1995-2002 Mitsubushi LANCER LANCER Super Service Repair Workshop Manual 1996 1997 1998 1999 2000 2001
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer / Lancer Super Model Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Codes Platform Chassis Code: CB/CC/CD (specific variants may vary slightly) 👋 Introduction Market Position Market Segment: Compact sedan/hatchback, often appealing to younger buyers or those seeking reliable transportation with sporty options. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Mazda 323/Familia. Key Features Vehicle Strengths During Era: Good value, reliable engines, increasingly sporty handling and styling, especially in Lancer Super trims. Manual Value Proposition: Essential resource for DIY mechanics and professional technicians to maintain and repair the vehicle efficiently and accurately. 📋 Manual Details Coverage Areas Markets Covered: Global (primarily North America, Europe, Asia, Oceania, depending on specific Lancer Super sub-models) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, valve train, timing systems (belt/chain), lubrication, cooling. Engine Management: Fuel injection (MPI/GDI), ignition system, emissions control (EGR, EVAP), sensors (O2, MAP, TPS, CKP, CMP), actuators, ECU diagnosis, troubleshooting. Transmission Manual: Clutch, gearbox assembly, gears, shafts, synchros, shift linkage, final drive, fluid specifications, repair procedures. Transmission Automatic: Torque converter, valve body, planetary gear sets, clutches, bands, hydraulic control system, electronic control, fluid specifications, repair procedures. Drivetrain And Axles: Front-wheel drive (FWD), all-wheel drive (AWD) systems, CV joints, drive shafts, differentials, hub bearings, repair and replacement. Suspension: Front suspension (MacPherson struts, control arms), rear suspension (multi-link or torsion beam), springs, shock absorbers, bushings, alignment specifications, diagnosis. Steering: Power steering system (hydraulic), steering rack, tie rods, power steering pump, fluid types, diagnosis and repair. Brakes: Front disc brakes, rear disc or drum brakes, ABS (Anti-lock Braking System) components and diagnosis, brake fluid specifications, bleeding procedures, caliper and rotor replacement. Electrical System: Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, wiring diagrams, diagnostic connectors (OBD-I/OBD-II depending on specific models/years). HVAC: Heating, ventilation, and air conditioning system, refrigerant types, compressor, condenser, evaporator, blower motor, controls, diagnosis. Body And Interior: Body panels, doors, hood, trunk, bumpers, glass, interior trim, seats, safety belts, airbag systems (SRS), diagnosis and repair. Diagnostics And Troubleshooting: Fault codes (DTCs), diagnostic procedures for all major systems, testing of sensors and actuators, common problems and solutions. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug intervals, coolant flushes, brake fluid changes, timing belt replacement (if applicable), inspections. Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures. Transmission Repair: Detailed instructions for repairing both manual and automatic transmissions. Brake System Repair: Pad and rotor replacement, caliper overhaul, bleeding, ABS component testing. Suspension Component Replacement: Shock absorber, strut, control arm, ball joint, and bushing replacement. Electrical Component Replacement: Alternator, starter, ignition coils, sensors, and other electrical parts. Body Panel Repair And Replacement: Procedures for removing, installing, and repairing body panels, doors, and trim. HVAC System Repair: Diagnosis and repair of A/C and heating system components. Wiring Diagram Interpretation: Guidance on reading and understanding complex electrical schematics. Technical Depth Depth Of Information: Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete rebuilds. Diagnostic Capability: Detailed diagnostic flowcharts, trouble code explanations, and component testing procedures. Torque Specifications: Precise torque values for all critical fasteners across all systems. Clearances And Tolerances: Specific measurement data for engine components, bearings, and other wear parts. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Illustration Quality: High-resolution, clear, step-by-step illustrations and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Common Engine Variants: 1.5L (4G15), 1.6L (4G92), 1.8L (4G93), 2.0L (4G63/4G63T - Turbocharged in Evolution/GSR models). Engine Technology: SOHC and DOHC, Multi-Point Fuel Injection (MPI), some variants with Electronic Fuel Injection (EFI), Turbocharging (4G63T). Performance Horsepower Range: Approx. 90 hp (1.5L) to 250+ hp (2.0L Turbocharged). Torque Range: Approx. 130 Nm (1.5L) to 350+ Nm (2.0L Turbocharged). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) / Multi-Point Injection (MPI). Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Optional Optional Transmission Type: 4-speed Automatic Features AWD Availability: Available on certain Lancer Super models (e.g., GSR, Evolution variants) often with viscous coupling or active center differentials. 📐 Dimensions Exterior Typical Length: Approx. 4340-4420 mm (170.9-174.0 in) Typical Width: Approx. 1690-1705 mm (66.5-67.1 in) Typical Height: Approx. 1390-1430 mm (54.7-56.3 in) Weights Curb Weight Range: Approx. 1100-1300 kg (2425-2866 lbs) Wheelbase: Approx. 2500 mm (98.4 in) 🛡️ Safety Features Ratings NHTSA Ratings: Varies by specific model year and market; generally moderate for the era. Refer to specific market regulations. Active Features Active Safety Features: Anti-lock Braking System (ABS) often optional or standard on higher trims; Traction Control...
Front suspension (MacPherson struts, control arms), rear suspension (multi-link or torsion beam), springs, shock absorbers, bushings, alignment specifications, diagnosis.
Steering:
Power steering system (hydraulic), steering rack, tie rods, power steering pump, fluid types, diagnosis and repair.
Brakes:
Front disc brakes, rear disc or drum brakes, ABS (Anti-lock Braking System) components and diagnosis, brake fluid specifications, bleeding procedures, caliper and rotor replacement.
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, wiring diagrams, diagnostic connectors (OBD-I/OBD-II depending on specific models/years).
HVAC:
Heating, ventilation, and air conditioning system, refrigerant types, compressor, condenser, evaporator, blower motor, controls, diagnosis.
Body And Interior:
Body panels, doors, hood, trunk, bumpers, glass, interior trim, seats, safety belts, airbag systems (SRS), diagnosis and repair.
Diagnostics And Troubleshooting:
Fault codes (DTCs), diagnostic procedures for all major systems, testing of sensors and actuators, common problems and solutions.
Available on certain Lancer Super models (e.g., GSR, Evolution variants) often with viscous coupling or active center differentials.
📐 Dimensions
Exterior
Typical Length:
Approx. 4340-4420 mm (170.9-174.0 in)
Typical Width:
Approx. 1690-1705 mm (66.5-67.1 in)
Typical Height:
Approx. 1390-1430 mm (54.7-56.3 in)
Weights
Curb Weight Range:
Approx. 1100-1300 kg (2425-2866 lbs)
Wheelbase:
Approx. 2500 mm (98.4 in)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by specific model year and market; generally moderate for the era. Refer to specific market regulations.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS) often optional or standard on higher trims; Traction Control System (TCS) less common.
Passive Features
Passive Safety Features:
Front airbags (driver and passenger), three-point seatbelts with pretensioners, side-impact door beams.
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM/Cassette/CD players, speaker systems. Limited integration with external devices by modern standards.
Driver Assistance
Driver Assistance Features:
Primarily ABS on higher trims. Advanced driver-assistance systems (ADAS) were not common for this era.
Connectivity
Connectivity Options:
Minimal. Features like power windows, locks, and mirrors were common on higher trims. Cruise control was also available.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions.
Timing Belt Replacement:
Typically every 60,000-90,000 miles (96,000-144,000 km) for belt-driven engines. Crucial due to interference engine design.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on spark plug type (standard vs. platinum/iridium).
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 10W-30 or 5W-30 (check owner's manual for specific climate recommendations).
Coolant Specification:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent Ethylene Glycol-based coolant with OAT (Organic Acid Technology) inhibitors. (e.g., Pentofrost A3).
Automatic Transmission Fluid:
Mitsubishi DiaQueen SP-III or equivalent ATF (Dexron III/Mercon is NOT a direct substitute but some manuals might list it as an older alternative).
Brake Fluid Specification:
DOT 3 or DOT 4.
Known Issues
Common Engine Issues:
Oil leaks (valve cover gasket, oil pan gasket), timing belt failure (if not replaced on schedule), minor oil consumption in high-mileage engines.
Worn ball joints and tie rod ends, degraded bushings, strut/shock absorber leaks.
Common Electrical Issues:
Alternator failure, corroded grounds, power window motor issues.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Heritage:
Mitsubishi Motors has a long history in automotive manufacturing, known for engineering prowess, particularly in performance and rally vehicles (e.g., Lancer Evolution).
Model Evolution
Lancer Evolution Lineage:
This generation (CJ/CK/CM chassis) laid crucial groundwork for the highly successful Lancer Evolution series, sharing many mechanical components and design philosophies.
Production
Production Period For Generation:
1992-2000 (JDM), later variants and exports extended into early 2000s. This manual covers the later years of this generation.
Key Manufacturing Locations:
Japan, with assembly also occurring in other countries depending on market.
🏆 Awards & Recognition
Recognitions
Rally Heritage:
The Lancer platform, especially the Evolution variants, is highly decorated in World Rally Championship (WRC), contributing to the model's performance image.
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