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Mitsubishi Lancer Evolution 3 1995-1996 Full Service Repair Manual

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The Mitsubishi Lancer Evolution III, produced from 1995 to 1996, stands as a celebrated performance sedan and rally homologation special. Available in GSR and RS variants, this CE9A chassis code vehicle is powered by the legendary 4G63T 2.0L DOHC turbocharged inline-4 engine, renowned for its robust engineering and tuning potential. Its design emphasizes high performance and rally-inspired driving dynamics, featuring advanced All-Wheel Drive systems and aerodynamic enhancements. The Evolution III's strong motorsport legacy, particularly its foundation in World Rally Championship (WRC) homologation, has cemented its status among enthusiasts seeking exceptional driving capabilities and a direct connection to rally racing heritage. This comprehensive manual serves as an indispensable guide for the Mitsubishi Lancer Evolution III (CE9A) covering model years 1995-1996. It provides full service repair information, including routine maintenance, detailed troubleshooting, diagnostics, and overhaul procedures for all major vehicle systems. Key areas covered encompass the engine mechanicals, lubrication, cooling, fuel, ignition, emissions, turbocharger, and engine management systems, as well as the 5-speed manual transmission, transfer case, and AWD components. Furthermore, it details suspension, steering, brakes, electrical systems, bodywork, and interior. This resource is meticulously crafted to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing their Lancer Evolution III, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution III Model Variant: GSR, RS Years Covered: 1995-1996 Codes Chassis Code: CE9A Engine Code: 4G63T (2.0L DOHC Turbocharged Inline-4) 👋 Introduction Market Position Segment: Performance Sedan, Rally Homologation Special Target Audience: Enthusiasts, tuners, owners seeking in-depth repair and maintenance knowledge Competitive Analysis Key Rivals: Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth, Lancia Delta Integrale Key Features Performance Focus: Engineered for high performance and rally-inspired driving dynamics AWD System: Advanced Active All-Wheel Drive system with adjustable center differential (ACD) on some models/regions Turbocharged Engine: Renowned 4G63T engine, a legend in the tuning community 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Page Count: Approximately 1000+ Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control, turbocharger system, engine management (ECU/ECM) Transmission: 5-speed manual transmission (F5M33), transfer case, viscous coupling unit (VCU), rear differential Drivetrain: All-Wheel Drive (AWD) system, driveshafts, CV joints, wheel hubs Suspension: Front struts, rear shock absorbers, control arms, anti-roll bars, coil springs, bushings Steering: Power steering system, steering rack, tie rods, steering column Brakes: Front and rear disc brakes, ABS system (if equipped), brake lines, master cylinder, calipers, pads, rotors Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams Body Exterior: Body panels, doors, hood, trunk, bumpers, aerodynamics (spoiler, splitter), glass, mirrors Body Interior: Seats, dashboard, interior trim, carpets, HVAC system, airbags (if equipped), seat belts Wheels Tires: Wheel specifications, tire sizes, rotation, balancing Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections Engine Repair: Engine removal and installation, cylinder head disassembly and reassembly, piston and connecting rod installation, crankshaft bearing service, timing belt replacement Transmission Repair: Transmission disassembly and reassembly, clutch replacement, gearset service, differential overhaul Brake System Service: Brake pad and rotor replacement, caliper overhaul, brake bleeding, ABS component diagnosis and replacement Suspension And Steering Repair: Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, power steering pump and rack service Electrical Diagnostics: Troubleshooting wiring issues, component testing, using diagnostic tools, wiring diagram interpretation Troubleshooting Guides: Diagnostic flowcharts for common problems, symptom-based troubleshooting Body Repair: Panel alignment, rust repair, glass replacement, bumper repair and replacement Technical Depth Depth Level: Comprehensive (from basic maintenance to full engine and transmission rebuilds) Diagnostic Capability: Advanced diagnostics, including ECU/ECM codes and interpretation Special Tools: Identification of required special tools for specific procedures 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Image Resolution: High-resolution for clear diagrams and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: 2.0L DOHC 16-valve Turbocharged Inline-4 Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Performance Horsepower Gsr: 270 PS (approx. 266 hp) at 6,500 rpm Torque Gsr: 30.7 kg⋅m (approx. 222 lb-ft) at 5,000 rpm Horsepower Rs: 250 PS (approx. 247 hp) at 6,000 rpm (often slightly detuned for rally regulations) Torque Rs: 29.4 kg⋅m (approx. 213 lb-ft) at 5,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch fuel injectors Turbocharger: Mitsubishi TD05H-16G turbocharger Intercooler: Air-to-air front-mounted intercooler (FMIC) Fluid Specs Engine Oil Capacity: 4.5 Liters (4.7 US Quarts) with filter Recommended Oil Viscosity: 10W-30 or 10W-40 (API SG or...
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Mitsubishi Lancer Evolution 3 1995-1996 Full Service Repair ManualMitsubishi Lancer Evolution 3 1995-1996 Full Service Repair ManualMitsubishi Lancer Evolution 3 1995-1996 Full Service Repair ManualMitsubishi Lancer Evolution 3 1995-1996 Full Service Repair Manual
The Mitsubishi Lancer Evolution III, produced from 1995 to 1996, stands as a celebrated performance sedan and rally homologation special. Available in GSR and RS variants, this CE9A chassis code vehicle is powered by the legendary 4G63T 2.0L DOHC turbocharged inline-4 engine, renowned for its robust engineering and tuning potential. Its design emphasizes high performance and rally-inspired driving dynamics, featuring advanced All-Wheel Drive systems and aerodynamic enhancements. The Evolution III's strong motorsport legacy, particularly its foundation in World Rally Championship (WRC) homologation, has cemented its status among enthusiasts seeking exceptional driving capabilities and a direct connection to rally racing heritage. This comprehensive manual serves as an indispensable guide for the Mitsubishi Lancer Evolution III (CE9A) covering model years 1995-1996. It provides full service repair information, including routine maintenance, detailed troubleshooting, diagnostics, and overhaul procedures for all major vehicle systems. Key areas covered encompass the engine mechanicals, lubrication, cooling, fuel, ignition, emissions, turbocharger, and engine management systems, as well as the 5-speed manual transmission, transfer case, and AWD components. Furthermore, it details suspension, steering, brakes, electrical systems, bodywork, and interior. This resource is meticulously crafted to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing their Lancer Evolution III, ensuring optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution III
Model Variant:
GSR, RS
Years Covered:
1995-1996
Codes
Chassis Code:
CE9A
Engine Code:
4G63T (2.0L DOHC Turbocharged Inline-4)
👋 Introduction
Market Position
Segment:
Performance Sedan, Rally Homologation Special
Target Audience:
Enthusiasts, tuners, owners seeking in-depth repair and maintenance knowledge
Competitive Analysis
Key Rivals:
Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Performance Focus:
Engineered for high performance and rally-inspired driving dynamics
AWD System:
Advanced Active All-Wheel Drive system with adjustable center differential (ACD) on some models/regions
Turbocharged Engine:
Renowned 4G63T engine, a legend in the tuning community
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Page Count
Estimated Page Count:
Approximately 1000+
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control, turbocharger system, engine management (ECU/ECM)
Transmission:
5-speed manual transmission (F5M33), transfer case, viscous coupling unit (VCU), rear differential
Drivetrain:
All-Wheel Drive (AWD) system, driveshafts, CV joints, wheel hubs
Suspension:
Front struts, rear shock absorbers, control arms, anti-roll bars, coil springs, bushings
Steering:
Power steering system, steering rack, tie rods, steering column
Brakes:
Front and rear disc brakes, ABS system (if equipped), brake lines, master cylinder, calipers, pads, rotors
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams
Body Exterior:
Body panels, doors, hood, trunk, bumpers, aerodynamics (spoiler, splitter), glass, mirrors
Body Interior:
Seats, dashboard, interior trim, carpets, HVAC system, airbags (if equipped), seat belts
Wheels Tires:
Wheel specifications, tire sizes, rotation, balancing
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections
Engine Repair:
Engine removal and installation, cylinder head disassembly and reassembly, piston and connecting rod installation, crankshaft bearing service, timing belt replacement
Transmission Repair:
Transmission disassembly and reassembly, clutch replacement, gearset service, differential overhaul
Brake System Service:
Brake pad and rotor replacement, caliper overhaul, brake bleeding, ABS component diagnosis and replacement
Suspension And Steering Repair:
Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, power steering pump and rack service
Electrical Diagnostics:
Troubleshooting wiring issues, component testing, using diagnostic tools, wiring diagram interpretation
Troubleshooting Guides:
Diagnostic flowcharts for common problems, symptom-based troubleshooting
Body Repair:
Panel alignment, rust repair, glass replacement, bumper repair and replacement
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to full engine and transmission rebuilds)
Diagnostic Capability:
Advanced diagnostics, including ECU/ECM codes and interpretation
Special Tools:
Identification of required special tools for specific procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High-resolution for clear diagrams and illustrations
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L DOHC 16-valve Turbocharged Inline-4
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Performance
Horsepower Gsr:
270 PS (approx. 266 hp) at 6,500 rpm
Torque Gsr:
30.7 kg⋅m (approx. 222 lb-ft) at 5,000 rpm
Horsepower Rs:
250 PS (approx. 247 hp) at 6,000 rpm (often slightly detuned for rally regulations)
Torque Rs:
29.4 kg⋅m (approx. 213 lb-ft) at 5,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch fuel injectors
Turbocharger:
Mitsubishi TD05H-16G turbocharger
Intercooler:
Air-to-air front-mounted intercooler (FMIC)
Fluid Specs
Engine Oil Capacity:
4.5 Liters (4.7 US Quarts) with filter
Recommended Oil Viscosity:
10W-30 or 10W-40 (API SG or higher)
Coolant Capacity:
6.0 Liters (6.3 US Quarts)
Recommended Coolant:
Ethylene glycol-based antifreeze (50% solution)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (F5M33)
Optional
Transmission Type:
N/A (Manual transmission only for Evolution models)
Features
Drivetrain Configuration:
Full-time All-Wheel Drive (AWD) with Active Center Differential (ACD) on GSR, Viscous Coupling Unit (VCU) on RS
Rear Differential:
Mechanical Limited Slip Differential (LSD) on GSR, Viscous LSD on RS
Fluid Specs
Transmission Oil Capacity:
2.5 Liters (2.6 US Quarts)
Recommended Transmission Oil:
GL-4 or GL-5 Gear Oil (75W-90 recommended)
Transfer Case Oil Capacity:
0.7 Liters (0.7 US Quarts)
Recommended Transfer Case Oil:
GL-4 or GL-5 Gear Oil (75W-90 recommended)
Rear Differential Oil Capacity:
1.0 Liters (1.0 US Quarts)
Recommended Rear Differential Oil:
GL-5 Gear Oil (80W-90 recommended, Hypoid Gear Oil)
📐 Dimensions
Exterior
Length:
4,330 mm (170.5 in)
Width:
1,770 mm (69.7 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,600 mm (102.4 in)
Front Track:
1,500 mm (59.1 in)
Rear Track:
1,495 mm (58.9 in)
Weights
Curb Weight Gsr:
1,400 kg (3,086 lbs)
Curb Weight Rs:
1,370 kg (3,020 lbs)
Gross Vehicle Weight Rating:
Approx. 1,800 kg (3,968 lbs)
Fuel Tank Capacity:
50 Liters (13.2 US Gallons)
🛡️ Safety Features
Ratings
Crash Test Ratings:
No official NHTSA/Euro NCAP ratings available for this specific model and era.
Active Features
ABS:
Anti-lock Braking System (ABS) available on GSR, optional on RS
AWD:
Advanced All-Wheel Drive system enhances stability and traction
Passive Features
Airbags:
Driver-side airbag standard; passenger airbag optional/unavailable depending on market
Seat Belts:
3-point front seat belts with pre-tensioners, 3-point rear seat belts
Body Structure:
Reinforced chassis with front and rear crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory radio with cassette player and AM/FM tuner, 4-speaker system.
Climate Control:
Manual climate control with A/C
Driver Assistance
Traction Control:
Not typically equipped with electronic traction control beyond the mechanical AWD system.
Connectivity
Connectivity Features:
Basic connectivity, primarily focused on audio playback via cassette.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first (severe use may require more frequent changes)
Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000 - 30,000 km (9,000 - 18,000 miles)
Spark Plug Replacement:
Every 30,000 - 50,000 km (18,000 - 30,000 miles), depending on plug type (e.g., platinum or iridium)
Timing Belt Replacement:
Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5-7 years
Coolant Flush:
Every 2 years or 50,000 km (30,000 miles)
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron II or equivalent
Clutch Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Reliability:
Known for robust 4G63T engine, but requires diligent maintenance. Issues can arise from worn valve stem seals, turbocharger wear, and cracked exhaust manifolds under extreme use.
AWD System Maintenance:
VCU and ACD units require regular fluid changes to maintain performance and prevent premature failure.
Rust:
Common rust points include wheel arches, rocker panels, and subframes, especially in regions with road salt.
Suspension Wear:
Bushings, ball joints, and wheel bearings can wear over time due to the car's aggressive nature.
Cooling System:
Radiator leaks and thermostat issues can occur, especially if maintenance is neglected.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's extensive rally heritage, particularly in the World Rally Championship (WRC)
Model Evolution
Evo Series Origin:
The Lancer Evolution series was developed to homologate vehicles for Group A racing in the WRC.
Evolution Iii Development:
The Evo III was a significant evolution of the Evo II, featuring aerodynamic enhancements and an improved engine output.
Key Iii Upgrades:
Larger front air dam, side skirts, rear spoiler extension, revised engine management, improved turbocharger efficiency, slight power increase.
Production
Production Period:
August 1995 - August 1996
Production Volume:
Approximately 5,000 units produced in total
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Motorsport Success:
While not direct 'awards', the Evo III's platform success in international rallying significantly boosted its reputation and desirability.
Enthusiast Acclaim:
Highly regarded by automotive enthusiasts and tuners for its performance capabilities and rally pedigree.
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