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2004 Mitsubishi Lancer/Lancer Sportback/Lancer Evolution Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Variant: Lancer Sportback, Lancer Evolution Model Year: 2004 Codes Chassis Codes: CS/CT (Lancer), CT9A (Lancer Evolution VIII) Engine Codes: 4G63 (Evolution), 4G93, 4G94 (Standard Lancer) 👋 Introduction Market Position Market Segment: Compact to compact performance sedan/hatchback. The Lancer offered a range from economical transportation to a high-performance rally homologation special (Evolution). Competitive Analysis Competitors: Standard Lancer: Honda Civic, Toyota Corolla, Mazda3. Lancer Evolution: Subaru Impreza WRX/STI, Ford Focus RS, Volkswagen Golf R. Key Features Performance Variant: The Lancer Evolution VIII is renowned for its rally-bred technology, including advanced all-wheel-drive (AWD) systems, turbocharged engines, and performance-tuned suspensions, offering exceptional handling and acceleration. Versatility: The availability of the Sportback variant offered a more practical, hatchback body style, broadening the Lancer's appeal beyond traditional sedans. 📋 Manual Details Coverage Areas Coverage Scope: All model and all engine types for the 2004 model year. Page Count Estimated Pages: Extensive; likely over 1500 pages based on typical factory service manuals for this era and scope. Manual Type Manual Type: Original Factory Service Repair Manual Language Language: English Format Format: Likely a digital format (PDF) or a multi-volume printed set. 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (4G63, 4G93, 4G94), engine management, fuel system, cooling system, lubrication system, exhaust system, transmission (manual and automatic), drivetrain components (differentials, driveshafts, axles). Chassis: Suspension (front and rear), steering system, braking system (including ABS for applicable models), wheels and tires, body structure. Electrical: Wiring diagrams, lighting, ignition system, starting system, charging system, instrument panel, power accessories, HVAC controls, audio system, body control module (BCM). Body & Trim: Exterior body panels, interior trim, doors, windows, glass, locks, security system, bumpers. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement. Repair Procedures: Detailed step-by-step instructions for component removal, installation, overhaul, and replacement for all major systems. Troubleshooting: Diagnostic charts, symptom-to-cause analysis, fault code interpretation (OBD-II), and diagnostic procedures for electrical and mechanical issues. Specifications: Torque specifications, clearances, fluid capacities, electrical specifications, and diagnostic data. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Designed for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: Likely searchable PDF, allowing for quick information retrieval. Print Quality Print Quality: Original factory quality, typically high-resolution with clear diagrams and schematics. Binding Type Binding: If printed, likely a durable, multi-volume comb or spiral binding for ease of use in a workshop environment. Paper Type Paper Quality: If printed, on sturdy, perhaps coated paper to withstand workshop use. ⚙️ Engine Specifications Primary Engine Lancer Engine 1: 2.0L 4G63 SOHC MPI Inline-4 (Standard Lancer, e.g., ES, OZ Rally) Lancer Engine 2: 2.4L 4G94 DOHC MPI Inline-4 (Standard Lancer, e.g., LS, GTS) Lancer Evolution Engine: 2.0L 4G63 DOHC MIVEC Turbocharged Inline-4 (Lancer Evolution VIII) Performance Lancer Horsepower 4G94: Approximately 160 hp @ 5500 rpm Torque 4G94: Approximately 150 lb-ft @ 3500 rpm Performance Evolution Horsepower 4G63 Evoviii: Approximately 271 hp @ 6500 rpm (US Spec) Torque 4G63 Evoviii: Approximately 273 lb-ft @ 3500 rpm (US Spec) Fuel System Fuel Delivery Standard: Multi-Point Fuel Injection (MPI) Fuel Delivery Evolution: Sequential Electronic Fuel Injection (SEFI) with a high-flow fuel pump and intercooler. Engine Features Evoviii Technology: MIVEC (Mitsubishi Innovative Valve timing Electronic Control), twin-scroll turbocharger, intercooler, cast-iron engine block, forged crankshaft and connecting rods. 🔧 Transmission Standard Lancer Transmission Type Lancer: 5-speed manual transmission. Optional 4-speed automatic transmission on some trims. Standard Evolution Transmission Type Evolution: 6-speed manual transmission (Getrag G5M-SS5-2). Features Evolution AWD System: Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) system for advanced torque vectoring and handling. Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL-4 or GL-5 gear oil specifications based on transmission type. Typically SAE 75W-90. Automatic Transmission Fluid: Mitsubishi DiaQueen ATF-SP III or equivalent. 📐 Dimensions Exterior Lancer Sedan Length: Approx. 176.4 inches Width: Approx. 67.5 inches Height: Approx. 56.7 inches Exterior Lancer Evolutionviii Length: Approx. 170.9 inches Width: Approx. 70.1 inches Height: Approx. 56.1 inches Wheelbase Wheelbase Lancer: Approx. 103.0 inches Wheelbase Evolutionviii: Approx. 104.3 inches Weights Curb Weight Lancer: Approx. 2800-3000 lbs depending on trim and equipment. Curb Weight Evolutionviii: Approx. 3300-3400 lbs. Cargo Trunk Capacity Sedan: Approx. 13.6 cu ft. Cargo Capacity Sportback: Significantly more than sedan due to hatchback design; specific figure varies. 🛡️ Safety Features Ratings Nhtsa Frontal Crash Rating 2004 Lancer: Good (for Lancer sedan models). Not rated for Evolution. Ratings Iihs Frontal Offset Rating 2004 Lancer: Acceptable (for Lancer sedan models). Not rated for Evolution. Active Features ABS: Standard on Evolution VIII, optional or standard on higher trims of Lancer. Traction Control: Standard on Evolution VIII (integrated with AWD system). Optional on some Lancer models. Passive Features Airbags: Driver...
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2004 Mitsubishi Lancer/Lancer Sportback/Lancer Evolution Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Model Variant:
Lancer Sportback, Lancer Evolution
Model Year:
2004
Codes
Chassis Codes:
CS/CT (Lancer), CT9A (Lancer Evolution VIII)
Engine Codes:
4G63 (Evolution), 4G93, 4G94 (Standard Lancer)
👋 Introduction
Market Position
Market Segment:
Compact to compact performance sedan/hatchback. The Lancer offered a range from economical transportation to a high-performance rally homologation special (Evolution).
Competitive Analysis
Competitors:
Standard Lancer: Honda Civic, Toyota Corolla, Mazda3. Lancer Evolution: Subaru Impreza WRX/STI, Ford Focus RS, Volkswagen Golf R.
Key Features
Performance Variant:
The Lancer Evolution VIII is renowned for its rally-bred technology, including advanced all-wheel-drive (AWD) systems, turbocharged engines, and performance-tuned suspensions, offering exceptional handling and acceleration.
Versatility:
The availability of the Sportback variant offered a more practical, hatchback body style, broadening the Lancer's appeal beyond traditional sedans.
📋 Manual Details
Coverage Areas
Coverage Scope:
All model and all engine types for the 2004 model year.
Page Count
Estimated Pages:
Extensive; likely over 1500 pages based on typical factory service manuals for this era and scope.
Manual Type
Manual Type:
Original Factory Service Repair Manual
Language
Language:
English
Format
Format:
Likely a digital format (PDF) or a multi-volume printed set.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (4G63, 4G93, 4G94), engine management, fuel system, cooling system, lubrication system, exhaust system, transmission (manual and automatic), drivetrain components (differentials, driveshafts, axles).
Chassis:
Suspension (front and rear), steering system, braking system (including ABS for applicable models), wheels and tires, body structure.
Electrical:
Wiring diagrams, lighting, ignition system, starting system, charging system, instrument panel, power accessories, HVAC controls, audio system, body control module (BCM).
Body & Trim:
Exterior body panels, interior trim, doors, windows, glass, locks, security system, bumpers.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement.
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, overhaul, and replacement for all major systems.
Troubleshooting:
Diagnostic charts, symptom-to-cause analysis, fault code interpretation (OBD-II), and diagnostic procedures for electrical and mechanical issues.
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, and diagnostic data.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Designed for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
Likely searchable PDF, allowing for quick information retrieval.
Print Quality
Print Quality:
Original factory quality, typically high-resolution with clear diagrams and schematics.
Binding Type
Binding:
If printed, likely a durable, multi-volume comb or spiral binding for ease of use in a workshop environment.
Paper Type
Paper Quality:
If printed, on sturdy, perhaps coated paper to withstand workshop use.
⚙️ Engine Specifications
Primary Engine
Lancer Engine 1:
2.0L 4G63 SOHC MPI Inline-4 (Standard Lancer, e.g., ES, OZ Rally)
Lancer Engine 2:
2.4L 4G94 DOHC MPI Inline-4 (Standard Lancer, e.g., LS, GTS)
Lancer Evolution Engine:
2.0L 4G63 DOHC MIVEC Turbocharged Inline-4 (Lancer Evolution VIII)
Performance Lancer
Horsepower 4G94:
Approximately 160 hp @ 5500 rpm
Torque 4G94:
Approximately 150 lb-ft @ 3500 rpm
Performance Evolution
Horsepower 4G63 Evoviii:
Approximately 271 hp @ 6500 rpm (US Spec)
Torque 4G63 Evoviii:
Approximately 273 lb-ft @ 3500 rpm (US Spec)
Fuel System
Fuel Delivery Standard:
Multi-Point Fuel Injection (MPI)
Fuel Delivery Evolution:
Sequential Electronic Fuel Injection (SEFI) with a high-flow fuel pump and intercooler.
Engine Features
Evoviii Technology:
MIVEC (Mitsubishi Innovative Valve timing Electronic Control), twin-scroll turbocharger, intercooler, cast-iron engine block, forged crankshaft and connecting rods.
🔧 Transmission
Standard Lancer
Transmission Type Lancer:
5-speed manual transmission. Optional 4-speed automatic transmission on some trims.
Standard Evolution
Transmission Type Evolution:
6-speed manual transmission (Getrag G5M-SS5-2).
Features Evolution
AWD System:
Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) system for advanced torque vectoring and handling.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 gear oil specifications based on transmission type. Typically SAE 75W-90.
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF-SP III or equivalent.
📐 Dimensions
Exterior Lancer Sedan
Length:
Approx. 176.4 inches
Width:
Approx. 67.5 inches
Height:
Approx. 56.7 inches
Exterior Lancer Evolutionviii
Length:
Approx. 170.9 inches
Width:
Approx. 70.1 inches
Height:
Approx. 56.1 inches
Wheelbase
Wheelbase Lancer:
Approx. 103.0 inches
Wheelbase Evolutionviii:
Approx. 104.3 inches
Weights
Curb Weight Lancer:
Approx. 2800-3000 lbs depending on trim and equipment.
Curb Weight Evolutionviii:
Approx. 3300-3400 lbs.
Cargo
Trunk Capacity Sedan:
Approx. 13.6 cu ft.
Cargo Capacity Sportback:
Significantly more than sedan due to hatchback design; specific figure varies.
🛡️ Safety Features
Ratings Nhtsa
Frontal Crash Rating 2004 Lancer:
Good (for Lancer sedan models). Not rated for Evolution.
Ratings Iihs
Frontal Offset Rating 2004 Lancer:
Acceptable (for Lancer sedan models). Not rated for Evolution.
Active Features
ABS:
Standard on Evolution VIII, optional or standard on higher trims of Lancer.
Traction Control:
Standard on Evolution VIII (integrated with AWD system). Optional on some Lancer models.
Passive Features
Airbags:
Driver and front passenger airbags. Side airbags were optional on some Lancer models and standard on Evolution.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Factory standard CD player with AM/FM radio. Higher trims may feature upgraded speaker systems or an optional Rockford Fosgate system. Aux input or USB was uncommon for this model year.
Driver Assistance
Cruise Control:
Available on most Lancer and Evolution models.
Connectivity
Keyless Entry:
Available on most Lancer and Evolution models.
Climate Control
HVAC System:
Manual or automatic climate control depending on trim level. The manual covers operation and basic service.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval Gasoline:
Every 3,750 to 7,500 miles or 6-12 months, depending on driving conditions and oil type used (refer to manual for exact recommendation).
Service Intervals Filters
Engine Oil Filter Part Number Example:
MD095938 (or equivalent aftermarket).
Air Filter Part Number Example:
MR235721 (or equivalent aftermarket).
Cabin Air Filter Part Number Example:
MR500650 (or equivalent aftermarket).
Service Intervals Fluids
Coolant Capacity Lancer 2.4L:
Approx. 6.4 quarts (6.1 L).
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent HOAT coolant.
Brake Fluid Spec:
DOT 3 or DOT 4.
Known Issues
Common Issue Lancer Sludge:
Early 4G6x engines (though less common on later models like the 2004) could be prone to oil sludge if maintenance is neglected. Regular oil changes are crucial.
Common Issue Evolution Clutch:
The Evolution's high-performance clutch can wear faster under aggressive driving conditions.
Common Issue Evolution Ayc Pump:
The AYC pump can occasionally fail, leading to error lights and loss of the AYC system functionality.
Common Issue General Electrical:
Minor electrical gremlins can occur with age, particularly with window regulators and power locks.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Mitsubishi Motors has a long history in automotive manufacturing, with roots dating back to 1917. Known for robust engineering and innovative technologies, particularly in AWD systems and performance vehicles.
Model Evolution
Lancer Generation:
The 2004 model year falls within the 8th generation of the Mitsubishi Lancer (CY/CZ chassis, 2000-2007). The Lancer Evolution VIII (CT9A chassis) is a distinct performance variant based on this generation.
Lancer Evolution Development:
The Lancer Evolution was developed to homologate the Lancer for Group A racing in the World Rally Championship (WRC). It quickly gained a reputation for its exceptional performance and technological advancements.
Production
Production Location:
Japan.
🏆 Awards & Recognition
Recognitions
Lancer Evolution Reputation:
Consistently praised by automotive journalists for its exceptional handling, acceleration, and performance-to-price ratio. Often cited as a benchmark in the affordable performance car segment.
Lancer General Reputation:
The standard Lancer was generally regarded as a reliable and practical compact car with a sporty option in the Evolution variant.
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