Mitsubishi Lancer Evolution 3 1995-1996 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution III Model Variant: GSR, RS Years Covered: 1995-1996 Codes Chassis Code: CE9A Engine Code: 4G63T (2.0L DOHC Turbocharged Inline-4) 👋 Introduction...

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Type: Car

Vendor:

Sku: 83908

Tags: 1995 1996 Car Cars Lancer Evolution 3 Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution III

Model Variant:

GSR, RS

Years Covered:

1995-1996

Codes

Chassis Code:

Engine Code:

4G63T (2.0L DOHC Turbocharged Inline-4)

👋 Introduction

Market Position

Segment:

Performance Sedan, Rally Homologation Special

Target Audience:

Enthusiasts, tuners, owners seeking in-depth repair and maintenance knowledge

Competitive Analysis

Key Rivals:

Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth, Lancia Delta Integrale

Key Features

Performance Focus:

Engineered for high performance and rally-inspired driving dynamics

AWD System:

Advanced Active All-Wheel Drive system with adjustable center differential (ACD) on some models/regions

Turbocharged Engine:

Renowned 4G63T engine, a legend in the tuning community

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Overhaul

Page Count

Estimated Page Count:

Approximately 1000+

Manual Type

Manual Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control, turbocharger system, engine management (ECU/ECM)

Transmission:

5-speed manual transmission (F5M33), transfer case, viscous coupling unit (VCU), rear differential

Drivetrain:

All-Wheel Drive (AWD) system, driveshafts, CV joints, wheel hubs

Suspension:

Front struts, rear shock absorbers, control arms, anti-roll bars, coil springs, bushings

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Front and rear disc brakes, ABS system (if equipped), brake lines, master cylinder, calipers, pads, rotors

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams

Body Exterior:

Body panels, doors, hood, trunk, bumpers, aerodynamics (spoiler, splitter), glass, mirrors

Body Interior:

Seats, dashboard, interior trim, carpets, HVAC system, airbags (if equipped), seat belts

Wheels Tires:

Wheel specifications, tire sizes, rotation, balancing

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections

Engine Repair:

Engine removal and installation, cylinder head disassembly and reassembly, piston and connecting rod installation, crankshaft bearing service, timing belt replacement

Transmission Repair:

Transmission disassembly and reassembly, clutch replacement, gearset service, differential overhaul

Brake System Service:

Brake pad and rotor replacement, caliper overhaul, brake bleeding, ABS component diagnosis and replacement

Suspension And Steering Repair:

Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, power steering pump and rack service

Electrical Diagnostics:

Troubleshooting wiring issues, component testing, using diagnostic tools, wiring diagram interpretation

Troubleshooting Guides:

Diagnostic flowcharts for common problems, symptom-based troubleshooting

Body Repair:

Panel alignment, rust repair, glass replacement, bumper repair and replacement

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine and transmission rebuilds)

Diagnostic Capability:

Advanced diagnostics, including ECU/ECM codes and interpretation

Special Tools:

Identification of required special tools for specific procedures

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Printability:

Printable pages

Print Quality

Image Resolution:

High-resolution for clear diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

2.0L DOHC 16-valve Turbocharged Inline-4

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Performance

Horsepower Gsr:

270 PS (approx. 266 hp) at 6,500 rpm

Torque Gsr:

30.7 kg⋅m (approx. 222 lb-ft) at 5,000 rpm

Horsepower Rs:

250 PS (approx. 247 hp) at 6,000 rpm (often slightly detuned for rally regulations)

Torque Rs:

29.4 kg⋅m (approx. 213 lb-ft) at 5,000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Bosch fuel injectors

Turbocharger:

Mitsubishi TD05H-16G turbocharger

Intercooler:

Air-to-air front-mounted intercooler (FMIC)

Fluid Specs

Engine Oil Capacity:

4.5 Liters (4.7 US Quarts) with filter

Recommended Oil Viscosity:

10W-30 or 10W-40 (API SG or higher)

Coolant Capacity:

6.0 Liters (6.3 US Quarts)

Recommended Coolant:

Ethylene glycol-based antifreeze (50% solution)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (F5M33)

Optional

Transmission Type:

N/A (Manual transmission only for Evolution models)

Features

Drivetrain Configuration:

Full-time All-Wheel Drive (AWD) with Active Center Differential (ACD) on GSR, Viscous Coupling Unit (VCU) on RS

Rear Differential:

Mechanical Limited Slip Differential (LSD) on GSR, Viscous LSD on RS

Fluid Specs

Transmission Oil Capacity:

2.5 Liters (2.6 US Quarts)

Recommended Transmission Oil:

GL-4 or GL-5 Gear Oil (75W-90 recommended)

Transfer Case Oil Capacity:

0.7 Liters (0.7 US Quarts)

Recommended Transfer Case Oil:

GL-4 or GL-5 Gear Oil (75W-90 recommended)

Rear Differential Oil Capacity:

1.0 Liters (1.0 US Quarts)

Recommended Rear Differential Oil:

GL-5 Gear Oil (80W-90 recommended, Hypoid Gear Oil)

📐 Dimensions

Exterior

Length:

4,330 mm (170.5 in)

Width:

1,770 mm (69.7 in)

Height:

1,415 mm (55.7 in)

Wheelbase:

2,600 mm (102.4 in)

Front Track:

1,500 mm (59.1 in)

Rear Track:

1,495 mm (58.9 in)

Weights

Curb Weight Gsr:

1,400 kg (3,086 lbs)

Curb Weight Rs:

1,370 kg (3,020 lbs)

Gross Vehicle Weight Rating:

Approx. 1,800 kg (3,968 lbs)

Fuel Tank Capacity:

50 Liters (13.2 US Gallons)

🛡️ Safety Features

Ratings

Crash Test Ratings:

No official NHTSA/Euro NCAP ratings available for this specific model and era.

Active Features

Anti-lock Braking System (ABS) available on GSR, optional on RS

Advanced All-Wheel Drive system enhances stability and traction

Passive Features

Airbags:

Driver-side airbag standard; passenger airbag optional/unavailable depending on market

Seat Belts:

3-point front seat belts with pre-tensioners, 3-point rear seat belts

Body Structure:

Reinforced chassis with front and rear crumple zones

💡 Technology Features

Infotainment

Audio System:

Factory radio with cassette player and AM/FM tuner, 4-speaker system.

Climate Control:

Manual climate control with A/C

Driver Assistance

Traction Control:

Not typically equipped with electronic traction control beyond the mechanical AWD system.

Connectivity

Connectivity Features:

Basic connectivity, primarily focused on audio playback via cassette.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first (severe use may require more frequent changes)

Oil Filter Replacement:

With every oil change

Air Filter Replacement:

Every 15,000 - 30,000 km (9,000 - 18,000 miles)

Spark Plug Replacement:

Every 30,000 - 50,000 km (18,000 - 30,000 miles), depending on plug type (e.g., platinum or iridium)

Timing Belt Replacement:

Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5-7 years

Coolant Flush:

Every 2 years or 50,000 km (30,000 miles)

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

ATF Dexron II or equivalent

Clutch Fluid Type:

DOT 3 or DOT 4

Known Issues

Engine Reliability:

Known for robust 4G63T engine, but requires diligent maintenance. Issues can arise from worn valve stem seals, turbocharger wear, and cracked exhaust manifolds under extreme use.

AWD System Maintenance:

VCU and ACD units require regular fluid changes to maintain performance and prevent premature failure.

Rust:

Common rust points include wheel arches, rocker panels, and subframes, especially in regions with road salt.

Suspension Wear:

Bushings, ball joints, and wheel bearings can wear over time due to the car's aggressive nature.

Cooling System:

Radiator leaks and thermostat issues can occur, especially if maintenance is neglected.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi's extensive rally heritage, particularly in the World Rally Championship (WRC)

Model Evolution

Evo Series Origin:

The Lancer Evolution series was developed to homologate vehicles for Group A racing in the WRC.

Evolution Iii Development:

The Evo III was a significant evolution of the Evo II, featuring aerodynamic enhancements and an improved engine output.

Key Iii Upgrades:

Larger front air dam, side skirts, rear spoiler extension, revised engine management, improved turbocharger efficiency, slight power increase.

Production

Production Period:

August 1995 - August 1996

Production Volume:

Approximately 5,000 units produced in total

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama Prefecture, Japan

🏆 Awards & Recognition

Recognitions

Motorsport Success:

While not direct 'awards', the Evo III's platform success in international rallying significantly boosted its reputation and desirability.

Enthusiast Acclaim:

Highly regarded by automotive enthusiasts and tuners for its performance capabilities and rally pedigree.