2004 Mitsubishi Lancer/Lancer Sportback/Lancer Evolution Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Variants: Lancer, Lancer Sportback, Lancer Evolution Year: 2004 Codes Chassis Code General: CS (for non-Evolution variants), CT9A (for Lancer Evolution VIII) 👋 Introduction Market Position Vehicle Segment: Compact car (sedan and hatchback), with a high-performance variant (Evolution). Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Mazda3, Subaru Impreza (WRX for Evolution variant). Key Features Lancer Features: Reliability, affordability, practical for everyday use, available in sedan and sporty hatchback (Sportback) body styles. Evolution Features: All-wheel drive (AWD) with Active Yaw Control (AYC), turbocharged engine, high performance, rally-inspired engineering, Recaro seats, Brembo brakes (on some models). 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (likely PDF) Page Count Estimated Page Count: Extensive (typically over 1500-2000 pages for comprehensive factory manuals) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, emission control, engine control system (ECU), manual transmission, automatic transmission, transfer case (AWD models), drive shafts, differentials. Chassis: Suspension (front and rear), steering system, braking system (including ABS), wheels and tires, chassis electrical. Body And Electrical: Body and frame, exterior trim, interior trim, heating, ventilation, and air conditioning (HVAC), electrical systems (lighting, power windows, door locks, mirrors, instrumentation), infotainment, security system, airbags. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement. Diagnostics And Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, mechanical component diagnosis. Repair And Overhaul: Engine disassembly and assembly, transmission overhaul, brake component replacement, suspension component replacement, body panel repair, electrical component repair. Special Procedures: Wheel alignment specifications, torque specifications for all fasteners, diagnostic tool usage, emissions testing procedures. Technical Depth Depth Level: Comprehensive factory-level detail, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Digital Format Type: PDF (Portable Document Format) Searchability: Likely fully searchable text for quick access to information. Print Quality Illustration Detail: High-quality, detailed illustrations, diagrams, and schematics. Binding Type Binding Type Physical: N/A (Digital Format) Paper Type Paper Type Physical: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Lancer Engine Options: 2.0L 4G63 SOHC/DOHC (non-turbo), 2.4L 4G69 SOHC (North American market). Evolution Engine: 2.0L 4G63T DOHC Turbocharged Inline-4 (MIVEC) Performance Lancer Horsepower Range: Approximately 120-160 hp, depending on engine variant. Evolution Horsepower: Approximately 265-280 hp (varies by market and specific Evolution VIII model, e.g., VIII MR). Evolution Torque: Approximately 257-273 lb-ft (varies by market and specific Evolution VIII model). Fuel System Fuel Delivery: Multi-point fuel injection (MPI). Fuel Type: Unleaded gasoline (Premium unleaded recommended/required for Evolution). 🔧 Transmission Standard Lancer Transmission Standard: 5-speed manual transmission. Optional Lancer Transmission Optional: 4-speed automatic transmission. Features Evolution Transmission: 6-speed manual transmission (Getrag). Evolution Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Active Center Differential (ACD). 📐 Dimensions Exterior Lancer Sedan Length: Approx. 177.4 inches (4506 mm) Lancer Sportback Length: Approx. 170.7 inches (4336 mm) Evolution Viii Length: Approx. 170.9 inches (4340 mm) Wheelbase: Approx. 103.3 inches (2624 mm) for sedan, approx. 102.4 inches (2600 mm) for Sportback/Evolution. Weights Lancer Curb Weight: Approx. 2800-3000 lbs (1270-1360 kg) Evolution Viii Curb Weight: Approx. 3285-3384 lbs (1490-1535 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Likely 4 or 5 stars (for Lancer standard models, based on era). NHTSA Front Impact Passenger: Likely 4 or 5 stars (for Lancer standard models, based on era). IIHS Side Impact: Varies, often 'Good' or 'Acceptable' for Lancer models. Active Features Braking System: Standard front disc, rear drum/disc. ABS optional/standard depending on trim. Evolution models feature Brembo brakes. Traction Control: Available on some Lancer models. Standard on Evolution (via AYC/ACD). Passive Features Airbags: Driver and front passenger airbags. Side airbags optional/standard depending on trim and model year. Seatbelts: Front pretensioners and load limiters, 3-point rear seatbelts. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio systems (e.g., Rockford Fosgate on some models). Navigation: Rarely offered on base Lancer models, potentially available on higher trims or as an aftermarket option. Driver Assistance Cruise Control: Available on most Lancer trims and Evolution. Stability Control: Not commonly available on standard Lancer models of this era. Evolution models have advanced drivetrain management for stability. Connectivity Power Accessories: Power windows, power door locks, power mirrors. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions. Major Service Interval: Timing belt (if applicable to specific engine), spark plugs, coolant, etc., typically around 60,000-100,000 miles (96,000-160,000 km). Fluid Specifications Engine Oil Spec: API SJ or SL, ILSAC GF-3. Viscosity typically 5W-30 or 10W-30 (check manual for specific engine). Coolant Spec: Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with deionized water. Transmission Fluid Manual:...
Compact car (sedan and hatchback), with a high-performance variant (Evolution).
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Mazda3, Subaru Impreza (WRX for Evolution variant).
Key Features
Lancer Features:
Reliability, affordability, practical for everyday use, available in sedan and sporty hatchback (Sportback) body styles.
Evolution Features:
All-wheel drive (AWD) with Active Yaw Control (AYC), turbocharged engine, high performance, rally-inspired engineering, Recaro seats, Brembo brakes (on some models).
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count
Estimated Page Count:
Extensive (typically over 1500-2000 pages for comprehensive factory manuals)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, emission control, engine control system (ECU), manual transmission, automatic transmission, transfer case (AWD models), drive shafts, differentials.
Chassis:
Suspension (front and rear), steering system, braking system (including ABS), wheels and tires, chassis electrical.
Body And Electrical:
Body and frame, exterior trim, interior trim, heating, ventilation, and air conditioning (HVAC), electrical systems (lighting, power windows, door locks, mirrors, instrumentation), infotainment, security system, airbags.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Engine disassembly and assembly, transmission overhaul, brake component replacement, suspension component replacement, body panel repair, electrical component repair.
Special Procedures:
Wheel alignment specifications, torque specifications for all fasteners, diagnostic tool usage, emissions testing procedures.
Technical Depth
Depth Level:
Comprehensive factory-level detail, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format Type:
PDF (Portable Document Format)
Searchability:
Likely fully searchable text for quick access to information.
Print Quality
Illustration Detail:
High-quality, detailed illustrations, diagrams, and schematics.
Binding Type
Binding Type Physical:
N/A (Digital Format)
Paper Type
Paper Type Physical:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Lancer Engine Options:
2.0L 4G63 SOHC/DOHC (non-turbo), 2.4L 4G69 SOHC (North American market).
Evolution Engine:
2.0L 4G63T DOHC Turbocharged Inline-4 (MIVEC)
Performance
Lancer Horsepower Range:
Approximately 120-160 hp, depending on engine variant.
Evolution Horsepower:
Approximately 265-280 hp (varies by market and specific Evolution VIII model, e.g., VIII MR).
Evolution Torque:
Approximately 257-273 lb-ft (varies by market and specific Evolution VIII model).
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI).
Fuel Type:
Unleaded gasoline (Premium unleaded recommended/required for Evolution).
🔧 Transmission
Standard
Lancer Transmission Standard:
5-speed manual transmission.
Optional
Lancer Transmission Optional:
4-speed automatic transmission.
Features
Evolution Transmission:
6-speed manual transmission (Getrag).
Evolution Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Active Center Differential (ACD).
📐 Dimensions
Exterior
Lancer Sedan Length:
Approx. 177.4 inches (4506 mm)
Lancer Sportback Length:
Approx. 170.7 inches (4336 mm)
Evolution Viii Length:
Approx. 170.9 inches (4340 mm)
Wheelbase:
Approx. 103.3 inches (2624 mm) for sedan, approx. 102.4 inches (2600 mm) for Sportback/Evolution.
Weights
Lancer Curb Weight:
Approx. 2800-3000 lbs (1270-1360 kg)
Evolution Viii Curb Weight:
Approx. 3285-3384 lbs (1490-1535 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Likely 4 or 5 stars (for Lancer standard models, based on era).
NHTSA Front Impact Passenger:
Likely 4 or 5 stars (for Lancer standard models, based on era).
IIHS Side Impact:
Varies, often 'Good' or 'Acceptable' for Lancer models.
Active Features
Braking System:
Standard front disc, rear drum/disc. ABS optional/standard depending on trim. Evolution models feature Brembo brakes.
Traction Control:
Available on some Lancer models. Standard on Evolution (via AYC/ACD).
Passive Features
Airbags:
Driver and front passenger airbags. Side airbags optional/standard depending on trim and model year.
Seatbelts:
Front pretensioners and load limiters, 3-point rear seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems (e.g., Rockford Fosgate on some models).
Navigation:
Rarely offered on base Lancer models, potentially available on higher trims or as an aftermarket option.
Driver Assistance
Cruise Control:
Available on most Lancer trims and Evolution.
Stability Control:
Not commonly available on standard Lancer models of this era. Evolution models have advanced drivetrain management for stability.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions.
Major Service Interval:
Timing belt (if applicable to specific engine), spark plugs, coolant, etc., typically around 60,000-100,000 miles (96,000-160,000 km).
Fluid Specifications
Engine Oil Spec:
API SJ or SL, ILSAC GF-3. Viscosity typically 5W-30 or 10W-30 (check manual for specific engine).
Coolant Spec:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with deionized water.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil (specific viscosity recommended, e.g., 75W-90).
Transmission Fluid Automatic:
Mitsubishi DIA QUEEN ATF-II or equivalent ATF fluid.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Lancer Issues:
Catalytic converter failure, rust on wheel arches and underbody, minor oil leaks, potential transmission issues on high-mileage automatics.
Common Evolution Issues:
Clutch wear (especially if driven hard), turbocharger issues (if maintenance neglected), differential issues (AYC/ACD), timing belt failure (if not replaced on schedule), rod knock (in extreme cases of abuse/neglect).
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Long history in automotive manufacturing, known for durability and engineering, particularly in rally sports with the Lancer Evolution.
Model Evolution
Lancer Generations:
The 2004 model year falls within the 8th generation (CY/CZ chassis, 2000-2007) of the Mitsubishi Lancer. The Lancer Evolution VIII (CT9A) is a specific high-performance variant of this generation.
Production
Global Production:
Produced globally, with major assembly plants in Japan.
Evolution Rally Heritage:
The Lancer Evolution's lineage is directly tied to Mitsubishi's success in the World Rally Championship (WRC), earning numerous manufacturer and driver titles.
🏆 Awards & Recognition
Recognitions
Evolution Performance Accolades:
Consistently praised by automotive media for its performance, handling, and rally-bred capabilities, often considered a benchmark in its class.
Ratings
Vehicle Reliability:
Generally considered reliable, though specific components like the catalytic converter and clutch on high-performance variants require diligent maintenance.