Mitsubishi Lancer Evolution 1 1992-1994 All Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution 1 Model Code: CD9A Generation Generation: I Codes Production Years: 1992-1994 👋 Introduction Market Position Positioning: Performance homologation model for rallying, street-legal sports sedan Competitive Analysis Competitors: Subaru Impreza WRX STI (later generations), Ford Escort RS Cosworth Key Features Engine: Legendary 4G63T engine, known for robustness and tuning potential Drivetrain: Advanced AWD system with driver-adjustable center differential (Holo-Shift) and Active Yaw Control (AYC) Suspension: Purpose-built performance suspension for superior handling Brakes: Upgraded braking system to handle performance demands Aerodynamics: Aggressive body kit, rear wing, and functional aero elements 📋 Manual Details Coverage Areas Coverage: All service and repair procedures for the Mitsubishi Lancer Evolution 1 Page Count Page Count: Estimated 1500+ pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine: 4G63T (2.0L DOHC Turbocharged) Engine Management: ECU, ignition, fuel injection, emissions control Transmission: 5-speed manual (W5M33-2-J1) Drivetrain: All-Wheel Drive (AWD) system, Active Yaw Control (AYC) system Suspension: Front MacPherson struts, Rear multi-link independent suspension Brakes: Front and rear disc brakes, ABS Steering: Power-assisted rack and pinion Electrical: Wiring diagrams, charging system, starting system, lighting, accessories Body: Body panels, chassis, interior trim, climate control Heating Ventilation Air Conditioning: HVAC system components and operation Interior: Seats, dashboard, door panels, trim components Safety Systems: SRS airbags (if equipped), seat belt systems Procedures Included Maintenance: Routine checks, fluid changes, filter replacements, belt adjustments Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation Repair: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component repair Disassembly Assembly: Detailed step-by-step instructions for component removal and installation Torque Specifications: Precise torque values for all critical fasteners Special Tools: Identification and usage of specialized tools required for certain procedures Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds Diagnostics Level: Advanced, including ECU diagnostic procedures and sensor testing Electrical Schematics: Detailed wiring diagrams for all vehicle systems 📊 Manual Specifications File Format File Format: PDF Searchable Text: Likely searchable text within the PDF for quick reference Print Quality Print Quality: High resolution, suitable for printing specific sections or the entire manual Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: 2.0L Inline-4 DOHC 16-valve Turbocharged Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Valvetrain: DOHC, 16 valves, timing belt Performance Horsepower: 241 hp @ 6000 rpm (JDM Spec) Torque: 242 lb-ft @ 3000 rpm (JDM Spec) Fuel System Fuel Type: Unleaded Gasoline (Premium Recommended) Fuel Injection: Electronic Fuel Injection (EFI) Turbocharger: Mitsubishi TD05-14B or TD05HR-15G (depending on market/spec) Intercooler: Air-to-air front-mounted intercooler 🔧 Transmission Standard Type: 5-speed Manual Model Code: W5M33-2-J1 Features Drivetrain: All-Wheel Drive (AWD) with mechanical front differential, viscous center coupling, and mechanical rear differential Ayc: Active Yaw Control (AYC) system for torque vectoring to rear wheels 📐 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) Front Track: 1,495 mm (58.9 in) Rear Track: 1,490 mm (58.7 in) Weights Curb Weight: Approx. 1,200 kg (2,646 lbs) Gross Weight: Approx. 1,475 kg (3,252 lbs) 🛡️ Safety Features Ratings Keselamatan Rating: Specific official crash test ratings may vary by region and year; generally considered robust for its era. Active Features ABS: Anti-lock Braking System (ABS) standard Ayc: Active Yaw Control (AYC) for enhanced stability and cornering Passive Features Airbags: Driver's airbag standard, passenger airbag optional on some models Seatbelts: Three-point inertia reel seatbelts Chassis: Reinforced chassis and safety cell design 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player with basic speaker configuration Gauges: Comprehensive instrument cluster including boost gauge, oil pressure, and oil temperature Driver Assistance ABS: Standard Anti-lock Braking System Ayc: Active Yaw Control system, a pioneering torque-vectoring technology for its era Connectivity Connectivity Features: No advanced connectivity features (Bluetooth, USB) as standard due to the era of production. 🔧 Maintenance Service Intervals Oil Change: Every 5,000 km (3,000 miles) or 6 months, whichever comes first (especially under spirited driving) Air Filter: Inspect every 10,000 km (6,000 miles), replace as needed or at 20,000 km (12,000 miles) Spark Plugs: Replace every 40,000 km (25,000 miles) Timing Belt: Replace every 90,000 km (56,000 miles) or 5 years Coolant: Flush and replace every 40,000 km (25,000 miles) or 2 years Fluid Specifications Engine Oil: API SG or SH, SAE 10W-30 or 10W-40 (for turbo engines, higher viscosity may be preferred) Transmission Fluid: Mitsubishi DiaQueen Super Multi Gear Oil (GL-5 75W-85W) Transfer Case Fluid: Mitsubishi DiaQueen Super Multi Gear Oil (GL-5 75W-85W) Rear Differential Fluid: Mitsubishi DiaQueen Super Multi Gear Oil (GL-5 75W-85W) Coolant: Ethylene Glycol-based antifreeze, 50/50 mix with distilled water...
Detailed step-by-step instructions for component removal and installation
Torque Specifications:
Precise torque values for all critical fasteners
Special Tools:
Identification and usage of specialized tools required for certain procedures
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds
Diagnostics Level:
Advanced, including ECU diagnostic procedures and sensor testing
Electrical Schematics:
Detailed wiring diagrams for all vehicle systems
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Likely searchable text within the PDF for quick reference
Print Quality
Print Quality:
High resolution, suitable for printing specific sections or the entire manual
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
2.0L Inline-4 DOHC 16-valve Turbocharged
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Valvetrain:
DOHC, 16 valves, timing belt
Performance
Horsepower:
241 hp @ 6000 rpm (JDM Spec)
Torque:
242 lb-ft @ 3000 rpm (JDM Spec)
Fuel System
Fuel Type:
Unleaded Gasoline (Premium Recommended)
Fuel Injection:
Electronic Fuel Injection (EFI)
Turbocharger:
Mitsubishi TD05-14B or TD05HR-15G (depending on market/spec)
Intercooler:
Air-to-air front-mounted intercooler
🔧 Transmission
Standard
Type:
5-speed Manual
Model Code:
W5M33-2-J1
Features
Drivetrain:
All-Wheel Drive (AWD) with mechanical front differential, viscous center coupling, and mechanical rear differential
Ayc:
Active Yaw Control (AYC) system for torque vectoring to rear wheels
📐 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)
Front Track:
1,495 mm (58.9 in)
Rear Track:
1,490 mm (58.7 in)
Weights
Curb Weight:
Approx. 1,200 kg (2,646 lbs)
Gross Weight:
Approx. 1,475 kg (3,252 lbs)
🛡️ Safety Features
Ratings
Keselamatan Rating:
Specific official crash test ratings may vary by region and year; generally considered robust for its era.
Active Features
ABS:
Anti-lock Braking System (ABS) standard
Ayc:
Active Yaw Control (AYC) for enhanced stability and cornering
Passive Features
Airbags:
Driver's airbag standard, passenger airbag optional on some models
Seatbelts:
Three-point inertia reel seatbelts
Chassis:
Reinforced chassis and safety cell design
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player with basic speaker configuration
Gauges:
Comprehensive instrument cluster including boost gauge, oil pressure, and oil temperature
Driver Assistance
ABS:
Standard Anti-lock Braking System
Ayc:
Active Yaw Control system, a pioneering torque-vectoring technology for its era
Connectivity
Connectivity Features:
No advanced connectivity features (Bluetooth, USB) as standard due to the era of production.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first (especially under spirited driving)
Air Filter:
Inspect every 10,000 km (6,000 miles), replace as needed or at 20,000 km (12,000 miles)
Spark Plugs:
Replace every 40,000 km (25,000 miles)
Timing Belt:
Replace every 90,000 km (56,000 miles) or 5 years
Coolant:
Flush and replace every 40,000 km (25,000 miles) or 2 years
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-30 or 10W-40 (for turbo engines, higher viscosity may be preferred)
Transmission Fluid:
Mitsubishi DiaQueen Super Multi Gear Oil (GL-5 75W-85W)
Transfer Case Fluid:
Mitsubishi DiaQueen Super Multi Gear Oil (GL-5 75W-85W)
Rear Differential Fluid:
Mitsubishi DiaQueen Super Multi Gear Oil (GL-5 75W-85W)
Coolant:
Ethylene Glycol-based antifreeze, 50/50 mix with distilled water
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Reliability:
Generally robust, but prone to head gasket failure if overheated or poorly maintained. Turbocharger lifespan can be reduced by aggressive driving and improper warm-up/cool-down procedures.
Ayc Pump:
AYC hydraulic pump can fail over time, leading to loss of AYC function.
Rust:
Common for rust to form on wheel arches, sills, and underbody, especially in humid or winter climates.
Clutch:
Clutch wear can be accelerated by spirited driving and repeated hard launches.
Suspension Bushings:
Wear in suspension bushings can lead to play and reduced handling precision.
📚 Vehicle History
Brand Heritage
Rally Roots:
Developed as a homologation special for Group A rallying, based on the Lancer sedan
Model Evolution
Introduction:
First generation of the Lancer Evolution series, launched in 1992
Key Changes Vs Lancer:
Significantly revised chassis, stronger 4G63T engine, AWD system, and performance-oriented suspension and brakes
Production
Manufacture Location:
Japan
Production Volume:
Limited production numbers, highly sought after
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution platform achieved legendary status in WRC, with the Evo I laying the groundwork for future victories.
Magazine Reviews:
Consistently praised by automotive journalists for its exceptional performance, handling, and rally-bred capabilities.
Certifications
Homologation:
Built to homologate the Lancer for Group A rally regulations.