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Mitsubishi Lancer Evolution 2 1994-1995 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution II (Evo 2) Product Name: Mitsubishi Lancer Evolution 2 1994-1995 Factory Service Repair Manual Codes Chassis Code: CD9A Engine Code Family:...
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Mitsubishi Lancer Evolution 2 1994-1995 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution II (Evo 2)
Product Name:
Mitsubishi Lancer Evolution 2 1994-1995 Factory Service Repair Manual
Codes
Chassis Code:
CD9A
Engine Code Family:
4G63
👋 Introduction
Market Position
Segment:
Performance Compact Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, tuners, professional mechanics, dedicated owners of the Lancer Evolution II.
Competitive Analysis
Competitors:
Subaru Impreza WRX STi, Ford Escort RS Cosworth, Toyota Celica GT-Four.
Key Features
Rally Heritage:
Developed for Group A WRC homologation, featuring advanced all-wheel-drive and turbocharged performance.
Tuning Potential:
Iconic platform for performance tuning and modification.
📋 Manual Details
Coverage Areas
Covered Years:
1994, 1995
Region Focus:
Global (primarily Japan Domestic Market - JDM)
Page Count
Estimated Pages:
500+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English (translation)
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine diagnostics, overhaul, timing belt, cooling, lubrication, fuel injection, ignition, turbocharger system.
Transmission:
5-speed manual gearbox (W5M42), clutch system, driveline, propeller shaft, drive shafts, viscous coupling unit (VCU) for center differential.
Suspension:
Front MacPherson struts, rear multi-link independent suspension, tuning adjustments, alignment specifications.
Brakes:
Front ventilated discs, rear solid discs, ABS (Anti-lock Braking System) diagnostics and repair, brake system bleeding.
Electrical:
Wiring diagrams, ECU (Engine Control Unit) pinouts, sensor diagnostics, starter, alternator, lighting, power windows, central locking.
Body And Chassis:
Body panel repair, structural components, aerodynamics, interior trim, glass replacement, chassis specifications.
Cooling System:
Radiator, fan, thermostat, water pump, coolant specifications and capacity.
Fuel System:
Fuel pump, injectors, fuel filter, fuel pressure regulator, fuel tank, EVAP system.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, O2 sensors.
Steering:
Power steering system, steering rack, tie rods, steering column.
Procedures Included
Diagnostics:
Comprehensive troubleshooting charts, fault code interpretation, component testing procedures.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, spark plug replacement, brake pad replacement.
Repair:
Detailed step-by-step repair instructions for all major vehicle systems, including engine rebuild, transmission overhaul, suspension component replacement.
Rebuilding:
Engine component specifications and tolerances for rebuilding, turbocharger assembly/disassembly.
Calibration And Adjustment:
Wheel alignment, ignition timing (if adjustable), clutch adjustment.
Technical Depth
Depth:
Expert level, covering complete overhaul and advanced diagnostics.
Diagnostic Tools:
Information on using MUT-II (Mitsubishi Ultrascan) or similar diagnostic tools for fault code reading and live data.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (text-searchable)
Print Quality
Quality:
High-resolution scans, clear diagrams and text.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
260 PS @ 6,500 rpm
Torque Nm:
304 Nm @ 3,000 rpm
Fuel System
Induction:
Multi-point Fuel Injection (MPI) with Electronic Fuel Control (EFC)
Turbocharger:
Mitsubishi TD05H-16G turbocharger with intercooler
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Engine Management
ECU:
ECU controlled ignition and fuel injection, with knock sensor feedback.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (W5M42)
Optional
Type:
None (Manual only for Evolution models of this era)
Features
All Wheel Drive:
Advanced All-Wheel Drive system with active center differential (ACD) using a viscous coupling unit (VCU).
Transfer Case:
Integrated with transmission, housing the VCU.
Fluid Specifications
Manual Transmission Fluid:
GL-4 Gear Oil (e.g., Diaqueen LSD Gear Oil or equivalent, viscosity typically 75W-90)
📐 Dimensions
Exterior
Length Mm:
4310
Width Mm:
1770
Height Mm:
1405
Wheelbase Mm:
2600
Weights
Curb Weight Kg:
~1370
Gross Vehicle Weight Rating Kg:
Unspecified (typical for performance models)
Cargo
Trunk Capacity Liters:
Unspecified (typically modest in performance sedans)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Era specific, JDM focus, no standardized global ratings like modern NCAP)
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
AWD:
Advanced All-Wheel Drive for enhanced traction and stability.
Passive Features
Airbags:
Driver's airbag (standard on many models of this era, check specific trim).
Seatbelts:
3-point front and rear seatbelts.
Roll Cage:
Optional factory-fitted or dealer-installed roll cage for track/rally use.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD player (market dependent), basic speaker setup.
Driver Assistance
ABS:
Standard ABS.
AWD Control:
Mechanical ACD with VCU, not electronically controlled like later models.
Connectivity
Connectivity Features:
Basic, no modern Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, depending on driving conditions.
Timing Belt:
Replace every 80,000 - 100,000 km (50,000 - 60,000 miles).
Spark Plugs:
Inspect every 20,000 km (12,000 miles), replace as needed (typically Iridium or Platinum type).
Transmission Fluid Change:
Every 40,000 - 60,000 km (25,000 - 37,000 miles).
Fluid Specifications
Engine Oil:
API SG/SH or higher, SAE 10W-30 or 10W-40 (synthetic recommended for performance driving).
Coolant:
Ethylene glycol based coolant (typically 50/50 mix with distilled water), Mitsubishi Long Life Coolant (LLC) or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine:
Cracked cylinder head on early models (especially if poorly maintained or over-boosted), turbocharger wear, piston ring wear due to high heat and stress.
Drivetrain:
Wear in the viscous coupling unit (VCU) of the ACD, differential wear under extreme use.
Body And Chassis:
Rust in common areas (wheel arches, sills, strut towers), electrical connector corrosion.
Part Numbers Example
Timing Belt Kit Part Number:
Example: Gates TCK200 or OE Mitsubishi equivalent.
📚 Vehicle History
Brand Heritage
Motorsport Roots:
Mitsubishi's strong rally heritage, stemming from the Lancer's success in the World Rally Championship (WRC).
Model Evolution
Evolution Series:
Second generation of the iconic Lancer Evolution, building on the foundation of the Evo I.
Key Upgrades From Evo I:
Increased engine power, revised suspension geometry, improved drivetrain, larger turbocharger (TD05H-16G), upgraded brakes.
Production
Production Years:
1993-1995
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Volume:
Limited (specific numbers vary, but significantly less than mass-market Lancers)
🏆 Awards & Recognition
Recognitions
Motorsport Success:
Foundation for numerous rally victories in Group A and subsequent WRC championships.
Enthusiast Acclaim:
Highly regarded as a landmark performance car, a cult classic among tuners and rally fans.
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