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Mitsubishi

Mitsubishi Lancer Evo 4 1996-1998 Repair Service Manual

Mitsubishi Lancer Evo 4 1996-1998 Repair Service Manual

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Vehicle data plateRef 70555
Brand
Mitsubishi
Vehicle
Cars
Models covered
Lancer Evo 4, Misc
Years
1996, 1997, 1998
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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This manual covers the Mitsubishi Lancer Evolution IV (Evo 4), produced from 1996 to 1998, identified by chassis code CN9A and featuring the robust 4G63 engine. Celebrated as an iconic rally homologation special, the Evo 4 is renowned for its exceptional performance and advanced engineering. Key highlights include its potent 2.0L turbocharged 4G63T engine, a sophisticated All-Wheel Drive system equipped with Active Yaw Control (AYC), an aggressive aerodynamic body kit, and a significantly reinforced chassis. These attributes cemented its status as a benchmark in performance sedans, rivaling contemporaries like the Subaru Impreza WRX STi. This comprehensive Factory Workshop Service Manual, approximately 1500+ pages in English, provides in-depth guidance for owners, mechanics, and technicians. It covers all essential aspects of the vehicle, from routine scheduled maintenance and fluid checks to complex engine and transmission rebuilds. Detailed sections include powertrain, drivetrain (featuring AYC), chassis, and electrical systems, alongside specific procedures for diagnostics, troubleshooting, and repair. The manual also details technical specifications, special tool requirements, and torque values, ensuring accurate and effective maintenance and repair for the Lancer Evolution IV.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV (Evo 4)
Model Code:
CN9A
Production Years:
1996-1998
Codes
Engine Codes Covered:
4G63
Chassis Codes Covered:
CN9A
👋 Introduction
Market Position
Positioning:
Iconic rally homologation special, celebrated for its performance and advanced technology.
Competitive Analysis
Competitors Covered By Manuals:
Provides in-depth data comparable to or exceeding factory manuals for vehicles like Subaru Impreza WRX STi, Toyota Celica GT-Four, and Ford Escort RS Cosworth of the era.
Key Features
Key Features Of Vehicle:
4G63 2.0L turbocharged engine, advanced All-Wheel Drive with Active Yaw Control (AYC), aggressive aerodynamic body kit, stiffened chassis.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Yes
Specific Markets Covered:
Japan (JDM)
Page Count
Estimated Page Count:
Approximately 1500+
Manual Type
Type:
Factory Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System
Drivetrain:
Transmission (Manual & Automatic), Transfer Case, Front Differential, Rear Differential, Active Yaw Control (AYC)
Chassis:
Suspension (Front & Rear), Steering System, Brake System (ABS Included), Wheels & Tires
Electrical:
Wiring Diagrams, Lighting System, Ignition System, Starting System, Charging System, Instrumentation, HVAC Controls, Audio System, Power Accessories
Body:
Exterior Body Panels, Interior Trim, Glass, Doors, Locks, Bumpers, Aerodynamics
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks & Replenishments, Spark Plug Service, Belt Replacement
Troubleshooting:
Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting Guides
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair, Body Panel Repair
Diagnostics:
On-Board Diagnostics (OBD-I/OBD-II as applicable), Sensor Testing, Actuator Testing
Special Procedures:
AYC System Calibration, Timing Belt Replacement, Turbocharger Servicing, Differential Fluid Changes
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and fault isolation procedures.
Torque Specifications:
Extensive torque specifications for all critical fasteners.
Special Tools:
Identification and usage of required special service tools (SST).
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans, clear text and diagrams.
Searchable:
Yes, typically text-searchable PDF.
Print Quality
Printable:
Yes, designed for printing.
Binding Type
Binding Type For Original:
Perfect bound or spiral bound (for original manuals).
Paper Type
Paper Type For Original:
High-quality, durable paper stock.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged and intercooled
Engine Code:
4G63T
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
280 PS (276 hp) @ 6500 rpm (JDM spec, often under-rated)
Torque Nm:
350 Nm (258 lb-ft) @ 3000 rpm (JDM spec)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with Electronic Fuel Control System (EFCS)
Fuel Type:
Unleaded premium gasoline (95-98 RON recommended)
Cooling System
Cooling Medium:
Water-cooled, pressurized system
Lubrication System
Oil Capacity Liters:
4.5 Liters (with filter change)
Ignition System
Ignition Type:
Electronic ignition system with distributorless ignition system (DIS) on later models or distributor on early models.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Type-MR)
Optional
Type:
None (Evo 4 was exclusively manual)
Features
Drivetrain Type:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Ayc Description:
Electronically controlled torque distribution to rear wheels for enhanced cornering stability.
📐 Dimensions
Exterior
Length Mm:
4350 mm
Width Mm:
1770 mm
Height Mm:
1415 mm
Wheelbase Mm:
2600 mm
Track Front Mm:
1515 mm
Track Rear Mm:
1505 mm
Weights
Curb Weight Kg:
1400 kg
Gross Vehicle Weight Kg:
1700 kg
Wheels Tires
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
215/45R17
Bolt Pattern:
5x114.3
🛡️ Safety Features
Ratings
Overall Ratings:
N/A (Vehicle of its era, crash testing standards were different)
Active Features
Active Safety:
All-Wheel Drive, AYC, ABS (Anti-lock Braking System), Helical Limited Slip Differential (Front), Viscous Coupling Center Differential.
Passive Features
Passive Safety:
Reinforced chassis structure, driver-side airbag (standard in many markets), three-point seatbelts with pre-tensioners.
Brakes
Front Brakes:
Ventilated Discs, 2-piston calipers (Brembo on RS models)
Rear Brakes:
Solid Discs, 1-piston calipers
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Basic speaker system.
Climate Control:
Manual air conditioning and heating controls.
Driver Assistance
Advanced Features:
Active Yaw Control (AYC) is the primary advanced drivetrain technology.
Connectivity
Connectivity Options:
None from factory (era-appropriate).
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
5,000 - 7,500 km or 6 months (severe use recommended for performance driving)
Spark Plug Replacement Km:
40,000 - 60,000 km (depending on plug type)
Timing Belt Replacement Km:
90,000 - 100,000 km or 5-7 years (critical maintenance item)
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-30 / 10W-40 (synthetic recommended for high performance)
Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (Manual Transmission)
Transfer Case Fluid Type:
API GL-5, SAE 75W-90
Rear Differential Fluid Type:
API GL-5, SAE 75W-90 (Limited Slip Differential oil may be required for AYC rear diff)
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water)
Known Issues
Common Wear Items:
Clutch, brake pads/rotors, suspension bushings, turbocharger seals, engine mounts.
Potential Failures:
Connecting rod failure due to detonation (if improperly tuned or maintained), AYC pump failure, turbocharger failure from lack of maintenance or oil starvation.
Corrosion:
Check for rust on chassis, suspension components, and exhaust system, especially in areas with harsh winters.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Built on Mitsubishi's extensive success in the World Rally Championship (WRC).
Model Evolution
Evolution Series:
Fourth generation in the Lancer Evolution lineage, introducing significant chassis and drivetrain enhancements over the Evo III.
Key Changes From Evo Iii:
Wider track, revised suspension geometry, introduction of AYC, stronger chassis rigidity, new twin-scroll turbocharger.
Production
Production Location:
Mizushima Plant, Kurashiki, Japan
Production Volume:
Approximately 10,000 units (combined for GSR and RS variants)
🏆 Awards & Recognition
Recognitions
Automotive Press Recognition:
Consistently praised by automotive journalists for its incredible handling, grip, and rally-bred performance.
Performance Benchmarks:
Often ranked among the best performance sedans of its era, a benchmark for AWD performance.
Certifications
Homologation:
Built to meet Group A homologation requirements for the World Rally Championship.

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