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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:...
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2004 Mitsubishi Lancer/Lancer Sportback/Lancer Evolution Workshop Service Repair Manual
🏷️ 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:
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.
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