🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution I

Model Code:

CD9A

Model Variant:

GSR

Production Years Covered:

1992-1994

Chassis Code:

CD9A

Engine Code Primary:

4G63

👋 Introduction

Introduction Year:

1992

Target Audience:

Enthusiasts, professional mechanics, and owners seeking in-depth knowledge for maintenance and repair of the Lancer Evolution I.

Reputation:

The Evo I established Mitsubishi's rally heritage, known for its performance and advanced technology for its era.

Key Competitors:

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

Performance Focus:

Homologation special for World Rally Championship (WRC), emphasizing AWD, turbocharged engine, and stiff chassis.

Technological Advancements:

First generation of the Evo series, introducing key performance technologies that would be refined in subsequent models.

📋 Manual Details

Manual Title:

Mitsubishi Lancer Evolution I 1992-1994 Service Repair Manual

Market Focus:

Global (primary focus on Japanese domestic market specifications for this generation)

Estimated Page Count:

Approximately 1000+ pages (typical for comprehensive factory service manuals)

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system, fuel injection system (MPI), turbocharger system (TD05HR-16G).

Engine Electrical:

Ignition system, starting system, charging system, ECU (Engine Control Unit) diagnosis and wiring diagrams, sensors (MAP, TPS, knock, O2, etc.).

Transmission:

Manual transmission (Type-R), clutch system, transfer case, viscous coupling center differential, drivetrain components (driveshafts, CV joints).

Suspension:

Front strut suspension, rear multi-link suspension, springs, shock absorbers, control arms, anti-roll bars, power steering system.

Brakes:

Front ventilated discs (300mm), rear solid discs (284mm), ABS (Anti-lock Braking System) components and diagnosis, brake lines, master cylinder, calipers.

Electrical System:

Lighting system, instrument cluster, power windows, central locking, audio system, horn, battery, fuse box and relay locations, wiring diagrams for all major systems.

Body And Chassis:

Body structural components, exterior panels, doors, hood, trunk, bumpers, interior trim, seat adjustments, glass replacement.

HVAC:

Air conditioning system, heating system, ventilation, refrigerant charging, component replacement.

General Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant checks, belt inspections and adjustments.

Engine Repair:

Engine overhaul, cylinder head gasket replacement, piston ring replacement, timing belt replacement, turbocharger rebuild, fuel injector service.

Transmission Service:

Transmission fluid change, clutch replacement, differential service, transfer case maintenance.

Brake Service:

Brake pad replacement, rotor resurfacing/replacement, brake fluid flush, ABS system bleeding and repair.

Suspension And Steering:

Shock absorber replacement, ball joint replacement, tie rod end replacement, wheel alignment procedures, power steering pump and rack repair.

Electrical Diagnostics:

Troubleshooting electrical faults, wiring harness repair, component testing, ECU flashing (if applicable).

Bodywork And Interior:

Panel replacement, door mechanism repair, glass replacement, interior trim removal and installation.

Diagnostic Capabilities:

Detailed troubleshooting guides, diagnostic trouble codes (DTCs), component testing procedures, wiring diagrams for diagnosis.

Repair Complexity:

Covers everything from basic maintenance to complete engine and transmission rebuilds, including specialized systems like AYC (Active Yaw Control) if applicable to this specific manual version (though less common on Evo I).

Specification Accuracy:

Precise torque specifications, clearance measurements, fluid capacities, and timing settings.

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Print Quality Recommendation:

High resolution for clear diagrams and text when printed.

Binding Type:

N/A (Digital download)

Paper Type:

N/A (Digital download)

⚙️ Engine Specifications

Engine Type:

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

Engine Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Horsepower Ps:

241 PS @ 6000 rpm

Horsepower Hp:

237 hp @ 6000 rpm

Torque Lb-Ft:

255 lb-ft @ 3000 rpm

Torque Nm:

345 Nm @ 3000 rpm

Fuel Delivery:

Electronic Fuel Injection (MPI), Bosch electronic ignition

Turbocharger:

Mitsubishi TD05HR-16G, intercooled

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations)

Engine Oil Capacity Liters:

4.5 Liters (with filter change)

Coolant Capacity Liters:

7.0 Liters

🔧 Transmission

Transmission Type:

5-speed manual

Drivetrain:

All-Wheel Drive (AWD)

Center Differential:

Viscous coupling limited-slip center differential

Rear Differential:

Helical limited-slip rear differential

Manual Transmission Fluid Type:

API GL-4, SAE 75W-90 (check manual for specific part numbers)

Manual Transmission Fluid Capacity Liters:

2.3 Liters

📐 Dimensions

Length Mm:

4310 mm

Width Mm:

1770 mm

Height Mm:

1405 mm

Wheelbase Mm:

2500 mm

Front Track Mm:

1480 mm

Rear Track Mm:

1470 mm

Curb Weight Kg:

1220 kg

Gross Vehicle Weight Kg:

1650 kg

Wheel Size:

15 x 6.5J

Bolt Pattern:

4x114.3 mm

Tire Size:

205/60R15

🛡️ Safety Features

Safety Ratings:

N/A (Pre-dates widespread standardized crash testing for this segment and market)

ABS:

Standard Anti-lock Braking System (ABS)

AWD:

Advanced All-Wheel Drive system with center differential

Seatbelts:

3-point front and rear seatbelts

Airbags:

Driver airbag (standard on most markets)

Body Construction:

Reinforced chassis and safety cell for improved structural integrity.

💡 Technology Features

Infotainment System:

Basic AM/FM stereo with cassette player (CD player optional on later models/markets). Standard speaker configuration.

Driver Assistance Features:

ABS.

Connectivity Options:

N/A (No factory Bluetooth, USB, or modern connectivity features).

🔧 Maintenance

Oil Change Interval:

Every 5,000 km or 6 months, whichever comes first (severe use may require shorter intervals).

Air Filter Replacement:

Every 20,000 km or 12 months.

Fuel Filter Replacement:

Every 40,000 km or 24 months.

Spark Plug Replacement:

Every 60,000 km or 36 months.

Timing Belt Replacement:

Every 100,000 km or 5 years, whichever comes first.

Brake Fluid Type:

DOT 3 or DOT 4

Coolant Type:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant.

Engine Wear:

Potential for ring land failure in high-mileage or poorly maintained 4G63 engines due to stress. Regular oil changes are critical.

Turbocharger Reliability:

The TD05HR turbo is generally robust, but requires proper warm-up and cool-down procedures. Oil leaks or bearing wear can occur with age.

Suspension Components:

Wear on bushings, ball joints, and control arms is common due to performance driving and age.

Rust Corrosion:

Common in older vehicles, especially in areas exposed to salt. Areas to inspect include wheel arches, rocker panels, and suspension components.

📚 Vehicle History

Motorsport Connection:

Directly linked to Mitsubishi's motorsport division and its efforts in the World Rally Championship (WRC).

Predecessor:

Lancer (standard models)

Successor:

Mitsubishi Lancer Evolution II

Production Start:

1992

Production End:

1994

Production Location:

Japan

Total Production Units:

Approximately 5,000 units (estimated)

🏆 Awards & Recognition

Rally Heritage:

The Lancer Evolution series is legendary in motorsport, particularly its dominance in WRC, which the Evo I initiated.

Performance Acclaim:

Widely recognized by automotive press and enthusiasts as a benchmark for performance sedans of its era.