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Mitsubishi Lancer Evolution 3 1995-1996 All Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution III Generation: CE9A Production Years Covered: 1995-1996 Codes Chassis Code: CE9A 👋 Introduction Market Position Positioning: Iconic rally homologation special, highly sought after by enthusiasts and performance drivers Competitive Analysis Competitors: Subaru Impreza WRX STI (GC8), Ford Escort RS Cosworth, Lancia Delta Integrale Key Features Performance: Advanced all-wheel-drive system (AYC - Active Yaw Control), turbocharged engine, rally-bred chassis Manual Utility: Empowers owners for independent maintenance and repair, saving costs and ensuring quality work Target Audience Audience: Mitsubishi Lancer Evolution III owners, performance tuning enthusiasts, DIY mechanics, restoration specialists 📋 Manual Details Coverage Areas Primary Coverage: All aspects of repair, maintenance, and troubleshooting Specific Sections: General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Engine Control System, Chassis/Body, Restraint System, Axle Page Count Estimated Page Count: Comprehensive (Specific count not provided, but extensive coverage implies hundreds of pages) Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed repair, overhaul, diagnosis for 4G63T engine components Transmission: Manual (W5M33) and potentially Automatic (F4A51, though less common for Evo III) service, overhaul, diagnostics Brakes: Front and rear brake systems, ABS (if equipped), component replacement, bleeding procedures Electrical: Full wiring diagrams, component testing, diagnostic procedures, ECU operations Suspension Steering: Front and rear suspension components, alignment, steering system service Fuel Emission: Fuel injection system, fuel pump, injectors, emissions control systems, diagnosis Cooling Lubrication: Radiator, water pump, thermostat, lubrication system, oil change procedures Body Chassis: Body panel repair, interior trim, chassis components, structural integrity Restraint System: Airbag system (if equipped), seatbelts, safety system diagnostics Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements Troubleshooting: Step-by-step diagnostic guides for common and uncommon issues Repair Overhaul: Detailed instructions for disassembling, repairing, and reassembling all major vehicle components Technical Specifications: Torque specifications, clearances, tolerances, electrical values Wiring Diagrams: Comprehensive and detailed electrical schematics Technical Depth Depth: Full workshop level, covering from basic checks to complete engine and transmission rebuilds 📊 Manual Specifications File Format Format: PDF Compatibility: All Windows & Mac versions Software Requirements: Adobe PDF Reader, WinZip Print Quality Quality: Digital download, print quality depends on user's printer Binding Type Type: Digital Download (not physically bound) Paper Type Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: Inline-4, DOHC, 16-valve, turbocharged, intercooled Displacement: 2.0 Liters (1997 cc) Performance Horsepower Ps: 270 PS (approx. 266 hp) at 6,500 rpm (JDM spec) Torque Nm: 309 Nm (approx. 228 lb-ft) at 3,000 rpm (JDM spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Multi-point injection Turbocharger: Mitsubishi TD05HR-16G or similar, with intercooler Cooling System Cooling Type: Water-cooled 🔧 Transmission Standard Type: 5-speed Manual (W5M33) Optional Type: 4-speed Automatic (F4A51) - Less common for performance variants Features AWD System: Full-time 4WD with Active Yaw Control (AYC) and Viscous Coupling Center Differential (VCCD) 📐 Dimensions Exterior Length: 4,350 mm (171.3 in) Width: 1,770 mm (69.7 in) Height: 1,415 mm (55.7 in) Wheelbase: 2,600 mm (102.4 in) Weights Curb Weight: Approximately 1,400 kg (3,086 lbs) 🛡️ Safety Features Ratings Crash Test Info: Safety ratings from the era are difficult to quantify with modern standards; focus on structural integrity and rally-derived safety features. Active Features AWD Ayc: Active Yaw Control (AYC) significantly enhances cornering stability and traction Passive Features Airbags: Driver's airbag (standard on many models), passenger airbag optional or market dependent Seatbelts: Three-point inertia-reel seatbelts with pre-tensioners 💡 Technology Features Infotainment Audio System: Factory fitted cassette player and radio, often upgraded by owners with modern head units. Driver Assistance Ayc System Tech: Active Yaw Control (AYC) is a sophisticated torque-vectoring system for its time. Connectivity Connectivity Features: None by modern standards. Primarily mechanical and electrical systems. 🔧 Maintenance Service Intervals Oil Change: Every 5,000 km (3,000 miles) or 3 months, whichever comes first, especially under spirited driving conditions. Spark Plugs: Inspect every 20,000 km (12,000 miles), replace as needed (typically high-performance iridium plugs recommended). Timing Belt: Replace every 80,000 km (50,000 miles) or 5 years. Critical for the 4G63T engine. Fluid Specifications Engine Oil: API SG/SH, SAE 10W-30 or 10W-40 (high-performance synthetic recommended). Transmission Fluid Manual: API GL-3 or GL-4, SAE 75W-90 (specific Mitsubishi fluid or equivalent). Coolant: Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors) - typically 50/50 mix with distilled water. Brake Fluid: DOT 3 or DOT 4 (high-performance DOT 4 recommended for spirited driving). Known Issues Engine Reliability: While robust, the 4G63T can be susceptible to rod bearing failure if not properly maintained or if pushed beyond its limits without supporting modifications. Overheating can also be an issue if cooling system is neglected. Ayc System: The Active Yaw Control (AYC) pump and...
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Mitsubishi Lancer Evolution 3 1995-1996 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution III
Generation:
CE9A
Production Years Covered:
1995-1996
Codes
Chassis Code:
CE9A
👋 Introduction
Market Position
Positioning:
Iconic rally homologation special, highly sought after by enthusiasts and performance drivers
Competitive Analysis
Competitors:
Subaru Impreza WRX STI (GC8), Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Performance:
Advanced all-wheel-drive system (AYC - Active Yaw Control), turbocharged engine, rally-bred chassis
Manual Utility:
Empowers owners for independent maintenance and repair, saving costs and ensuring quality work
Target Audience
Audience:
Mitsubishi Lancer Evolution III owners, performance tuning enthusiasts, DIY mechanics, restoration specialists
📋 Manual Details
Coverage Areas
Primary Coverage:
All aspects of repair, maintenance, and troubleshooting
Specific Sections:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Engine Control System, Chassis/Body, Restraint System, Axle
Page Count
Estimated Page Count:
Comprehensive (Specific count not provided, but extensive coverage implies hundreds of pages)
Manual Type
Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed repair, overhaul, diagnosis for 4G63T engine components
Transmission:
Manual (W5M33) and potentially Automatic (F4A51, though less common for Evo III) service, overhaul, diagnostics
Brakes:
Front and rear brake systems, ABS (if equipped), component replacement, bleeding procedures
Electrical:
Full wiring diagrams, component testing, diagnostic procedures, ECU operations
Suspension Steering:
Front and rear suspension components, alignment, steering system service
Fuel Emission:
Fuel injection system, fuel pump, injectors, emissions control systems, diagnosis
Cooling Lubrication:
Radiator, water pump, thermostat, lubrication system, oil change procedures
Body Chassis:
Body panel repair, interior trim, chassis components, structural integrity
Restraint System:
Airbag system (if equipped), seatbelts, safety system diagnostics
Procedures Included
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon issues
Repair Overhaul:
Detailed instructions for disassembling, repairing, and reassembling all major vehicle components
Technical Specifications:
Torque specifications, clearances, tolerances, electrical values
Wiring Diagrams:
Comprehensive and detailed electrical schematics
Technical Depth
Depth:
Full workshop level, covering from basic checks to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All Windows & Mac versions
Software Requirements:
Adobe PDF Reader, WinZip
Print Quality
Quality:
Digital download, print quality depends on user's printer
Binding Type
Type:
Digital Download (not physically bound)
Paper Type
Type:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
Inline-4, DOHC, 16-valve, turbocharged, intercooled
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Ps:
270 PS (approx. 266 hp) at 6,500 rpm (JDM spec)
Torque Nm:
309 Nm (approx. 228 lb-ft) at 3,000 rpm (JDM spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point injection
Turbocharger:
Mitsubishi TD05HR-16G or similar, with intercooler
Cooling System
Cooling Type:
Water-cooled
🔧 Transmission
Standard
Type:
5-speed Manual (W5M33)
Optional
Type:
4-speed Automatic (F4A51) - Less common for performance variants
Features
AWD System:
Full-time 4WD with Active Yaw Control (AYC) and Viscous Coupling Center Differential (VCCD)
📐 Dimensions
Exterior
Length:
4,350 mm (171.3 in)
Width:
1,770 mm (69.7 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,600 mm (102.4 in)
Weights
Curb Weight:
Approximately 1,400 kg (3,086 lbs)
🛡️ Safety Features
Ratings
Crash Test Info:
Safety ratings from the era are difficult to quantify with modern standards; focus on structural integrity and rally-derived safety features.
Active Features
AWD Ayc:
Active Yaw Control (AYC) significantly enhances cornering stability and traction
Passive Features
Airbags:
Driver's airbag (standard on many models), passenger airbag optional or market dependent
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners
💡 Technology Features
Infotainment
Audio System:
Factory fitted cassette player and radio, often upgraded by owners with modern head units.
Driver Assistance
Ayc System Tech:
Active Yaw Control (AYC) is a sophisticated torque-vectoring system for its time.
Connectivity
Connectivity Features:
None by modern standards. Primarily mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 km (3,000 miles) or 3 months, whichever comes first, especially under spirited driving conditions.
Spark Plugs:
Inspect every 20,000 km (12,000 miles), replace as needed (typically high-performance iridium plugs recommended).
Timing Belt:
Replace every 80,000 km (50,000 miles) or 5 years. Critical for the 4G63T engine.
Fluid Specifications
Engine Oil:
API SG/SH, SAE 10W-30 or 10W-40 (high-performance synthetic recommended).
Transmission Fluid Manual:
API GL-3 or GL-4, SAE 75W-90 (specific Mitsubishi fluid or equivalent).
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors) - typically 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 (high-performance DOT 4 recommended for spirited driving).
Known Issues
Engine Reliability:
While robust, the 4G63T can be susceptible to rod bearing failure if not properly maintained or if pushed beyond its limits without supporting modifications. Overheating can also be an issue if cooling system is neglected.
Ayc System:
The Active Yaw Control (AYC) pump and sensors can fail over time, requiring specialized diagnosis and repair.
Rust:
Common in older performance vehicles, check wheel arches, sills, and subframes for corrosion.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi's rich history in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution series.
Model Evolution
Evo Iii Development:
Evolved from the Evo I and II, featuring improved aerodynamics, chassis rigidity, and engine cooling. Debuted in 1995.
Production
Manufacturing Location:
Japan
Production Volume:
Limited, high-performance homologation model; exact figures vary but generally tens of thousands globally.
🏆 Awards & Recognition
Recognitions
Rally Performance:
Won the 1995 FIA World Rally Championship for Manufacturers with Tommi Mäkinen.
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