Page 2 of 558

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
N9806CNCP9-A
WORKSHOP MANUAL
S9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
The EVOLUTION -VI is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VI is a rally-
based model, it will not be warranted and will not be
homologated for general production. Therefore, any
service matters on the EVOLUTION-VI should be
inquired to RALLIART Inc. as usual.
EVOLUTION-VI
Mitsubishi Motors Corporation March 1999
Interior and Supplemental
Restraint System (SRS) . . . . . . . . .
.
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . .
.
Page 17 of 558
GENERAL – Models00-14
MODELS
Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
E-CN9ASNDF’97RS4G63 (2,000-DOHC –
16 valves-intercooler
W5M51
(4WD-5M/T)
Electronically
controlledfuel
SRGF’97GSR
16 valves-intercooler
turbo)
(4WD-5M/T)controlled fuel
injection (MPI)
Applicable serial numbers
E-CN9A: CN9A – 0000001
Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
GF-CP9ASNDF’98EVOLUTION-V RS4G63 (2,000-DOHC –
16 valves intercooler
W5M51
(4WD 5M/T)
MPI
SNGF’98EVOLUTION-V
GSR
16 valves-intercooler
turbo)(4WD-5M/T)
Applicable serial numbers
GF-CP9A: CP9A – 0000001
Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
GF-CP9ASNDF’99EVOLUTION-VI
RS4G63 (2,000-DOHC –
16 valves-intercooler
turbo)
W5M51
(4WD-5M/T)MPI
SNGF’99EVOLUTION-VI
GSRturbo)
Applicable serial numbers
GF-CP9A: CP9A – 0100001
Page 26 of 558

11-1
ENGINE
CONTENTS
GENERAL INFORMATION 2. . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . .
Service Specifications 3. . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 5. . . . . . . . . . . . . . . . . . . . . .
New Tightening Method by Use of Bolts
to Be Tightened in Plastic Area 9. . . . . . . . . . . .
Sealants 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Form-In-Place Gasket 10. . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 11. . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR AND IGNITION SYSTEM 14.
TIMING BELT 15. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL AND EMISSION CONTROL PARTS 27
SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST MANIFOLD 31. . . . . . . . . . . . . . . . .
WATER PUMP AND WATER HOSE 34. . . . .
ROCKER ARMS AND CAMSHAFT 37. . . . . .
CYLINDER HEAD AND VALVES 43. . . . . . . .
FRONT CASE, COUNTERBALANCE
SHAFT AND OIL PAN 51. . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD 59. . . . . .
CRANKSHAFT AND FLYWHEEL 67. . . . . . . .
THROTTLE BODY 73. . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER 75. . . . . . . . . . . . . . . . . . . . .
ALTERNATOR 79. . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR 83. . . . . . . . . . . . . . . . . . . . .
Page 31 of 558
ENGINE – Specifications11-6
ItemsNm
Rocker cover3.5
Engine support bracket49
Camshaft sprocket bolt88
Timing belt rear right cover11
Timing belt rear left upper cover11
Fuel and emission control parts
Throttle body18
Fuel pressure regulator9
Delivery pipe11
Vacuum tank bracket9
Solenoid valve bracket9
Solenoid valve9
Vacuum hose and vacuum pipe11
Secondary air intake manifold
Heat protector13
Vacuum hose and vacuum pipe11
Air pipe (Heat protector side)13
Air pipe (Cam position sensor side)11
Air pipe (Eye bolt)49
Air pipe (Control valve side)24
Air control valve21
Air control valve bracket24
Intake manifold stay30
Intake manifold (M8)19
Intake manifold (M10)35
Exhaust manifold
Engine hanger12
Heat protector (Turbocharger side)14
Oxygen sensor54
Exhaust fitting bolt59
Exhaust fitting nut59
Air outlet fitting19
Page 52 of 558
ENGINE – Fuel and Emission Control Parts11-27
FUEL AND EMISSION CONTROL PARTS
REMOVAL AND INSTALLATION
1
2 3
456
78 9
1011
12
1314
15
16
9 Nm 11 N m
9 Nm 11 N m
18 Nm
Removal steps
1. Throttle body
C2. Throttle body gasket
3. Fuel return pipe
B4. Fuel pressure regulator
5. O-ring
6. Insulator
7. Insulator
A8. Injector9. O-ring
10. Grommet
11. Delivery pipe
12. Vacuum hose and vacuum pipe
13. Vacuum tank
14. Vacuum tank bracket
15. Solenoid valve
16. Solenoid valve bracket
Page 53 of 558
ENGINE – Fuel and Emission Control Parts11-28
INSTALLATION SERVICE POINTS
AINJECTORS INSTALLATION
(1) Before installing an injector, the rubber O-ring must be
lubricated with a drop of clean engine oil to aid in
installation.
(2) Install injector top end. Be careful not to damage O-ring
during installation.
BFUEL PRESSURE REGULATOR INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring.
Insert the fuel pressure regulator into the delivery pipe
being careful not to damage the O-ring.
Caution
Be sure not to let engine oil get into the delivery
pipe.
(2) Check that the fuel pressure regulator turns smoothly.
If it does not turn smoothly, the O-ring may be trapped.
Remove the fuel pressure regulator and check the O-ring
for damage, and then re-insert it into the delivery pipe
and check once again.
CGASKET INSTALLATION
Position the projection as shown in the illustration.
1EN0388
Grommet
O-ring
Projection
Page 63 of 558

ENGINE – Rocker Arms and Camshaft11-38
INSTALLATION SERVICE POINTS
ALASH ADJUSTER INSTALLATION
Caution
If the lash adjuster is re-used, clean the lash adjuster.
Fit the lash adjuster onto rocker arm without allowing diesel
fuel to spill out.
BCAMSHAFT INSTALLATION
(1) Apply engine oil to the journals and cams of the camshafts.
Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
(2) Install the crankshaft sprocket B or spacer and flange
to one end of the crankshaft, and turn the crankshaft
until the timing marks are lined up, setting No. 1 cylinder
to the TDC.
(3) Set the camshafts so that their dowel pins are positioned
at top.
CBEARING CAP INSTALLATION
(1) According to the identification mark stamped on the top
of each bearing cap, install the caps to the cylinder head.
Only “L” or “R” is stamped on front bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing caps. Rear
bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
(2) Tighten the bearing caps in the order shown two to three
times by torquing progressively.
Tighten to the specification in the final sequence.
(3) Check to ensure that the rocker arm is positioned correctly
on the lash adjuster and valve stem end.
Camshaft sprocket side
Slit
Intake side
camshaft
Dowel pin
Cam number
Symbol identifying
intake or exhaust
Timing belt side
Page 65 of 558

ENGINE – Rocker Arms and Camshaft11-40
LASH ADJUSTER
Caution
(1) The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
(2) Do not attempt to disassemble the lash adjusters.
(3) Use only fresh diesel fuel to clean the lash adjusters.
(1) Prepare three containers and approximately five liters
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
(3) While gently pushing down the internal steel ball using
wire (0.5 mm in diameter) or special tool MD998442,
move the plunger through 5 to 10 strokes until it slides
smoothly. In addition to eliminating stiffness in the plunger,
this operation will remove dirty oil.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
Outside
cleaningInside
cleaningFilling with
diesel fuel
A
B
C
Diesel
fuel
MD998442Diesel fuel