🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution I

Production Years Covered:

1992, 1993, 1994

Chassis Code:

CD9A

Engine Code:

4G63 (DOHC Turbocharged)

👋 Introduction

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, professional mechanics, and owners seeking to maintain or repair their Mitsubishi Lancer Evolution I.

Key Competitors:

Subaru Impreza WRX (though WRX arrived later, conceptually similar rally-bred cars), Ford Escort RS Cosworth, Lancia Delta Integrale.

Performance Orientation:

The Lancer Evolution I was developed for WRC homologation, emphasizing performance, handling, and advanced drivetrain technology for its era.

All Wheel Drive:

Features Mitsubishi's sophisticated all-wheel-drive system with a mechanically locking center differential for enhanced traction and cornering ability.

Turbocharged Engine:

Powered by the legendary 4G63 engine, known for its robust construction and tuning potential.

📋 Manual Details

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF (Downloadable)

Estimated Page Count:

1000+

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, inspection, assembly, torque specifications, timing belt, piston/ring installation, valve train, cylinder head, crankshaft, camshafts.

Engine Management And Fuel:

Fuel injection system (MPI), ignition system, ECU diagnostics, sensors (MAP, TPS, O2, Crank Angle, Cam Angle), fuel pump, injectors, throttle body, turbocharger operation and maintenance.

Transmission And Drivetrain:

5-speed manual transmission (KM212), transfer case, viscous coupling (VCU) center differential, mechanical rear differential, clutch operation and replacement, gearbox assembly and disassembly, gear oil specifications.

Suspension And Steering:

Front and rear suspension components (MacPherson struts, multi-link), control arms, bushings, sway bars, steering rack, power steering system, wheel alignment specifications, hub bearing replacement.

Braking System:

Front and rear disc brakes, ABS (Anti-lock Braking System) operation and troubleshooting, brake fluid specifications, caliper and rotor replacement, brake pad wear indicators, parking brake.

Electrical System:

Wiring diagrams, fuse box layouts, relay locations, battery, alternator, starter motor, lighting systems, power windows, central locking, dashboard instrumentation, diagnostic trouble codes (DTCs).

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, soundproofing, chassis rigidity, underbody protection, jacking points, towing instructions.

HVAC System:

Air conditioning system, heater core, blower motor, climate control panel, refrigerant types and capacities.

Preventive Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flush and replacement, brake fluid flush, transmission fluid change, differential fluid change, timing belt inspection/replacement intervals.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, diagnostic trouble code (DTC) interpretation.

Repair And Rebuild:

Detailed step-by-step instructions for component repair, removal, and installation, including major component overhauls and rebuilds (e.g., engine, transmission, turbocharger).

Component Replacement:

Headlight bulbs, taillights, mirrors, wiper blades, battery, tires, exhaust system components, radiator, water pump, alternator, starter, sensors, fuel pump, brake pads/rotors, clutch assembly, CV joints.

Diagnostic Capability:

Advanced diagnostic procedures, including testing of electronic control units (ECUs), sensors, actuators, and wiring harnesses. Covers proprietary diagnostic connectors if applicable.

Precision Specifications:

Includes detailed torque specifications for all critical fasteners, engine clearance measurements, gear backlash specifications, and alignment angles.

Rebuild Procedures:

Comprehensive instructions for engine and transmission rebuilding, including part specifications and tolerances.

📊 Manual Specifications

File Type:

Searchable PDF

Print Quality:

High-resolution scans, clear text, and legible diagrams.

Binding Type For Digital:

N/A (Digital Download)

Paper Type For Digital:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Turbocharger:

Mitsubishi TD05H-14B

Horsepower:

244 PS (241 hp; 179 kW) at 6000 rpm

Torque:

30.4 kg⋅m (298 N⋅m; 220 lb⋅ft) at 3000 rpm

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, Octane rating 95 (RON)

Ignition System:

Electronic Ignition ( Distributorless Ignition System - DIS in later Evolutions, but CD9A likely uses distributor)

Engine Oil Type:

API SG or higher, Viscosity SAE 10W-30 or 10W-40 (refer to manual for specific climate/performance recommendations)

Engine Oil Capacity:

Approximately 4.5 Liters (with filter)

Coolant Type:

Ethylene Glycol based coolant (Mitsubishi Genuine Super Long Life Coolant or equivalent)

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Transmission Model:

KM212

Optional Transmission:

None available for Evolution I.

Drivetrain:

Advanced All-Wheel Drive (AWD) with Active Center Differential (ACD) and Viscous Coupling (VCU) center differential.

Rear Differential:

Mechanical Limited-Slip Differential (LSD) in rear.

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific AWD/LSD requirements)

Transfer Case Fluid:

API GL-3 or GL-4, SAE 75W-90 or 80W-90 gear oil

Rear Differential Fluid:

API GL-5, SAE 90 Hypoid gear oil (or specified LSD fluid)

📐 Dimensions

Length:

4310 mm (169.7 in)

Width:

1690 mm (66.5 in)

Height:

1405 mm (55.3 in)

Wheelbase:

2500 mm (98.4 in)

Track Front:

1460 mm (57.5 in)

Track Rear:

1450 mm (57.1 in)

Ground Clearance:

Approx. 140 mm (5.5 in) (may vary with suspension setup)

Curb Weight:

Approx. 1200 kg (2646 lbs)

Gross Vehicle Weight Rating:

Not typically specified for this performance model, focus is on performance metrics.

Fuel Tank Capacity:

50 Liters (13.2 US gal)

Wheel Size:

15x6.5 inches (standard)

Bolt Pattern:

4x114.3 mm

Tire Size Standard:

205/60 R15 (standard)

Tire Size Performance:

205/50 R16 (optional/later models/upgrades)

🛡️ Safety Features

Crash Test Ratings:

Limited official crash test data available for this era's homologation specials. Focus was on structural integrity for rally use.

ABS:

Standard Anti-lock Braking System (ABS)

AWD:

Advanced All-Wheel Drive system provides significant active safety benefits in adverse conditions.

Airbags:

Driver's airbag was optional or standard depending on market. Passenger airbag not common.

Seatbelts:

3-point seatbelts with pre-tensioners

Chassis Construction:

Reinforced chassis for structural rigidity and safety.

💡 Technology Features

Infotainment System:

Basic analog gauges, AM/FM radio with cassette player. No integrated navigation or advanced digital displays.

Driver Assistance Features:

ABS is the primary driver assistance feature. No electronic stability control (ESC) or traction control (aside from AWD).

Connectivity Features:

Limited to power accessories. No Bluetooth, USB ports, or smartphone integration.

🔧 Maintenance

Engine Oil And Filter Change:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first, especially with spirited driving.

Air Filter Replacement:

Every 15,000 - 20,000 km (9,000 - 12,000 miles) or as needed based on driving conditions.

Fuel Filter Replacement:

Every 30,000 - 40,000 km (18,000 - 25,000 miles).

Spark Plug Replacement:

Every 30,000 - 40,000 km (18,000 - 25,000 miles) for standard plugs; longer for platinum/iridium.

Timing Belt Replacement:

Every 90,000 km (56,000 miles) or 5-7 years, whichever comes first. Crucial due to interference engine design.

Brake Fluid Flush:

Every 2 years or 30,000 km (18,000 miles).

Transmission Fluid Change:

Every 30,000 - 40,000 km (18,000 - 25,000 miles), especially for AWD components.

Coolant Flush:

Every 2-3 years or 40,000 - 50,000 km (25,000 - 30,000 miles).

Engine Reliability:

4G63 is robust, but premature wear can occur on piston rings, rod bearings, and turbocharger seals with aggressive use or poor maintenance. Head gasket issues can arise from overheating.

Drivetrain Wear:

Viscous coupling center differential (VCU) can overheat and fail if subjected to prolonged hard use or if fluid degrades. Rear differential clutch packs can wear.

Suspension Bushings:

Rubber suspension bushings are prone to degradation and wear over time, leading to sloppy handling and alignment issues.

Cooling System:

Original radiators and hoses can degrade, leading to leaks and overheating. Turbocharged engines generate significant heat.

Rust And Corrosion:

Common for vehicles of this age, especially in regions with salt exposure. Areas to check include wheel arches, sills, and subframes.

📚 Vehicle History

Brand History:

Mitsubishi Motors has a strong heritage in motorsport, particularly in rallying with the Lancer platform.

Evolution Series Introduction:

The Lancer Evolution series was born out of Mitsubishi's desire to compete in the World Rally Championship (WRC). The Evo I marked the debut of this legendary lineage.

Homologation Purpose:

The Evo I was built to meet Group A regulations for WRC, requiring a certain number of road-going models to be produced.

Design Basis:

Based on the Mitsubishi Galant VR-4, it incorporated its robust 4G63 engine and AWD system but in a lighter, more agile Lancer chassis.

Production Period:

August 1992 - December 1993

Production Volume:

Approximately 5,000 units (estimated, exact numbers vary by source).

Manufacturing Location:

Japan

🏆 Awards & Recognition

Motorsport Legacy:

The Lancer Evolution series, starting with the Evo I, is a celebrated icon in motorsport, particularly in the World Rally Championship, achieving significant success.

Performance Benchmarks:

Widely regarded as a benchmark for performance sedans of its era, influencing the development of many subsequent performance vehicles.

Homologation Status:

Certified for Group A rally racing homologation.