🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution I (Evo I)

Sub Model:

Evolution I

Chassis Code Prefix:

CD9A

Engine Code:

4G63

Generation Name:

First Generation

Generation Code:

Evo I

👋 Introduction

Positioning:

The Mitsubishi Lancer Evolution I was a homologation special for Group A rallying, establishing the legendary Evo lineage. It was a performance-oriented compact sedan designed for enthusiasts and motorsport.

Competitors:

Primarily targeted performance sedans and homologation specials of its era, though direct competitors were few. Its closest rivals in spirit and performance were rally-bred homologation cars from Subaru (Impreza WRX STi) and other specialized performance vehicles.

Performance Focus:

The Evo I was engineered for outright performance, featuring a potent turbocharged engine, advanced all-wheel-drive system, and sophisticated suspension.

Rally Homologation:

Created to meet FIA homologation requirements for the World Rally Championship (WRC), inheriting motorsport-derived technology.

Manual Value Proposition:

Provides essential, detailed information for maintaining and repairing this iconic performance vehicle, crucial for preserving its condition and performance.

📋 Manual Details

Coverage Years:

1992-1995

Coverage Models:

Mitsubishi Lancer Evolution I (Evo I)

Coverage Regions:

Primarily Japanese Domestic Market (JDM) specification; may include minor variations for export markets if applicable for the era.

Estimated Page Count:

Extensive, typically 1000+ pages for a complete factory-style manual.

Manual Type:

Service and Repair Manual

Manual Classification:

Factory-style Workshop Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the 4G63 engine, including cylinder head, block, pistons, crankshaft, connecting rods, camshafts, valvetrain, timing belt, oil pump, and lubrication system.

Engine Fuel System:

Fuel injection system (ECI-Multi), injectors, fuel pump, fuel filter, fuel pressure regulator, throttle body, and emissions control systems.

Engine Ignition System:

Ignition coils, spark plugs, ECU control of ignition timing, distributor (if applicable to specific market variant), and related sensors.

Engine Cooling System:

Radiator, fan, water pump, thermostat, coolant passages, and hoses.

Engine Exhaust System:

Exhaust manifold, catalytic converter (if equipped for market), muffler, and emissions control components.

Transmission Manual:

Service and repair of the 5-speed manual transmission (e.g., KM213), including clutch, gear sets, shift mechanism, and gearbox housing.

Transmission Transfer Case:

Service and repair of the front and rear differentials, viscous coupling center differential, and Active Yaw Control (AYC) system components (if applicable to specific Evo I variants).

Drivetrain AWD:

Detailed coverage of the full-time four-wheel-drive system, including the center differential, viscous coupling unit, and related driveline components.

Suspension Front:

MacPherson strut front suspension, including struts, springs, control arms, sway bar, and bushings.

Suspension Rear:

Multi-link rear suspension, including shocks, springs, trailing arms, control arms, and bushings.

Steering System:

Power steering system, including pump, rack and pinion, steering column, and related components.

Brake System:

Hydraulic brake system, including master cylinder, brake booster, front and rear disc brakes (often Brembo on performance variants), ABS components, and brake lines.

Electrical System Charging:

Alternator, battery, charging circuit diagnostics.

Electrical System Starting:

Starter motor, ignition switch, starting circuit.

Electrical System Lighting:

Headlights, taillights, interior lighting, and wiring diagrams.

Electrical System Instruments:

Instrument cluster, gauges, warning lights, and their operation.

Electrical System ECM:

Engine Control Module (ECM) functions, sensor inputs, actuator outputs, and diagnostic troubleshooting.

Body Exterior:

Body panel removal and installation, door mechanisms, latches, hinges, glass, bumpers, and aerodynamic components.

Body Interior:

Dashboard, seats, door panels, trim pieces, HVAC controls, and interior lighting.

HVAC System:

Air conditioning, heating, ventilation system components, refrigerant, blower motor, and climate controls.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all systems, including engine, chassis, body, and accessories.

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotation, and general inspection procedures.

Engine Repair:

Head gasket replacement, piston ring replacement, bearing service, camshaft timing adjustments, turbocharger inspection and repair (if applicable to variant).

Transmission Repair:

Clutch replacement, transmission fluid change, seal replacement, gear synchro inspection and replacement.

Suspension And Steering Repair:

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

Brake System Repair:

Brake pad and rotor replacement, caliper rebuilding, brake fluid flush, ABS sensor replacement, brake line repair.

Electrical Diagnostics:

Troubleshooting common electrical faults, testing sensors and actuators, diagnosing ECM issues, and using diagnostic tools (e.g., MUT-II if covered).

Body And Trim Repair:

Door panel removal, seat adjustment and repair, bumper cover replacement, fender repair, glass replacement.

Troubleshooting Guides:

Step-by-step diagnostic procedures for various symptoms and issues, often presented in a flowchart format.

Torque Specifications:

Detailed torque values for all critical fasteners across all systems.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including diagnostics and component-level repair.

Diagnostics:

Advanced diagnostic procedures, including symptom-based troubleshooting, electrical system analysis, and potentially engine control module (ECM) data interpretation.

Component Rebuild:

Detailed instructions for rebuilding major components like the engine, transmission, differentials, and turbocharger (if applicable).

📊 Manual Specifications

File Type:

Likely PDF

Searchability:

High likelihood of text-searchable content if professionally produced digital version.

Print Quality:

Dependent on source; professional digital scans aim for clarity and readability.

Image Resolution:

Variable, but critical diagrams and illustrations should have sufficient resolution for clarity.

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

4G63

Engine Type:

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

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1 (typical)

Horsepower:

247 PS (approx. 244 hp) at 6000 rpm

Torque:

30.4 kg-m (approx. 219 lb-ft) at 3000 rpm

Fuel Delivery:

Electronic Fuel Injection (ECI-Multi) with multi-point injection

Fuel Type:

Premium Unleaded Gasoline

Turbocharger Details:

Mitsubishi TD05H-16G turbocharger with intercooler

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Optional Transmission:

Not typically offered with automatic transmission for the Evo I performance variants.

Drivetrain:

Full-time Four-Wheel-Drive (4WD) with Active Yaw Control (AYC) on some variants, and a viscous coupling center differential.

📐 Dimensions

Length:

4310 mm (approx. 169.7 inches)

Width:

1755 mm (approx. 69.1 inches)

Height:

1415 mm (approx. 55.7 inches)

Wheelbase:

2500 mm (approx. 98.4 inches)

Curb Weight:

Approx. 1230 kg (approx. 2711 lbs)

Gross Weight Rating:

Not commonly specified for performance variants.

🛡️ Safety Features

Crash Test Ratings:

No standardized global crash test ratings available for this era and specific JDM model. Safety features were focused on active systems for performance.

ABS:

Anti-lock Braking System (ABS) was available on some models.

Ayc:

Active Yaw Control (AYC) system for enhanced cornering stability on certain configurations.

Airbags:

Driver airbag was standard on many JDM models, passenger airbag availability varied.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Factory System:

Basic factory radio/cassette player. CD players were optional or aftermarket additions. Features were minimal, focusing on core vehicle functions.

ABS:

Anti-lock Braking System (ABS) was a significant driver assistance feature for its time.

Ayc:

Active Yaw Control (AYC) was a pioneering electronic system that actively managed torque distribution between the rear wheels to improve cornering grip and stability.

Connectivity Features:

No modern connectivity features such as Bluetooth, USB, or smartphone integration. Connectivity was limited to basic audio systems.

🔧 Maintenance

Engine Oil And Filter:

Every 5,000 km (approx. 3,000 miles) or 6 months, whichever comes first, under normal driving conditions. More frequent changes recommended for spirited driving or track use.

Transmission Fluid:

Every 40,000 km (approx. 25,000 miles) or 2 years.

Transfer Case And Differential Fluid:

Every 40,000 km (approx. 25,000 miles) or 2 years.

Timing Belt:

Every 80,000 km (approx. 50,000 miles) or 4 years. Crucial for the 4G63 engine due to interference design.

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 recommended for turbocharged applications. Specific viscosity may vary by climate.

Engine Oil Capacity:

Approx. 4.5 Liters (4.8 US Quarts) with filter change.

Transmission Fluid Type:

GL-4 SAE 75W-90 or 75W-85 gear oil. Some specialized fluids might be recommended for high-performance applications.

Coolant Type:

Ethylene glycol-based antifreeze (e.g., 50/50 mix with distilled water).

Engine Reliance:

The 4G63 is robust, but improper maintenance, especially oil changes and timing belt replacement, can lead to catastrophic failure. Overheating can also cause head gasket issues.

Ayc System:

AYC pumps and sensors can fail over time, leading to warning lights and loss of active yaw control functionality. The fluid in the AYC system requires periodic replacement.

Turbocharger Wear:

Wear on the turbocharger seals or bearings can lead to oil consumption or loss of boost. Regular oil changes are critical to turbo longevity.

Suspension Bushings:

Rubber suspension bushings can degrade over time, leading to imprecise handling and clunking noises. Performance-oriented polyurethane bushings are common upgrades.

Rust And Corrosion:

Common in vehicles of this age, especially in regions with harsh winters. Inspection of wheel arches, sills, and floor pans is recommended.

📚 Vehicle History

Mitsubishi Motorsport:

Mitsubishi has a strong heritage in motorsport, particularly in rallying, which heavily influenced the development of the Lancer Evolution series.

Evo I Introduction:

Launched in October 1992, the Evo I marked the beginning of the iconic Lancer Evolution line, based on the sixth-generation Lancer (CC platform).

Rally Focus:

Developed specifically for homologation in the Group A touring car category, aiming to compete in the World Rally Championship.

Key Distinctions Evo I:

Featured a modified 4G63 engine, advanced AWD system with a center differential, revised suspension, and aggressive aerodynamic body kit differentiating it from standard Lancers.

Production Period:

1992-1993

Production Volume:

Limited production numbers, typical for homologation specials, contributing to its collectible status.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Motorsport Success:

The Lancer Evolution platform achieved significant success in the World Rally Championship, establishing its performance credentials from its inception.

Performance Acclaim:

The Evo I and subsequent models were widely praised by automotive media for their exceptional handling, acceleration, and rally-bred performance.

Homologation Compliance:

Designed and built to meet FIA Group A homologation standards for rally competition.