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Mitsubishi Lancer Evolution 1 1992-1994 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution I Model Code: CD9A Generation: 1st Generation Codes Chassis Code: CD9A 👋 Introduction Market Position Market Segment: Performance Rally Homologation Special...
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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution I
Model Code:
CD9A
Generation:
1st Generation
Codes
Chassis Code:
CD9A
👋 Introduction
Market Position
Market Segment:
Performance Rally Homologation Special
Target Audience:
Enthusiasts, mechanics, tuners, and owners seeking in-depth technical knowledge and repair capabilities for the Lancer Evolution I
Competitive Analysis
Competitors Era:
Subaru Impreza WRX STi, Toyota Celica GT-Four, Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Rally Homologation:
Developed to meet Group A World Rally Championship regulations
AWD System:
Advanced Mitsubishi All-Wheel Control (AWC) system featuring viscous coupling center differential (VCU) and optional Active Yaw Control (AYC) in later iterations (though not standard on early Evo I)
Engine Technology:
High-performance turbocharged and intercooled 4G63T engine
📋 Manual Details
Coverage Areas
Years Covered:
1992, 1993, 1994
Regions Covered:
Primarily Japan Domestic Market (JDM)
Page Count
Estimated Page Count:
1000+ (typical for comprehensive factory service manuals)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
Japanese (with potential for translated sections or diagrams understandable internationally)
Format
Format:
Digital (e.g., PDF) or Printed
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63T), transmission, drivetrain, exhaust system
Chassis:
Suspension (front MacPherson strut, rear multi-link), steering, brakes (front ventilated discs, rear discs), wheels, tires
Electrical:
Wiring diagrams, lighting, ignition system, charging system, starting system, engine control unit (ECU), sensors
Body:
Body panels, interior trim, seating, glass, doors, bumpers, aerodynamics
HVAC:
Heating, ventilation, and air conditioning system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Troubleshooting:
Diagnostic procedures for common faults, symptom-based troubleshooting guides
Repair:
Detailed step-by-step repair instructions for all major components and systems
Overhaul:
Engine rebuild procedures, transmission overhaul, differential rebuild
Alignment:
Wheel alignment specifications and procedures
Torque Specifications:
Detailed torque values for all fasteners
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics with specific error code explanations and repair pathways
Component Level Detail:
In-depth component disassembly and reassembly instructions
Specifications And Tolerances:
Precise measurements, clearances, and wear limits for critical components
Electrical Schematics:
Comprehensive and detailed wiring diagrams for all electrical systems
📊 Manual Specifications
File Format
Digital Format:
PDF (Searchable text and high-resolution images recommended)
Print Quality
Print Quality:
High-resolution scans of original factory manuals, ensuring clarity of diagrams and text
Binding Type
Binding Type:
Digital: Downloadable/Printable; Printed: Spiral-bound or perfect-bound for durability
Paper Type
Paper Type:
N/A (for digital); High-quality, durable paper stock suitable for workshop environments (for printed)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Performance
Horsepower Ps:
241 PS @ 6000 rpm (JDM spec)
Horsepower Hp:
Approx. 237 hp @ 6000 rpm
Torque Nm:
304 Nm @ 3000 rpm (JDM spec)
Torque Lb-Ft:
Approx. 224 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (RON 98 recommended for optimal performance)
Turbocharger:
Mitsubishi TD05H-16G turbocharger with intercooler
Cooling System
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant)
Coolant Capacity:
Approximately 7.0 Liters
Lubrication
Engine Oil Type:
SAE 10W-30 or 10W-40 API SG or higher (e.g., Castrol GTX, Mobil 1)
Engine Oil Capacity:
Approximately 4.5 Liters (with filter change)
🔧 Transmission
Standard
Transmission Type:
5-speed manual transaxle
Optional
Optional Transmission:
N/A (Manual transmission only)
Features
Gear Ratios:
Specific gear ratios detailed within the manual, typically optimized for rally performance.
AWD System:
Advanced All-Wheel Control (AWC) with viscous coupling center differential (VCU) and helical gear type front limited-slip differential (LSD).
Fluid Specifications
Transmission Fluid Type:
API GL-4 SAE 75W-90 or SAE 80W-90 manual transmission fluid
Fluid Capacities
Transmission Fluid Capacity:
Approximately 3.3 Liters
📐 Dimensions
Exterior
Length:
4,260 mm (167.7 in)
Width:
1,770 mm (69.7 in)
Height:
1,420 mm (55.9 in)
Wheelbase:
2,600 mm (102.4 in)
Track Front:
1,500 mm (59.1 in)
Track Rear:
1,495 mm (58.9 in)
Weights
Curb Weight:
Approximately 1,200 kg (2,645 lbs)
Gross Vehicle Weight Rating:
N/A (typically not specified for performance models)
Wheels Tires
Standard Wheel Size:
15 x 6.5 inches
Standard Tire Size:
205/60R15
Bolt Pattern:
4x114.3 mm (4x4.5 inches)
Offset:
+38 mm
🛡️ Safety Features
Ratings
Fcc Crash Test Rating:
N/A (Vehicle not sold in North America during its initial production, thus no NHTSA ratings)
Active Features
Anti Lock Brakes:
Standard ABS (Anti-lock Braking System)
Traction Control:
N/A (No electronic traction control system on Evo I)
Limited Slip Differential:
Front Helical LSD, Viscous Center Diff
Passive Features
Airbags:
Driver airbag standard
Seatbelts:
Three-point inertia reel seatbelts with pretensioners
Body Structure:
Reinforced chassis and safety cell designed for rally conditions
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, potentially with CD changer option
Climate Control:
Manual climate control with air conditioning
Driver Assistance
Cruise Control:
Optional
Performance Monitoring:
Basic engine gauges, possibly boost gauge
Connectivity
Connectivity Features:
N/A (Pre-modern connectivity era)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first
Air Filter Replacement:
Every 15,000 km (9,000 miles) or 12 months
Spark Plug Replacement:
Every 30,000 km (18,000 miles)
Timing Belt Replacement:
Every 90,000 km (54,000 miles) or 5 years
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Power Steering Fluid Type:
Dexron III ATF or equivalent power steering fluid
Fluid Capacities
Brake Fluid Capacity:
Approximately 1.0 Liter
Power Steering Fluid Capacity:
Approximately 1.0 Liter
Known Issues
Engine Wear:
Piston ring wear, valve stem seal deterioration leading to oil consumption
Turbocharger:
Oil leaks, bearing wear, turbo seal failure
Cooling System:
Radiator leaks, thermostat failure, coolant hose degradation
Drivetrain:
Clutch wear, synchromesh wear in the transmission
Electrical:
Corroded connectors, failing sensors, ECU issues
📚 Vehicle History
Brand Heritage
Brand Origin:
Japan
Brand Focus:
Automotive manufacturing, with a history in rally racing and performance vehicles
Model Evolution
Predecessor:
None directly; evolved from the Lancer platform for homologation
Successor:
Mitsubishi Lancer Evolution II
Development Basis:
Based on the Mitsubishi Lancer CC (6th generation, 1988-1992)
Production
Production Years:
1992-1994
Manufacturing Location:
Japan
Production Volume:
Approximately 5,000 units (estimated)
🏆 Awards & Recognition
Recognitions
Rally Championships:
Foundation for the Mitsubishi Lancer Evolution's legendary rally status, achieving numerous rally victories and championships in subsequent generations.
Automotive Press Acclaim:
Praised by automotive journalists for its exceptional handling, performance, and rally-bred capabilities, setting a new benchmark for performance sedans.
Certifications
Homologation Status:
Homologated for Group A racing in the World Rally Championship (WRC)