Mitsubishi Lancer Evolution 1 1992-1994 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution I Generation Code: CD9A Production Years: 1992-1994 Codes Chassis Code: CD9A Engine Code: 4G63 👋 Introduction Market Position Segment: Performance Compact...

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Type: Car

Vendor:

Sku: 83906

Tags: 1992 1993 1994 Car Cars Lancer Evolution 1 Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution I

Generation Code:

Production Years:

1992-1994

Codes

Chassis Code:

Engine Code:

👋 Introduction

Market Position

Segment:

Performance Compact Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, rally drivers, performance vehicle owners, mechanics specializing in Japanese performance cars

Competitive Analysis

Key Competitors Era:

Subaru Impreza WRX (though primarily later generations), Ford Escort RS Cosworth, Lancia Delta Integrale

Key Features

Rally Homologation:

Developed for WRC Group A homologation, featuring advanced technology for its time.

Iconic Engine:

Legendary 4G63 turbocharged engine, known for its robustness and tuning potential.

AWD System:

Advanced four-wheel-drive system (Advanced Four-Wheel Drive System - Twin Clutch-SST predecessor) with driver-selectable modes (initially viscous coupling center diff and mechanical LSDs).

📋 Manual Details

Coverage Areas

Title:

Mitsubishi Lancer Evolution I 1992-1994 Full Service Repair Manual

Product Description Snippet:

Very detailed contains everything you will ever need to know about your Mitsubishi Lancer Evolution I

Page Count

Estimated Page Count:

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full overhaul, diagnosis, component replacement (pistons, rings, bearings, valves, camshafts, crankshaft, cylinder head, block)

Engine Management:

ECU, sensors (MAP, TPS, IAT, O2, knock), fuel injection, ignition system, emissions control

Turbocharger System:

Turbocharger operation, diagnosis, wastegate, intercooler, piping, oil/water cooling lines

Fuel System:

Fuel pump, injectors, fuel lines, fuel pressure regulator, fuel tank, fuel filter replacement

Cooling System:

Radiator, water pump, thermostat, hoses, fan, coolant specifications

Lubrication System:

Oil pump, oil pan, oil filter, oil specifications, oil cooler

Exhaust System:

Exhaust manifold, catalytic converter, muffler, O2 sensors

Transmission Manual:

Clutch assembly, gearbox overhaul, gear ratios, shift mechanism, transmission fluid specifications

Drivetrain:

Front/rear differentials, driveshafts, CV joints, transfer case

Suspension:

Front/rear suspension components (struts, shocks, control arms, bushings), alignment specifications

Steering System:

Power steering pump, rack and pinion, steering column, tie rods, steering fluid

Braking System:

Front/rear disc brakes, ABS system (if equipped), brake fluid specifications, bleeding procedures, component replacement (pads, rotors, calipers)

Electrical System:

Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system

Body And Chassis:

Body panel removal/installation, interior trim, door mechanisms, hood, trunk, chassis component replacement

HVAC System:

Air conditioning system, heater core, climate control

Procedures Included

Routine Maintenance:

Oil change, filter replacement, fluid checks and top-offs, tire rotation, spark plug replacement

Scheduled Maintenance:

10k, 20k, 30k, 50k, 100k mile service intervals and tasks

Troubleshooting Diagnostics:

Step-by-step diagnostic charts for common and uncommon issues, DTC code explanations

Component Removal Installation:

Detailed instructions for removing and installing all major and minor components

Engine Rebuild:

Complete procedures for engine disassembly, inspection, machining, and reassembly

Transmission Overhaul:

Complete procedures for manual transmission disassembly, inspection, and reassembly

Brake System Service:

Pad/rotor replacement, caliper overhaul, brake line replacement, bleeding procedures

Electrical Diagnostics:

Wiring diagram interpretation, component testing, circuit diagnosis

Suspension Alignment:

Adjustment procedures and specifications for camber, caster, toe

Body Repair:

Panel replacement, welding, sealing, paint preparation guidance

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and chassis work.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Searchable text (if digitally rendered with OCR)

Printable:

Printable pages

Print Quality

Illustrations:

High-quality diagrams and illustrations

Text Clarity:

Clear and legible text

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Engine Code:

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Performance

Horsepower Ps:

247 PS @ 6000 rpm

Horsepower Hp:

244 hp @ 6000 rpm

Torque Nm:

304 Nm @ 3000 rpm

Torque Lb Ft:

224 lb-ft @ 3000 rpm

Fuel System

Fuel Induction:

Electronic Fuel Injection (EFI), Multi-point injection

Fuel Type:

Unleaded gasoline (91+ RON recommended)

Turbocharger Model:

Mitsubishi TD05-14B

Intercooler:

Air-to-air

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

Features

AWD System:

Mitsubishi Active Four-Wheel Drive System (FCM - Front Center Mechanical, Rear Viscous Coupling Limited Slip Differential)

Differential Front:

Helical Limited Slip Differential (LSD)

Differential Rear:

Viscous Coupling Limited Slip Differential (VLSD)

📐 Dimensions

Exterior

Length:

4310 mm (169.7 in)

Width:

1770 mm (69.7 in)

Height:

1405 mm (55.3 in)

Wheelbase:

2600 mm (102.4 in)

Track Front:

1495 mm (58.9 in)

Track Rear:

1490 mm (58.7 in)

Weights

Curb Weight:

1370 kg (3020 lbs)

Gross Weight Rating:

Estimated 1800 kg

Towing Capacity:

Not Recommended/Specified

🛡️ Safety Features

Ratings

Fedor Rating:

N/A (Modern crash testing protocols were less prevalent)

Active Features

Standard Anti-lock Braking System (ABS)

AWD Stability:

Four-wheel-drive system contributes to enhanced traction and stability.

Passive Features

Airbags:

Driver airbag (standard), Passenger airbag (optional/market dependent)

Seatbelts:

3-point front and rear seatbelts

Body Structure:

Reinforced safety cell construction

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM stereo with cassette player, potentially with CD player as an option in later production years or market-specific variants.

Display:

Minimal dashboard displays, focus on essential driving information (speedometer, tachometer, boost gauge, coolant temp).

Driver Assistance

Standard ABS system on all wheels.

AWD Control:

Driver-selectable center differential mode (though the first Evo had a less electronically sophisticated system than later models, relying more on mechanical components).

Connectivity

Factory Connectivity:

None.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed.

Spark Plugs:

Replace every 30,000 miles (48,000 km) with correct platinum or iridium plugs.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Transmission Fluid:

Replace every 30,000 miles (48,000 km) or 2 years.

Differential Fluid Front Rear:

Replace every 30,000 miles (48,000 km) or 2 years.

Fluid Specifications

Engine Oil:

API SG/SH, Viscosity: 10W-30 or 10W-40 (check manual for climate specific recommendations). Capacity: Approx. 4.5 Liters (4.8 US Quarts) with filter.

Coolant:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors). Capacity: Approx. 7.5 Liters.

Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil. Capacity: Approx. 2.0 Liters.

Differential Fluid Front:

API GL-5, SAE 75W-90 gear oil. Capacity: Approx. 1.3 Liters.

Differential Fluid Rear:

API GL-5, SAE 75W-90 gear oil. Capacity: Approx. 1.0 Liters.

Brake Fluid:

DOT 3 or DOT 4 non-silicone based brake fluid.

Power Steering Fluid:

ATF Dexron II or III compatible fluid.

Known Issues

Head Gasket:

Prone to head gasket failure if overheated or pushed beyond stock limits, especially with aftermarket tuning. Early signs include coolant loss or oil-coolant mixing.

Clutch Wear:

The clutch can wear relatively quickly under spirited driving or frequent hard launches.

Turbo Wear:

The TD05-14B turbocharger, while robust, can eventually develop shaft play or bearing wear with high mileage or inadequate lubrication/cooling.

Engine Mounts:

Factory engine and transmission mounts can degrade over time, leading to increased vibration and harsher shifts.

Suspension Bushings:

Rubber bushings in the suspension can perish, leading to play, noise, and degraded handling.

📚 Vehicle History

Brand Heritage

Rally Roots:

Mitsubishi's extensive history in motorsport, particularly in the World Rally Championship (WRC).

Model Evolution

Inception:

Created as a homologation special to allow Mitsubishi to compete in WRC Group A regulations.

First Generation:

Based on the Mitsubishi Lancer GSR platform but heavily modified for performance.

Subsequent Generations:

Set the foundation for all future Lancer Evolution models, establishing its performance identity.

Production

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Volume:

Limited, specific numbers vary but generally considered low volume compared to standard Lancer.

🏆 Awards & Recognition

Recognitions

Motorsport Success:

While the Evo I itself was primarily a homologation model, it laid the groundwork for Mitsubishi's legendary WRC success in subsequent years, making it an iconic motorsport platform.

Ratings

Performance Benchmark:

Widely recognized as a benchmark in affordable, rally-bred performance during its era.