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Mitsubishi Lancer Evo 1-3 Workshop Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code Designation: Evo I, Evo II, Evo III Platform Chassis Code: CD9A (Evo I/II), CE9A (Evo II/III) Generation Generation: First...
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SKU: 406694
Mitsubishi Lancer Evo 1-3 Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Code Designation:
Evo I, Evo II, Evo III
Platform Chassis Code:
CD9A (Evo I/II), CE9A (Evo II/III)
Generation
Generation:
First Generation (1G)
Model Years Covered:
1992-1995
Codes
Engine Codes Covered:
4G63 (DOHC Turbocharged)
👋 Introduction
Market Position
Market Segment:
Performance Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, rally competitors, owners seeking in-depth maintenance and repair knowledge
Competitive Analysis
Key Competitors:
Subaru Impreza WRX (GC/GF generation), Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Legendary Status:
Iconic for its rally success and performance capabilities
Technical Innovation:
Advanced all-wheel-drive system (Super Select 4WD II), powerful turbocharged engine, active center differential (optional/later models)
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive mechanical and electrical repair and maintenance
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, piston, rings, connecting rods, crankshaft, cylinder head, camshafts, valve train, timing belt/chain, lubrication system, cooling system
Engine Management And Performance:
Fuel injection system (MPI), turbocharger system, intercooler, engine control unit (ECU) diagnosis, ignition system, emission controls
Transmission Drivetrain:
Manual transmission (5-speed), transfer case, differentials (front and rear), drive shafts, half shafts, clutch system, gearbox overhaul
Suspension And Steering:
Front and rear suspension components (struts, control arms, bushings, anti-roll bars), power steering system, steering rack, steering column
Brakes:
Front and rear brake systems (discs, calipers, pads), hydraulic system, parking brake, anti-lock braking system (ABS) (if equipped)
Electrical System:
Battery, alternator, starter motor, lighting system, wiring diagrams, fuse box locations, relays, ignition system, engine sensors, body electrical components
Body And Chassis:
Body panel removal and installation, interior trim, door mechanisms, glass, bumpers, frame and structural components
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair
Procedures Included
Routine Maintenance:
Oil and filter changes, coolant replacement, spark plug replacement, air filter replacement, fuel filter replacement, brake fluid flush, transmission fluid change
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common malfunctions, fault code interpretation (OBD-I era), symptom-based troubleshooting
Component Overhaul And Rebuild:
Detailed instructions for disassembling, inspecting, repairing, and reassembling major vehicle components
Timing Belt Replacement:
Precise procedures for timing belt removal, installation, and engine timing verification
Turbocharger Service:
Turbocharger inspection, repair, and replacement procedures
Clutch Replacement:
Detailed steps for clutch assembly replacement
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake line repair
Electrical Component Testing:
Testing of sensors, actuators, ignition coils, injectors, and other electrical components
Technical Depth
Depth Of Information:
Extensive, suitable for professional technicians and advanced DIY enthusiasts
Diagnostic Capabilities:
Detailed diagnostic charts, fault isolation procedures, wiring schematics for troubleshooting
Repair Procedures:
Step-by-step repair instructions with torque specifications, alignment procedures, and special tool requirements
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Image Resolution:
High resolution, clear diagrams and text
Searchability:
Fully searchable text for quick information retrieval
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-cylinder, DOHC, 16-valve, turbocharged, intercooled
Engine Family:
4G63
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Evo I:
247 PS (approx. 244 hp) at 6000 rpm
Torque Evo I:
304 Nm (224 lb-ft) at 3000 rpm
Horsepower Evo Ii:
252 PS (approx. 249 hp) at 6000 rpm
Torque Evo Ii:
309 Nm (228 lb-ft) at 3000 rpm
Horsepower Evo Iii:
270 PS (approx. 266 hp) at 6250 rpm
Torque Evo Iii:
309 Nm (228 lb-ft) at 4000 rpm
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Octane Rating: 98 RON recommended)
Turbocharger:
Mitsubishi TD05HR-16G (Evo I/II), TD05HA-16G (Evo III)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission:
N/A (Manual exclusively for this generation)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) (standard on Evo III, optional on Evo II, not on Evo I)
Gear Ratios:
Specific ratios vary by model year, detailed in manual
Transmission Fluid Spec:
API GL-4 or GL-5, SAE 75W-90 (check manual for exact spec and capacity)
📐 Dimensions
Exterior
Length:
Approx. 4,310 mm (169.7 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,405 mm (55.3 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Wheel Bolt Pattern:
5x114.3 mm
Wheel Size:
15x6.5J or 16x7J (depending on model/trim)
Tire Size:
205/60R15 or 205/50R16 (common sizes)
Weights
Curb Weight:
Approx. 1,240 kg - 1,300 kg (2,734 lbs - 2,866 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
No specific NHTSA/Euro NCAP ratings for this era, focus on structural integrity and driver control
Active Features
Active Safety Features:
Advanced All-Wheel Drive (Super Select 4WD II), Optional Active Center Differential (ACD), Powerful braking system
Passive Features
Passive Safety Features:
Reinforced chassis, front airbags (driver and passenger), seat belts
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM stereo with cassette player, optional CD player
Driver Assistance
Driver Assistance Features:
ABS (Anti-lock Braking System) available on some models
Connectivity
Connectivity Features:
N/A (pre-modern connectivity era)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, whichever comes first
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 4-5 years
Coolant Replacement:
Every 2 years or 40,000 km (25,000 miles)
Spark Plug Replacement:
Every 30,000-40,000 km (18,000-25,000 miles)
Fluid Specifications
Engine Oil Specification:
API SG/SH or higher, viscosity 10W-30 or 10W-40 (check manual for specific viscosity based on climate)
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US quarts) with filter change
Coolant Specification:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant, typically 50/50 mix with distilled water)
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Common Issues Engine:
Head gasket failure (due to heat and stress), oil leaks, turbocharger wear
Common Issues Drivetrain:
Clutch wear, differential wear (especially under hard use), manual transmission synchro wear
Common Issues Suspension:
Worn bushings, ball joints, and shock absorbers
Common Issues Electrical:
Aging wiring harness components, sensor failures (e.g., MAF, O2)
📚 Vehicle History
Brand Heritage
Brand Origins:
Mitsubishi Motors, Japan, established automotive manufacturer with strong rally heritage
Model Evolution
Evolution Of Evo I To Iii:
Evo I introduced based on Lancer GSR, Evo II improved handling and engine, Evo III featured increased power and aggressive aerodynamics
Rally Homologation:
Developed to meet Group A regulations for the World Rally Championship (WRC)
Production
Production Period:
1992-1995
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Rally Championships:
Dominant force in the World Rally Championship (WRC) during the early to mid-1990s, with multiple driver and manufacturer titles secured by drivers like Tommi Mäkinen
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