Mitsubishi Lancer Evo 5 1998 1999 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo 5) Chassis Code: CP9A Generation Generation: Fifth Generation Codes Production Years: 1998-1999 👋 Introduction Market Position Market Segment: High-performance...

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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:

Generation

Generation:

Fifth Generation

Codes

Production Years:

1998-1999

👋 Introduction

Market Position

Market Segment:

High-performance rally homologation special sedan

Target Audience:

Enthusiasts, tuners, mechanics specializing in rally-bred performance vehicles

Competitive Analysis

Key Competitors:

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

Key Features

Performance Focus:

Engineered for high-speed rallying and track performance

All Wheel Drive:

Advanced Super Active All-Wheel Drive (AYC) system

Turbocharged Engine:

Powerful turbocharged and intercooled engine designed for responsiveness

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Coverage Scope:

Comprehensive repair and overhaul

Page Count

Page Count:

N/A (PDF format, variable depending on digital rendering)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine overhaul, disassembly, assembly, tuning, diagnostics

Engine Electrical:

Ignition system, fuel injection system, starting and charging systems, ECU (Engine Control Unit) diagnostics

Transmission:

Manual transmission (Type-MR), transfer case, differentials (front, center, rear)

Suspension:

Front and rear suspension systems, struts, springs, bushings, alignment specifications

Brakes:

Front and rear brake systems, caliper overhaul, ABS (Anti-lock Braking System) diagnostics

Steering:

Power steering system, steering rack, tie rods, alignment

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan assembly

Fuel System:

Fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulator

Exhaust System:

Exhaust manifold, catalytic converter, muffler, pipes

Electrical System:

Wiring diagrams, lighting, accessories, battery, fuses, relays

Body And Chassis:

Body panel removal and installation, chassis components, corrosion protection

HVAC System:

Heating, Ventilation, and Air Conditioning system components and service

Interior Trim:

Dashboard, seats, door panels, carpet removal and installation

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, spark plug replacement

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based diagnosis

Component Overhaul:

Detailed steps for rebuilding major components like engines, transmissions, and turbochargers

Diagnostic Procedures:

Step-by-step guides for identifying and resolving issues using diagnostic tools and methods

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Tightening Torques:

Specific torque values for all critical fasteners

Special Tools:

Identification and usage of specialized tools required for specific procedures

Technical Depth

Depth:

In-depth, suitable for professional technicians and experienced DIY enthusiasts

Detail Level:

Detailed illustrations, diagrams, specifications, and step-by-step instructions

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable (depending on PDF source quality)

Print Quality:

Depends on the source PDF; generally printable at home or professional print shops

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T (Evo V)

Engine Type:

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

Displacement:

1997 cc (2.0 Liters)

Performance

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Horsepower Ps:

280 PS @ 6500 rpm (JDM specification; actual output often higher)

Horsepower Hp:

276 hp @ 6500 rpm (approx. US spec conversion)

Torque Nm:

372 Nm @ 3000 rpm (JDM specification)

Torque Lb-Ft:

275 lb-ft @ 3000 rpm (approx. US spec conversion)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (95 RON or higher recommended)

Turbocharger:

Mitsubishi TD05HR-16G (later spec, often upgraded from earlier models)

Intercooler:

Large Front-Mount Intercooler (FMIC)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Type-MR)

Optional

Type:

N/A (Manual transmission was standard for Evo V)

Features

Drivetrain:

All-Wheel Drive (AWD)

Center Differential:

Active Centre Differential (ACD) with mechanical limited-slip differential (LSD) capabilities

Rear Differential:

Active Yaw Control (AYC) equipped rear differential with LSD

Gear Ratios:

Specific ratios are detailed in the manual, critical for performance tuning.

Clutch Type:

Hydraulic, single-plate, dry

📐 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:

1505 mm (59.3 in)

Track Width Rear:

1500 mm (59.1 in)

Ground Clearance:

150 mm (5.9 in)

Weights

Curb Weight:

Approx. 1350 kg (2976 lbs)

Gross Vehicle Weight Rating:

N/A (Specific GVWR not commonly cited for homologation specials)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not specifically tested by modern agencies like NHTSA or Euro NCAP due to its era and limited production. Focus on active safety for its intended use.

Active Features

Standard Anti-lock Braking System (ABS)

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

Active Centre Differential (ACD) with selectable modes for varied traction conditions

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners

Chassis Reinforcement:

Enhanced chassis rigidity for rally-derived performance

💡 Technology Features

Infotainment

Audio System:

Basic factory AM/FM stereo with cassette player and CD compatibility (depending on market and trim). Likely aftermarket upgrades common.

Driver Assistance

Standard ABS system, crucial for high-performance braking.

Active Yaw Control (AYC) is a key technological feature for torque vectoring and dynamic stability.

Connectivity

Connectivity Features:

N/A (No modern connectivity features like Bluetooth or USB from factory)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first (depending on driving conditions). Manual specifies interval.

Air Filter Replacement:

Every 15,000 - 20,000 km (9,000 - 12,000 miles) or annually.

Spark Plug Replacement:

Every 30,000 - 40,000 km (18,000 - 25,000 miles).

Timing Belt Replacement:

Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5-7 years. Crucial due to interference engine design.

Fluid Specifications

Engine Oil:

API SG/SH, SAE 10W-30 or 10W-40 recommended (check manual for specific grades and capacities).

Coolant:

Ethylene Glycol-based antifreeze, 50/50 mix with distilled water. Capacity approx. 7.5 Liters.

Transmission Fluid:

Manual Transmission Fluid, API GL-4/GL-5, SAE 75W-90. Capacity approx. 2.5 Liters for gearbox, 0.6 Liters for transfer case, 1.0 Liter for rear diff.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

ATF Dexron II or equivalent.

Known Issues

Engine Reliability:

Generally robust 4G63T, but can suffer from ringland failure if consistently run with detonation or pushed beyond its limits without proper tuning/cooling. Turbocharger seals can wear.

Ayc System:

AYC pump and sensors can fail over time, leading to warning lights and loss of functionality. Repair or bypass options exist.

Clutch Wear:

Clutch wear is dependent on driving style; performance clutches can wear faster under aggressive use.

Suspension Bushings:

Rubber bushings in suspension and differentials can degrade over time, affecting handling.

📚 Vehicle History

Brand Heritage

Rally Legacy:

Mitsubishi has a storied history in the World Rally Championship (WRC), with the Lancer Evolution series being a direct result of homologation requirements.

Model Evolution

Evo V Development:

Evo V was a significant step up, featuring wider track, larger wheels, and revised aerodynamics compared to the Evo IV.

Engine Enhancements:

The 4G63T engine received further refinement, including a larger turbocharger and improved intercooler for increased power and responsiveness.

Production

Manufacturing Location:

Japan

Production Volume:

Limited production, highly sought after by enthusiasts and collectors.

Homologation Purpose:

Developed to meet Group A rally regulations for WRC.

🏆 Awards & Recognition

Recognitions

Rally Performance:

Consistently praised for its rally-bred performance and handling capabilities by automotive publications of its era.

Enthusiast Following:

Maintains a strong cult following among car enthusiasts globally for its iconic status and performance.