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Mitsubishi

Mitsubishi Evo 4 & 5 1996-1999 Service Repair Manual

Mitsubishi Evo 4 & 5 1996-1999 Service Repair Manual

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Vehicle data plateRef 500481
Brand
Mitsubishi
Vehicle
Cars
Models covered
Evo 4, Evo 5, Misc
Years
1996, 1997, 1998, 1999
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Generation:
IV & V
Model Code Evo Iv:
CN9A
Model Code Evo V:
CP9A
Model Years Covered:
1996, 1997, 1998, 1999
👋 Introduction
Market Position
Market Segment:
Performance Sedan / Rally Homologation Special
Reputation:
Iconic rally-bred performance car, celebrated for its sophisticated AWD system, powerful turbocharged engine, and handling prowess.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale.
Key Features
Signature Features:
Advanced All-Wheel Drive, turbocharged intercooled engine, aggressive styling, homologation for WRC, driver-focused cockpit.
Manual Value
Target Audience:
Mitsubishi Lancer Evolution owners, mechanics, performance tuners, enthusiasts.
Utility For Owners:
Enables DIY maintenance, repairs, and performance upgrades, saving costs and understanding vehicle systems.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primary focus on JDM and European markets)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full coverage: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system, timing belt/chain, seals, gaskets, engine mounts.
Engine Performance:
Turbocharger system (TD05HR-16G for Evo IV, TD05HRA-15G for Evo V), intercooler, fuel injection system (MPI), ignition system, engine control unit (ECU) operation and diagnostics.
Transmission:
Manual Transmission (W5M33), transfer case, clutch system, shift linkages, transmission mounts, fluid specifications.
Drivetrain:
All-Wheel Drive (AWD) system, Active Center Differential (ACD) for Evo V, viscous coupling, rear differential, driveshafts, CV joints, wheel bearings.
Suspension:
Front and rear suspension systems (MacPherson struts front, multi-link rear), springs, shock absorbers, control arms, anti-roll bars, bushings, alignment specifications.
Brakes:
Front ventilated discs, rear solid discs, ABS system (Bosch), brake calipers, master cylinder, brake lines, parking brake, brake fluid specifications.
Steering:
Power assisted rack and pinion steering system, steering column, tie rods, steering knuckle, power steering fluid.
Electrical:
Wiring diagrams, battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, power windows, power locks, central locking.
Body And Chassis:
Body panel removal and installation, door mechanisms, hood, trunk, bumpers, interior trim, chassis structure, rust prevention, body sealing.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, compressor, condenser, evaporator, refrigerant types, cabin filter.
Procedures Included
Maintenance:
Routine maintenance schedules, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change.
Repair:
Engine rebuild procedures, head gasket replacement, turbocharger rebuild/replacement, transmission overhaul, clutch replacement, suspension component replacement, brake caliper rebuild, electrical component diagnosis and repair.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, error code interpretation (OBD-I/OBD-II relevant codes), electrical circuit testing, mechanical component testing.
Special Tools:
Identification and usage of specialized tools required for specific repairs and adjustments.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Detailed diagnostic procedures and specifications for all major systems.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Scan Quality:
High-resolution scans, clear text and images, searchable content.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Evo Iv:
4G63T
Engine Code Evo V:
4G63T (revised)
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged, intercooled
Displacement:
1997cc (2.0 Liters)
Performance
Horsepower Evo Iv:
276 bhp @ 6250 rpm (JDM Spec)
Torque Evo Iv:
350 Nm (258 lb-ft) @ 3000 rpm (JDM Spec)
Horsepower Evo V:
276 bhp @ 6250 rpm (JDM Spec), increased torque
Torque Evo V:
373 Nm (275 lb-ft) @ 3000 rpm (JDM Spec)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI), Electronic Fuel Control (EFC)
Fuel Type:
Unleaded gasoline (98 RON recommended)
Ignition System:
Distributorless Ignition System (DIS) with individual coil packs
Turbocharger
Turbocharger Evo Iv:
Mitsubishi TD05HR-16G
Turbocharger Evo V:
Mitsubishi TD05HRA-15G (slightly smaller for improved response)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Transmission Code:
W5M33
Optional
Optional Transmission:
None (Only Manual Available)
Features
Drivetrain Type:
All-Wheel Drive (AWD)
Acd Evo V:
Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow) - Standard on Evo V
Transfer Case:
Mechanical transfer case with viscous coupling
Clutch Type:
Hydraulically operated, single dry plate clutch
Fluid Specifications
Transmission Fluid Type:
GL-4 Gear Oil (e.g., Mitsubishi Diaqueen LSD Gear Oil 75W-85)
Transfer Case Fluid Type:
GL-4 Gear Oil (e.g., Mitsubishi Diaqueen LSD Gear Oil 75W-85)
📐 Dimensions
Exterior
Length Evo Iv:
4350 mm (171.3 in)
Length Evo V:
4370 mm (172.0 in)
Width:
1770 mm (69.7 in)
Height Evo Iv:
1415 mm (55.7 in)
Height Evo V:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Front Track Evo V:
1505 mm (59.3 in)
Rear Track Evo V:
1505 mm (59.3 in)
Weights
Curb Weight Evo Iv:
Approx. 1450 kg (3197 lbs)
Curb Weight Evo V:
Approx. 1460 kg (3219 lbs)
Gross Vehicle Weight Rating:
Approx. 1735 kg (3825 lbs)
🛡️ Safety Features
Ratings
Crash Test Results:
No specific official crash test ratings widely published for these JDM-homologated models from the era, but engineered to strict rally safety standards.
Active Features
Active Features:
Anti-lock Braking System (ABS), Active Center Differential (ACD) on Evo V.
Passive Features
Passive Features:
Frontal airbags (driver and passenger), three-point seatbelts with pre-tensioners, reinforced chassis structure, impact-absorbing crumple zones.
Chassis Design
Chassis Type:
Monocoque chassis based on Lancer platform, significantly reinforced for rally use.
💡 Technology Features
Infotainment
Infotainment System:
Basic JDM radio/cassette player, optional CD player. Focus is on performance, not advanced infotainment.
Driver Assistance
Driver Assistance Features:
ABS, AYC (Evo IV), ACD (Evo V) - primarily focused on enhancing driving dynamics and control.
Connectivity
Connectivity:
N/A (No integrated Bluetooth, USB, or advanced connectivity features).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first (severe use recommended).
Air Filter Replacement:
Every 10,000 km (6,000 miles) or 12 months.
Spark Plug Replacement:
Every 30,000 km (18,000 miles).
Timing Belt Replacement:
Every 100,000 km (60,000 miles) or 5 years.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 (synthetic recommended for performance).
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene glycol-based coolant (Mitsubishi Super Long Life Coolant recommended), 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Problems:
Head gasket failure (especially if modified or poorly maintained), turbocharger wear, clutch wear, AYC/ACD system issues, rust in wheel arches and sills, differential wear.
Performance Tuning Considerations:
Requires careful tuning to avoid engine damage, particularly concerning air-fuel ratios and detonation under boost.
📚 Vehicle History
Brand Heritage
Brand History:
Mitsubishi Motors, a Japanese multinational automotive manufacturer with a strong heritage in motorsports, particularly rallying.
Model Evolution
Evolution Iv Introduction:
Introduced in August 1996, featuring a redesigned chassis, improved aerodynamics, and the introduction of the Active Yaw Control (AYC) system.
Evolution V Introduction:
Introduced in January 1998, significant updates included wider bodywork, larger wheels (17-inch), revised suspension geometry, and the introduction of the Active Center Differential (ACD) replacing AYC on some models.
Production
Production Location:
Japan (Mizushima Plant)
Production Years Overall:
1996-1999 (for Evo IV and V models)
Motorsport Connection
Wrc Homologation:
Developed as a homologation special for the World Rally Championship (WRC), featuring performance enhancements derived from rally racing technology.
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
The Lancer Evolution platform is a multiple-time World Rally Champion (driver and manufacturer titles achieved with subsequent models, but the DNA starts here).
Enthusiast Recognition
Reputation Among Enthusiasts:
Highly regarded as a future classic and one of the most iconic performance cars of the 1990s.

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