Mitsubishi Lancer Evolution 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Year: 1999 Codes Chassis Code: CP9A 👋 Introduction Market Position Vehicle Segment: Performance Compact Sedan / Rally Homologation Special Target Audience:...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Performance Compact Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, tuners, rally competitors, and owners seeking in-depth maintenance and repair knowledge.

Competitive Analysis

Direct Competitors:

Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort Cosworth.

Key Features

Performance Focus:

Engineered for high-performance driving and motorsport applications.

AWD System:

Advanced All-Wheel Drive (AWD) with Active Yaw Control (AYC) for superior traction and handling.

Engine Technology:

Robust 4G63T turbocharged inline-4 engine, renowned for its tuning potential and durability.

📋 Manual Details

Coverage Areas

Coverage Continents:

Global (primarily focused on JDM and European markets)

Coverage Regions:

Japan, Europe

Page Count

Estimated Page Count:

Approx. 2000+ pages (across multiple volumes or sections if compiled)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagnostics, disassembly, assembly, inspection, repair, and overhaul of 4G63T engine components (turbocharger, pistons, crankshaft, camshafts, valve train, cooling system, lubrication system).

Engine Management:

Engine Control Unit (ECU) operation, sensor diagnostics (MAP, TPS, IAT, Knock, O2), actuator control, fuel injection, ignition timing, emissions control systems.

Transmission Manual:

RM2A (5-speed) gearbox: inspection, repair, clutch system, gear shift mechanism, lubrication.

Transmission AWD:

Super Active Yaw Control (S-AYC) system: operation, diagnostics, hydraulic control unit, actuators, sensors. Rear differential, viscous coupling unit (VCU).

Braking System:

Front Brembo 4-piston calipers, rear 2-piston calipers: hydraulic system, brake fluid, master cylinder, power booster, ABS system diagnostics and repair, rotor and pad replacement.

Suspension Steering:

MacPherson strut front, multi-link rear suspension: component inspection, alignment specifications, shock absorber replacement, spring replacement, power steering system diagnostics.

Electrical System:

Wiring diagrams, fuse box locations, component testing, starter, alternator, battery, lighting system, horn, wipers, power windows, central locking.

Body Interior:

Body panel removal and installation, interior trim components, seat adjustment and removal, door mechanisms, glass replacement.

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, climate control operation.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, differential fluid changes.

Troubleshooting:

Diagnostic flowcharts for common engine performance issues, starting problems, electrical faults, and system malfunctions.

Repair Overhaul:

Complete engine rebuild procedures, transmission overhaul, turbocharger replacement, clutch replacement, brake caliper rebuilding.

Diagnostics:

On-Board Diagnostics (OBD-I/OBD-II) system, fault code retrieval and interpretation, live data stream analysis.

Installation:

Procedures for replacing major components such as the engine, transmission, turbocharger, suspension arms, and braking components.

Technical Depth

Diagnostic Tools:

References to required diagnostic tools, scan tools (MUT-II or equivalent), pressure gauges, multimeters.

Torque Specifications:

Comprehensive list of all critical torque specifications for engine, drivetrain, suspension, and chassis components.

Clearances Tolerances:

Detailed specifications for piston-to-wall clearance, bearing clearances, valve lash, gear backlash, and other critical engine and drivetrain tolerances.

Wiring Diagrams:

Full electrical schematics for all vehicle systems, including engine management, chassis electronics, lighting, and accessories.

Special Tools:

Identification and use of specialized tools required for specific repair procedures (e.g., piston ring compressor, valve spring compressor, flywheel locking tool).

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable PDF with clear diagrams and text.

Print Quality

Print Readability:

Designed for clear printing, ensuring legibility of technical diagrams and specifications.

Binding Type

Binding Type:

N/A (Digital PDF download)

Paper Type

Paper Type:

N/A (Digital PDF download)

Completeness

Completeness Level:

Complete Factory Service Manual (FSM)

Searchability

Search Functionality:

Fully searchable text for quick access to specific information.

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

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

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower:

Approx. 276-280 PS (272-276 hp) JDM/European spec

Torque:

Approx. 343-370 Nm (253-273 lb-ft) JDM/European spec

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (High Octane)

Turbocharger:

Mitsubishi TD05H-16G (or similar variant), twin-scroll

Lubrication

Oil Capacity:

Approx. 4.5 Liters (with filter)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Transmission Model:

Optional

Optional Transmission:

N/A (Manual transmission standard for Evolution models)

Features

Drive System:

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

Transfer Case:

Center viscous coupling

Gear Ratios Final Drive:

Manual 1-5: 3.083 / 2.000 / 1.304 / 0.912 / 0.741; Final Drive: 4.563 (typical)

📐 Dimensions

Exterior

Length:

Approx. 4350 mm (171.3 in)

Width:

Approx. 1770 mm (69.7 in)

Height:

Approx. 1415 mm (55.7 in)

Wheelbase:

Approx. 2600 mm (102.4 in)

Track Width Front:

Approx. 1500 mm (59.1 in)

Track Width Rear:

Approx. 1495 mm (58.9 in)

Weights

Curb Weight:

Approx. 1360-1400 kg (2998-3086 lbs)

Gross Vehicle Weight:

Not explicitly stated, but designed for performance.

🛡️ Safety Features

Ratings

NHTSA Rating:

Not available for this specific early model year in a standardized global format.

Euro Ncap Rating:

Not available for this specific early model year.

Active Features

Standard Anti-lock Braking System (ABS), likely 4-channel.

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

Passive Features

Airbags:

Driver and front passenger airbags (standard).

Seatbelts:

3-point front seatbelts with pretensioners.

Body Construction:

Reinforced body structure for increased rigidity and crash protection.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or CD player with optional upgraded systems.

Climate Control:

Manual climate control with A/C and heater.

Driver Assistance

Traction Control:

AWD with AYC provides advanced traction and stability control beyond basic systems.

Instrumentation:

Comprehensive gauge cluster including boost gauge, oil temperature, and water temperature.

Connectivity

Connectivity Features:

Basic vehicle connectivity; no modern infotainment integration like Bluetooth or USB.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, depending on driving conditions.

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 (18,000-24,000 miles) for standard plugs; platinum/iridium may vary.

Timing Belt Replacement:

Every 60,000-100,000 km (36,000-60,000 miles) or 5-7 years (critical maintenance item for 4G63T).

Fluid Specifications

Engine Oil Specification:

API SG or higher, SAE 10W-30 or 10W-40 (synthetic recommended for performance driving).

Coolant Specification:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant (50/50 mix with distilled water).

Brake Fluid Specification:

DOT 3 or DOT 4.

Transmission Fluid Specification:

API GL-4 or GL-5 SAE 75W-90 Hypoid Gear Oil (Manual Transmission).

Transfer Case Fluid Specification:

API GL-4 or GL-5 SAE 75W-90 Hypoid Gear Oil.

Rear Differential Fluid Specification:

API GL-5 SAE 75W-90 Hypoid Gear Oil.

Known Issues

Engine Bearing Wear:

Rod bearing failure can occur with aggressive driving, insufficient oil, or poor maintenance. Timing belt integrity is paramount.

Clutch Wear:

High-performance clutch can wear faster under aggressive driving conditions.

Ayc System Faults:

Hydraulic leaks or pump failures in the AYC system can occur over time, often indicated by warning lights.

Turbocharger Wear:

Oil starvation or contamination can lead to premature turbocharger wear or failure.

Suspension Bushings:

Rubber bushings in the suspension can degrade over time, affecting handling and requiring replacement.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Direct descendant of Mitsubishi's rally heritage, homologated for WRC Group A.

Model Evolution

Generation:

Fifth Generation Lancer Evolution (Evo V)

Key Changes From Previous:

Wider track, larger front bumper air intakes, revised front grille, larger rear spoiler, improved AYC system, revised ECU, larger intercooler.

Production

Production Years:

1998-1999

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorsport Dominance:

The Lancer Evolution platform is legendary for its success in the World Rally Championship (WRC).

Ratings

Performance Car Reviews:

Consistently lauded by automotive press for its sharp handling, powerful engine, and advanced AWD system.

Certifications

Homologation:

Built to homologate the Lancer for Group A rally racing.