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Mitsubishi Lancer EVO 1 EVO 2 EVO 3 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution I, II, III Model Code: CD9A (EVO I), CE9A (EVO II & III) Generation: First Generation (Evolution I-III) Codes Engine Codes:...
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Mitsubishi Lancer EVO 1 EVO 2 EVO 3 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution I, II, III
Model Code:
CD9A (EVO I), CE9A (EVO II & III)
Generation:
First Generation (Evolution I-III)
Codes
Engine Codes:
4G63, 4G63T
Chassis Codes:
CD9A (EVO I), CE9A (EVO II & III)
👋 Introduction
Market Position
Segment:
Compact performance sedan, rally homologation special
Positioning:
The Lancer Evolution I-III established Mitsubishi's reputation in motorsport and performance road cars, directly competing with rivals like the Subaru Impreza WRX.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX, Ford Escort RS Cosworth, Toyota Celica GT-Four
Key Features
Performance Focus:
Tuned turbocharged engine, advanced All-Wheel Drive system, sophisticated suspension for superior handling.
Rally Heritage:
Developed directly from Mitsubishi's World Rally Championship (WRC) efforts, bringing race-bred technology to the road.
4Wd System:
Advanced viscous coupling center differential and limited-slip differentials for exceptional traction.
📋 Manual Details
Coverage Areas
Covered Models:
Mitsubishi Lancer Evolution I, Evolution II, Evolution III
Applicable Years:
1992-1996
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, cylinder head, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system
Engine Management:
Fuel injection system (MPI), ignition system, ECU diagnosis, sensors, actuators, emissions control system
Turbocharger:
Turbocharger unit, wastegate, intercooler, piping, diagnosis, and overhaul
Transmission:
Manual transmission (W5M33), disassembly, assembly, lubrication, clutch system, transfer case
Drivetrain:
All-Wheel Drive (AWD) system, Active Yaw Control (AYC) on some models, front differential, rear differential, driveshafts, propeller shaft
Suspension:
Front suspension (MacPherson strut), rear suspension (multi-link), springs, shock absorbers, bushings, alignment specifications
Brakes:
Front and rear disc brakes, ABS system, hydraulic components, brake fluid specifications, bleeding procedures
Steering:
Power steering system, steering rack, tie rods, alignment
Electrical:
Battery, charging system, starting system, lighting, wipers, horn, power windows, central locking, fuses, relays, wiring diagrams
Body And Trim:
Exterior panels, interior trim, doors, windows, seats, body repair procedures
HVAC:
Heating, Ventilation, and Air Conditioning system, components, and service
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-I)
Repair:
Step-by-step repair instructions for all major mechanical and electrical components
Overhaul:
Complete engine and transmission overhaul procedures
Installation:
Installation of major components and accessories
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and drivetrain rebuilds. Suitable for both DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
File Type:
Likely PDF
Searchability:
Likely text-searchable PDF
Print Quality
Image Quality:
High quality, clear illustrations and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63 DOHC Inline-4 Turbocharged
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Evo1:
247 PS (244 hp) @ 6000 rpm
Torque Evo1:
309 Nm (228 lb-ft) @ 3000 rpm
Horsepower Evo2:
252 PS (249 hp) @ 6000 rpm
Torque Evo2:
309 Nm (228 lb-ft) @ 3000 rpm
Horsepower Evo3:
270 PS (266 hp) @ 6000 rpm
Torque Evo3:
309 Nm (228 lb-ft) @ 3000 rpm (increased at higher RPM in later models)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (RON 95/98 recommended)
Ignition System:
Electronic ignition with knock sensor
Engine Design
Block Material:
Cast Iron
Head Material:
Aluminum Alloy
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (W5M33)
Optional
Type:
N/A (Manual transmission was standard for all EVO I-III models)
Features
Drivetrain:
All-Wheel Drive (AWD) with viscous coupling center differential and optional Active Yaw Control (AYC) on later models.
Transfer Case:
Integrated with transmission and front differential
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, viscosity SAE 75W-90 (check manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 4,310 - 4,345 mm (169.7 - 171.1 in)
Width:
Approx. 1,690 - 1,770 mm (66.5 - 69.7 in)
Height:
Approx. 1,415 - 1,435 mm (55.7 - 56.5 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,240 - 1,340 kg (2,734 - 2,952 lbs)
Gross Vehicle Weight:
Varies by model and specification
🛡️ Safety Features
Ratings
Crash Test Data:
Limited data available for this era, primarily focused on JDM specifications. Likely met contemporary Japanese safety standards.
Active Features
ABS:
Standard on most models, 4-channel ABS system.
AWD:
Advanced AWD system provides significant traction advantage in adverse conditions.
Ayc:
Active Yaw Control (on Evolution II GSR, Evolution III GSR) to improve cornering stability and agility.
Passive Features
Airbags:
Driver's airbag typically standard, passenger airbag optional or unavailable on early models.
Seatbelts:
3-point seatbelts with pre-tensioners.
Chassis Design:
Reinforced chassis for improved rigidity and crashworthiness.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with cassette player or CD player (optional/later models). Likely aftermarket upgrades common.
Gauges:
Comprehensive gauge cluster including boost gauge, oil pressure, and voltmeter in GSR models.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) for enhanced braking control.
AWD Control:
Advanced AWD system with viscous coupling and center differential, and AYC on higher trims.
Connectivity
Original Connectivity:
Limited to basic vehicle functions. No integrated Bluetooth or smartphone connectivity from factory.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, depending on driving conditions. Frequent track use requires more frequent changes.
Timing Belt:
Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5-6 years. Critical replacement due to interference engine design.
Spark Plugs:
Every 40,000 - 60,000 km (25,000 - 37,000 miles), depending on plug type.
Coolant Flush:
Every 2 years or 40,000 km (25,000 miles).
Fluid Specifications
Engine Oil:
SAE 10W-30 or 10W-40 (synthetic recommended for performance driving). Check manual for specific API rating.
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change.
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4, High-performance DOT 4 recommended for spirited driving.
Power Steering Fluid:
Dexron II/III ATF or specific Mitsubishi power steering fluid.
Known Issues
Engine:
Head gasket failure (especially under high boost/heat), turbocharger wear, piston ring wear.
Drivetrain:
AYC pump failure, differential wear with aggressive use.
Electrical:
Corrosion in connectors, aging wiring harnesses.
Body:
Rust on chassis and wheel arches, particularly in humid climates or areas exposed to salt.
📚 Vehicle History
Brand Heritage
Motorsport Roots:
Mitsubishi's deep involvement in rallying, starting with the Lancer platform, directly led to the creation of the Evolution series.
Model Evolution
Evo I:
Debut in 1992, based on the Lancer (CB) platform. Introduced the 4G63T engine and advanced AWD.
Evo Ii:
Released in 1993, featured a revised engine, improved suspension geometry, and slightly wider track. Introduction of the GSR trim with AYC.
Evo Iii:
Launched in 1995, received significant engine and aerodynamic upgrades, including a redesigned front bumper and rear spoiler for better airflow and downforce. More powerful engine output.
Production
Production Period:
1992-1996
Manufacturing Location:
Japan
Total Units Produced:
Estimated ~10,000-15,000 units across all three generations, highly sought after.
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution platform achieved significant success in the World Rally Championship, solidifying its performance credentials.
Period Acclaim:
Widely praised by automotive journalists and enthusiasts for its handling, performance, and rally-bred technology upon release.
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