation, sensor testing using multimeters and oscilloscopes, specific diagnostic procedures for Super AYC.

Special Tools:

Listing and application of specific Mitsubishi special tools required for various repair procedures.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Detailed diagnostic procedures for all major systems.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Searchable text content for efficient information retrieval.

Print Quality

Printability:

Printable pages for workshop use.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4G63T MIVEC DOHC Inline-4

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Performance

Horsepower Ps:

280 PS @ 6500 rpm (Japanese Spec)

Torque Kgf M:

35.0 kgf·m @ 3000 rpm (Japanese Spec)

Boost Pressure:

1.0 bar (approx.)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) with Denso 560cc injectors

Fuel Type:

Unleaded Premium (95 RON recommended)

Turbocharger

Turbo Model:

Mitsubishi TD05HR-16G6-10.5cm²

🔧 Transmission

Standard

Type:

5-Speed Manual (W5M51)

Optional

Type:

4-Speed Automatic (F5A51) - Very Rare for Evo 5

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Yaw Control (AYC)

Transfer Case:

Mechanical, integrated with transmission

Limited Slip:

Front: Helical LSD, Rear: Mechanical LSD

📐 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)

Weights

Curb Weight:

1400 kg (3086 lbs)

🛡️ Safety Features

Ratings

NHTSA Rating:

Not Rated (Vehicle pre-dates extensive NHTSA testing for performance variants)

Active Features

Standard Anti-lock Braking System (ABS)

Active Yaw Control (AYC) for enhanced cornering stability and traction

Passive Features

Airbags:

Driver and Passenger Front Airbags

Seatbelts:

3-point Inertia-reel seatbelts with pre-tensioners

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio with CD player and cassette tape deck, speaker system.

Climate Control:

Manual or automatic climate control depending on trim level.

Driver Assistance

Standard ABS.

Advanced Active Yaw Control (AYC) system for superior handling.

Connectivity

Connectivity Features:

Limited by era; typically no Bluetooth or USB connectivity in factory form.

🔧 Maintenance

Service Intervals

Oil Change Interval:

5,000 km (3,000 miles) or 6 months, whichever comes first (severe usage recommended)

Timing Belt Replacement:

100,000 km (60,000 miles) or 5 years

Spark Plug Replacement:

40,000 km (25,000 miles) for standard plugs, or as per manual for iridium plugs

Fluid Specifications

Engine Oil:

API SG/SH or ACEA A2/A3, Viscosity: 10W-30 or 5W-30 (depending on climate). Capacity: 4.5 Liters with filter.

Coolant:

Mitsubishi Diaqueen Super Long Life Coolant (LLC) or equivalent (50/50 mix of ethylene glycol and distilled water). Capacity: Approx. 7.5 Liters.

Brake Fluid:

DOT 3 or DOT 4

Transmission Fluid:

Manual: SAE 75W-90 API GL-4/GL-5 (check specific manual for AYC compatibility). Capacity: Approx. 2.3 Liters.

Transfer Case Fluid:

SAE 75W-90 API GL-5. Capacity: Approx. 0.8 Liters.

Rear Differential Fluid:

SAE 75W-90 API GL-5. Capacity: Approx. 1.1 Liters.

Known Issues

Engine Wear:

Piston ring wear, connecting rod bearing failure (especially if modified or abused), turbocharger seal leaks.

Ayc System:

Failure of AYC pump, solenoids, or sensors leading to incorrect yaw control operation or warning lights.

Clutch:

Premature clutch wear, especially in high-performance driving scenarios.

Suspension Bushings:

Wear in suspension bushings leading to imprecise handling and noise.

Rust Corrosion:

Susceptible to rust on body panels, chassis components, and exhaust systems, particularly in regions with harsh climates.

📚 Vehicle History

Brand Heritage

Rally Success:

Mitsubishi's long-standing success in the World Rally Championship (WRC) heavily influenced the Lancer Evolution lineage.

Model Evolution

Evo V Development:

Evo 5 was a significant redesign, featuring a wider track, larger wheels, updated aerodynamics, and an improved AYC system to meet WRC homologation requirements.

Chassis Update:

Utilized the wider chassis of the Mitsubishi Lancer GSR Evolution IV.

Production

Production Volume:

Limited production, primarily for the Japanese domestic market, with some grey market imports globally.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Rally Credentials:

While the Evo 5 itself was primarily a homologation special, the Lancer Evolution platform consistently dominated WRC stages and championships throughout the 1990s and early 2000s.

Ratings

Performance Reviews:

Universally praised by automotive journalists for its exceptional handling, braking, and acceleration capabilities.

Certifications

Homologation:

Built to meet FIA Group A homologation requirements for rallying.