Mitsubishi Lancer Evolution 2 1994-1995 WSM Service Manual
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๐ท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution II (Evo II) Model Code: CD9A Codes Chassis Code: CD9A Engine Code Primary: 4G63T Generation Generation Name: Second Generation (Evo II) Production Years: 1994-1995 ๐ Introduction Market Position Market Segment: High-performance Rally Homologation Special, Enthusiast Sports Sedan Competitors: Subaru Impreza WRX (limited availability in some markets), Ford Escort RS Cosworth, Lancia Delta Integrale Key Features Performance Focus: All-wheel drive, turbocharged engine, advanced suspension and drivetrain electronics Rally Heritage: Developed for Group A rally homologation, featuring a potent drivetrain and chassis Technical Innovation: Introduction of Active Center Differential (ACD) and revised AYC (Active Yaw Control) system ๐ Manual Details Coverage Areas Manual Type: Factory Service Manual / Workshop Service Manual (WSM) Language: English Format: PDF Download Page Count Estimated Page Count: Approximately 800-1200 pages (typical for a comprehensive WSM of this era) ๐ Manual Coverage Systems Covered Powertrain: Engine (4G63T), Fuel System, Ignition System, Exhaust System, Lubrication System, Cooling System, Turbocharger System Drivetrain: Transmission (5-speed manual), Transfer Case, Driveshafts, Front Differential, Rear Differential (Active Center Differential - ACD, Rear Limited Slip Differential - LSD) Suspension Steering: Front Suspension (MacPherson Strut), Rear Suspension (Multi-link), Steering System (Power Steering) Brakes: Front Brakes (Ventilated Discs, 4-Piston Calipers), Rear Brakes (Ventilated Discs, 2-Piston Calipers), ABS System Electrical: Engine Control Unit (ECU), Ignition System, Lighting, Instruments, Audio System, Power Accessories, Wiring Diagrams, Fuses and Relays Body Chassis: Body Construction, Exterior Trim, Interior Trim, Doors, Windows, Seats, HVAC System, Frame and Structural Components Procedures Included Maintenance: Scheduled Maintenance Intervals, Fluid Checks and Changes, Filter Replacements, Belt Inspections Repair Rebuild: Engine Overhaul, Transmission Rebuild, Turbocharger Replacement, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis and Repair Troubleshooting: Diagnostic Procedures, Symptom-based Troubleshooting Charts, Fault Code Identification Technical Depth Diagnostics: Advanced Diagnostics, ECU Scan Data Interpretation, Sensor Data Analysis Specifications: Torque Specifications, Clearances, Tolerances, Electrical Schematics, Component Specifications Rebuild Procedures: Detailed Step-by-Step Reassembly Procedures for Major Components ๐ Manual Specifications File Format Digital Format: PDF Searchability: Likely Searchable Text (if professionally scanned and processed) Printability: Printable (high-resolution digital reproduction) Print Quality Quality Description: Professional Quality, In-depth Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) โ๏ธ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, Turbocharged, Intercooled Engine Code: 4G63T (Revision for Evo II) Displacement: 1997 cc (2.0 Liters) Performance Horsepower: Approx. 260 PS (191 kW; 256 hp) at 6,000 rpm (Japanese Spec) Torque: Approx. 309 Nm (228 lb-ft) at 3,000 rpm (Japanese Spec) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) with Electronic Control Fuel Type: Unleaded Premium Gasoline Turbocharger: Mitsubishi TD05H-16G Turbocharger with Water-Cooled Bearing Housing Maintenance Points Oil Type Spec: API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specifications) Oil Capacity: Approx. 4.5 Liters (with filter change) Spark Plugs: NGK BKR6E-11 (or equivalent, check manual for specific heat range) ๐ง Transmission Standard Type: 5-Speed Manual Transmission Optional Transmission Options: None (Manual Only) Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Center Differential (ACD) Differential Rear: Active Yaw Control (AYC) / Mechanical Limited Slip Differential (LSD) depending on specific model variant Maintenance Points Transmission Fluid Spec: API GL-4 or GL-5, SAE 75W-90 (refer to manual for exact specifications and capacity) ๐ Dimensions Exterior Length: Approx. 4,260 mm (167.7 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,435 mm (56.5 in) Wheelbase: Approx. 2,500 mm (98.4 in) Weights Curb Weight: Approx. 1,290 kg (2,844 lbs) Wheel Bolt Pattern: 5x114.3 mm Wheel Size Standard: 16 x 7.0 inches Tire Size Standard: 205/50R16 ๐ก๏ธ Safety Features Ratings Crash Test Data: Limited data available for this specific era and JDM homologation model. Focus was on structural integrity for rally. Active Features ABS: Standard Anti-lock Braking System (ABS) AWD: Advanced All-Wheel Drive System with ACD and AYC for enhanced traction and stability Passive Features Airbags: Driver's Airbag (standard on most models, check specific market) Seatbelts: Pre-tensioner seatbelts ๐ก Technology Features Infotainment Audio System: Factory radio with AM/FM and cassette player (upgradeable) Driver Assistance Torque Vectoring: Active Yaw Control (AYC) provides advanced torque vectoring for enhanced cornering stability. Traction Control: While lacking electronic traction control in the modern sense, the AWD system with ACD and AYC provides significant mechanical traction control. Connectivity Connectivity Features: Limited to factory wiring for audio accessories; no modern Bluetooth or USB integration from the factory. ๐ง Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 km (3,000 - 4,500 miles) or 6 months, whichever comes first (severe duty recommended). Transmission Fluid Interval: Every 40,000 - 60,000 km (25,000 - 37,500 miles) or 2-3 years. Timing Belt Replacement: Every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5-7 years. Crucial to follow this interval due to interference engine design. Fluid Specifications Coolant Type: Ethylene Glycol-based coolant (50/50 mix with distilled water), refer to manual...
Approx. 309 Nm (228 lb-ft) at 3,000 rpm (Japanese Spec)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) with Electronic Control
Fuel Type:
Unleaded Premium Gasoline
Turbocharger:
Mitsubishi TD05H-16G Turbocharger with Water-Cooled Bearing Housing
Maintenance Points
Oil Type Spec:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specifications)
Oil Capacity:
Approx. 4.5 Liters (with filter change)
Spark Plugs:
NGK BKR6E-11 (or equivalent, check manual for specific heat range)
๐ง Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Transmission Options:
None (Manual Only)
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Center Differential (ACD)
Differential Rear:
Active Yaw Control (AYC) / Mechanical Limited Slip Differential (LSD) depending on specific model variant
Maintenance Points
Transmission Fluid Spec:
API GL-4 or GL-5, SAE 75W-90 (refer to manual for exact specifications and capacity)
๐ Dimensions
Exterior
Length:
Approx. 4,260 mm (167.7 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,435 mm (56.5 in)
Wheelbase:
Approx. 2,500 mm (98.4 in)
Weights
Curb Weight:
Approx. 1,290 kg (2,844 lbs)
Wheel Bolt Pattern:
5x114.3 mm
Wheel Size Standard:
16 x 7.0 inches
Tire Size Standard:
205/50R16
๐ก๏ธ Safety Features
Ratings
Crash Test Data:
Limited data available for this specific era and JDM homologation model. Focus was on structural integrity for rally.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
AWD:
Advanced All-Wheel Drive System with ACD and AYC for enhanced traction and stability
Passive Features
Airbags:
Driver's Airbag (standard on most models, check specific market)
Seatbelts:
Pre-tensioner seatbelts
๐ก Technology Features
Infotainment
Audio System:
Factory radio with AM/FM and cassette player (upgradeable)
Driver Assistance
Torque Vectoring:
Active Yaw Control (AYC) provides advanced torque vectoring for enhanced cornering stability.
Traction Control:
While lacking electronic traction control in the modern sense, the AWD system with ACD and AYC provides significant mechanical traction control.
Connectivity
Connectivity Features:
Limited to factory wiring for audio accessories; no modern Bluetooth or USB integration from the factory.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 4,500 miles) or 6 months, whichever comes first (severe duty recommended).
Transmission Fluid Interval:
Every 40,000 - 60,000 km (25,000 - 37,500 miles) or 2-3 years.
Timing Belt Replacement:
Every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5-7 years. Crucial to follow this interval due to interference engine design.
Fluid Specifications
Coolant Type:
Ethylene Glycol-based coolant (50/50 mix with distilled water), refer to manual for specific color/type.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual)
Known Issues
Engine Reliability:
Generally robust 4G63T engine, but susceptible to damage from poor maintenance, overheating, or sustained high boost without proper supporting modifications.
Turbocharger Wear:
Turbocharger seals can wear over time leading to oil consumption or smoke.
Ayc System:
AYC hydraulic pump and sensors can be a failure point; requires specific fluid and maintenance.
Rust Corrosion:
As with many cars of this era, especially those used in competitive environments or harsh climates, rust can be a concern on body panels, chassis, and suspension components.
๐ Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors has a strong heritage in motorsport, particularly rallying, with the Lancer platform serving as a foundation.
Model Evolution
Evo I To Ii Changes:
The Evo II saw improvements including a slightly larger turbocharger, revised ECU mapping, strengthened suspension components, and a wider track for improved handling and stability. Power output was increased.
Production
Production Location:
Japan
Homologation Purpose:
Built to meet FIA Group A homologation regulations for the World Rally Championship (WRC).
๐ Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution platform (including Evo II) has a storied history in the World Rally Championship, achieving multiple driver and manufacturer championships for Mitsubishi.