Mitsubishi Lancer Mitsubishi Lancer Sportback Mitsubishi Lancer Evolution Complete Workshop Service Repair Manual 2004

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Sub Model: Lancer Sportback, Lancer Evolution Model Year: 2004 Codes Platform: Mitsubishi GS Platform Chassis Code: CT9A (Evolution VIII), CS(A) (Lancer/Sportback) 👋 Introduction Market Position Positioning: The Mitsubishi Lancer, particularly in its Evolution guise, occupied a significant niche in the performance sedan market, offering accessible rally-bred technology. Competitive Analysis Competitors: Subaru Impreza WRX/STI, Honda Civic Si, Volkswagen GTI, Ford Focus SVT. Key Features Lancer Features: Reliable powertrain, practical interior, aerodynamic Sportback option, sporty styling. Evolution Features: Advanced AWD system (ACD/AYC/DCCD), turbocharged 4G63 engine, Brembo brakes, Bilstein suspension, aggressive aerodynamics. Manual Value Proposition Value: This manual is an indispensable resource for maintaining, diagnosing, and repairing Mitsubishi Lancers, including the highly complex Evolution models, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service and repair for Lancer, Lancer Sportback, and Lancer Evolution models. Specific Models Covered: Mitsubishi Lancer (non-performance variants), Mitsubishi Lancer Sportback (hatchback variant), Mitsubishi Lancer Evolution VIII Page Count Estimated Pages: Likely over 1000 pages (typical for a complete workshop manual). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable (typically PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing components. Engine Management: Fuel injection, ignition system, emission controls, ECU diagnosis and troubleshooting, sensor data. Transmission Manual: Clutch system, gearbox assembly, shift mechanism, gear ratios, servicing. Transmission Automatic: Torque converter, planetary gears, valve body, electronic controls, fluid changes, servicing. Drivetrain: Front-wheel drive, all-wheel drive (AWD) for Evolution, driveshafts, differentials, transfer case (Evolution). Suspension: Front suspension (MacPherson strut), rear suspension (multi-link/independent), shock absorbers, springs, control arms, bushings. Steering: Power steering system (hydraulic), steering rack, tie rods, steering column. Brakes: Front and rear disc brakes, ABS system (including sensors, modulator), brake fluid specifications, bleeding procedures, caliper and rotor replacement. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams. Climate Control: Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, blower motor, HVAC controls. Body And Chassis: Body construction, exterior panels, doors, hood, trunk, interior trim, chassis components, mounting points. Safety Systems: Airbag system, seatbelt pre-tensioners, SRS module diagnosis. Evolution Specific Systems: Active Center Differential (ACD), Super Active Yaw Control (S-AYC), Driver Controlled Center Differential (DCCD) for Evo models. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotations. Troubleshooting: Diagnostic procedures for common issues, fault code interpretation, symptom-based diagnosis. Repair Procedures: Step-by-step instructions for component removal, installation, and repair (e.g., engine rebuild, transmission overhaul, brake caliper replacement). Overhaul Instructions: Detailed guidance for complete disassembly and reassembly of major components like engines and transmissions. Wiring Diagrams: Comprehensive electrical schematics for various systems. Technical Specifications: Torque values, clearances, fluid capacities, pressure specifications, diagnostic parameters. Technical Depth Depth: Full workshop level, suitable for professional technicians and advanced DIY mechanics. Diagnostic Capability: Includes diagnostic procedures, trouble codes (DTCs), and sensor data interpretation. Rebuild Capability: Covers complete engine and transmission rebuilds with detailed component specifications. 📊 Manual Specifications File Format Format: Digital Download (PDF) Print Quality Quality: High-resolution, searchable PDF content with clear diagrams and text. Binding Type Binding: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) Searchability Text Search: Yes, fully text-searchable for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Code Evo: 4G63T (2.0L DOHC MIVEC Turbocharged Inline-4) Engine Code Lancer Sportback: 4G64 (2.4L SOHC Inline-4) or 4G15 (1.5L SOHC Inline-4) - Varies by market and specific trim. Performance Horsepower Evo Viii: Approximately 271 hp @ 6500 rpm (USDM) / 280 PS (JDM). Torque Evo Viii: Approximately 273 lb-ft @ 3500 rpm (USDM) / 37 kgm (JDM). Bore Stroke 4G63T: 85.0 mm x 88.0 mm Compression Ratio 4G63T: 8.8:1 Fuel System Fuel Delivery Evo: Electronic Fuel Injection (EFI), high-flow injectors, higher-pressure fuel pump. Fuel Type Evo: Premium Unleaded Gasoline (91 octane or higher recommended). Fuel Type Lancer Sportback: Regular Unleaded Gasoline (87 octane). 🔧 Transmission Standard Transmission Evo: 6-speed manual transmission (Getrag). Optional Transmission Lancer Sportback: 5-speed manual or 4-speed INVECS-II automatic transmission. Features Clutch Evo: Twin-plate or single-plate heavy-duty clutch assembly. Transfer Case Evo: Center differential with Active Center Differential (ACD) and Driver Controlled Center Differential (DCCD) for manual variants. Fluid Specifications Manual Transmission Fluid Evo: Refer to manual for specific GL-4/GL-5 gear oil viscosity (e.g., 75W-90). Automatic Transmission Fluid Lancer: DIA-Queen ATF SP-III. 📐 Dimensions Exterior Wheelbase: Approximately 2630 mm (Lancer/Sportback), 2625 mm (Evolution VIII). Length: Approximately 4475 mm (Lancer Sedan), 4280 mm (Sportback), 4490 mm (Evolution VIII). Width: Approximately 1760 mm (Lancer/Sportback), 1770 mm (Evolution VIII). Height: Approximately 1445 mm (Lancer Sedan), 1475 mm (Sportback), 1450 mm (Evolution VIII). Weights Curb Weight Lancer Sportback: Approximately 1250 - 1350 kg (depending on engine and transmission). Curb Weight Evo Viii: Approximately 1400 kg. Wheel Bolt Pattern: 5x114.3 mm...

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Sku: 503921

Collections: ALL Mitsubishi

Availability: In stock

Tags: 2004 Car Cars Lancer Lancer Evolution Lancer Sportback Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Sub Model:

Lancer Sportback, Lancer Evolution

Model Year:

Codes

Platform:

Mitsubishi GS Platform

Chassis Code:

CT9A (Evolution VIII), CS(A) (Lancer/Sportback)

👋 Introduction

Market Position

Positioning:

The Mitsubishi Lancer, particularly in its Evolution guise, occupied a significant niche in the performance sedan market, offering accessible rally-bred technology.

Competitive Analysis

Competitors:

Subaru Impreza WRX/STI, Honda Civic Si, Volkswagen GTI, Ford Focus SVT.

Key Features

Lancer Features:

Reliable powertrain, practical interior, aerodynamic Sportback option, sporty styling.

Evolution Features:

Advanced AWD system (ACD/AYC/DCCD), turbocharged 4G63 engine, Brembo brakes, Bilstein suspension, aggressive aerodynamics.

Manual Value Proposition

Value:

This manual is an indispensable resource for maintaining, diagnosing, and repairing Mitsubishi Lancers, including the highly complex Evolution models, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive service and repair for Lancer, Lancer Sportback, and Lancer Evolution models.

Specific Models Covered:

Mitsubishi Lancer (non-performance variants), Mitsubishi Lancer Sportback (hatchback variant), Mitsubishi Lancer Evolution VIII

Page Count

Estimated Pages:

Likely over 1000 pages (typical for a complete workshop manual).

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable (typically PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing components.

Engine Management:

Fuel injection, ignition system, emission controls, ECU diagnosis and troubleshooting, sensor data.

Transmission Manual:

Clutch system, gearbox assembly, shift mechanism, gear ratios, servicing.

Transmission Automatic:

Torque converter, planetary gears, valve body, electronic controls, fluid changes, servicing.

Drivetrain:

Front-wheel drive, all-wheel drive (AWD) for Evolution, driveshafts, differentials, transfer case (Evolution).

Suspension:

Front suspension (MacPherson strut), rear suspension (multi-link/independent), shock absorbers, springs, control arms, bushings.

Steering:

Power steering system (hydraulic), steering rack, tie rods, steering column.

Brakes:

Front and rear disc brakes, ABS system (including sensors, modulator), brake fluid specifications, bleeding procedures, caliper and rotor replacement.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams.

Climate Control:

Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, blower motor, HVAC controls.

Body And Chassis:

Body construction, exterior panels, doors, hood, trunk, interior trim, chassis components, mounting points.

Safety Systems:

Airbag system, seatbelt pre-tensioners, SRS module diagnosis.

Evolution Specific Systems:

Active Center Differential (ACD), Super Active Yaw Control (S-AYC), Driver Controlled Center Differential (DCCD) for Evo models.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotations.

Troubleshooting:

Diagnostic procedures for common issues, fault code interpretation, symptom-based diagnosis.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair (e.g., engine rebuild, transmission overhaul, brake caliper replacement).

Overhaul Instructions:

Detailed guidance for complete disassembly and reassembly of major components like engines and transmissions.

Wiring Diagrams:

Comprehensive electrical schematics for various systems.

Technical Specifications:

Torque values, clearances, fluid capacities, pressure specifications, diagnostic parameters.

Technical Depth

Depth:

Full workshop level, suitable for professional technicians and advanced DIY mechanics.

Diagnostic Capability:

Includes diagnostic procedures, trouble codes (DTCs), and sensor data interpretation.

Rebuild Capability:

Covers complete engine and transmission rebuilds with detailed component specifications.

📊 Manual Specifications

File Format

Format:

Digital Download (PDF)

Print Quality

Quality:

High-resolution, searchable PDF content with clear diagrams and text.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

Searchability

Text Search:

Yes, fully text-searchable for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Code Evo:

4G63T (2.0L DOHC MIVEC Turbocharged Inline-4)

Engine Code Lancer Sportback:

4G64 (2.4L SOHC Inline-4) or 4G15 (1.5L SOHC Inline-4) - Varies by market and specific trim.

Performance

Horsepower Evo Viii:

Approximately 271 hp @ 6500 rpm (USDM) / 280 PS (JDM).

Torque Evo Viii:

Approximately 273 lb-ft @ 3500 rpm (USDM) / 37 kgm (JDM).

Bore Stroke 4G63T:

85.0 mm x 88.0 mm

Compression Ratio 4G63T:

8.8:1

Fuel System

Fuel Delivery Evo:

Electronic Fuel Injection (EFI), high-flow injectors, higher-pressure fuel pump.

Fuel Type Evo:

Premium Unleaded Gasoline (91 octane or higher recommended).

Fuel Type Lancer Sportback:

Regular Unleaded Gasoline (87 octane).

🔧 Transmission

Standard

Transmission Evo:

6-speed manual transmission (Getrag).

Optional

Transmission Lancer Sportback:

5-speed manual or 4-speed INVECS-II automatic transmission.

Features

Clutch Evo:

Twin-plate or single-plate heavy-duty clutch assembly.

Transfer Case Evo:

Center differential with Active Center Differential (ACD) and Driver Controlled Center Differential (DCCD) for manual variants.

Fluid Specifications

Manual Transmission Fluid Evo:

Refer to manual for specific GL-4/GL-5 gear oil viscosity (e.g., 75W-90).

Automatic Transmission Fluid Lancer:

DIA-Queen ATF SP-III.

📐 Dimensions

Exterior

Wheelbase:

Approximately 2630 mm (Lancer/Sportback), 2625 mm (Evolution VIII).

Length:

Approximately 4475 mm (Lancer Sedan), 4280 mm (Sportback), 4490 mm (Evolution VIII).

Width:

Approximately 1760 mm (Lancer/Sportback), 1770 mm (Evolution VIII).

Height:

Approximately 1445 mm (Lancer Sedan), 1475 mm (Sportback), 1450 mm (Evolution VIII).

Weights

Curb Weight Lancer Sportback:

Approximately 1250 - 1350 kg (depending on engine and transmission).

Curb Weight Evo Viii:

Approximately 1400 kg.

Wheel Bolt Pattern:

5x114.3 mm

Tire Size Evo Stock:

235/45R17

Tire Size Lancer Stock:

Varies by trim, commonly 195/60R15 or 205/55R16

🛡️ Safety Features

Ratings

NHTSA Rating Lancer:

Refer to specific model year NHTSA reports for detailed ratings; generally good for its class.

Active Features

Active Safety Evo:

ABS, Active Center Differential (ACD), Super Active Yaw Control (S-AYC), Brembo brakes.

Active Safety Lancer:

ABS, EBD (Electronic Brakeforce Distribution) on some trims.

Passive Features

Passive Safety Features:

Front airbags, side airbags (optional on some models), 3-point seatbelts, reinforced chassis.

💡 Technology Features

Infotainment

Infotainment Features:

Basic AM/FM/CD player, optional premium audio systems (e.g., Rockford Fosgate on some Evolution models).

Driver Assistance

Driver Assistance Features:

Limited by modern standards; primarily ABS and EBD. Evolution models featured advanced mechanical and electronic aids for traction and handling.

Connectivity

Connectivity Features:

Basic auxiliary inputs or CD changers available on higher trims; no Bluetooth or USB connectivity standard for this era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 3,000-5,000 miles or 6 months for older vehicles, 7,500-10,000 miles for synthetic oil (check manual).

Timing Belt Replacement 4G63:

Recommended every 60,000 - 70,000 miles or 5-7 years. Crucial for the 4G63T engine to prevent catastrophic failure.

Spark Plug Replacement 4G63T:

Iridium spark plugs: 60,000-100,000 miles. Platinum: 30,000-50,000 miles.

Fluid Specifications

Engine Oil Specification:

For 4G63T: SAE 5W-30 or 10W-30 synthetic oil (API SG/SH/SJ or higher). Check manual for exact viscosity based on climate.

Coolant Specification:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent OAT coolant.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Known Issues

4G63T Common Issues:

Turbocharger wear, head gasket failure (especially if neglected or heavily modified), valve seal leaks, worn piston rings leading to oil consumption.

Lancer Common Issues:

Exhaust manifold cracks, minor electrical gremlins, suspension wear, rust on early models, automatic transmission issues in high-mileage vehicles.

Evolution Specific Issues:

ACD/AYC pump failure, clutch wear (especially with aggressive driving), differential wear, turbo coolant hose leaks.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Founded in 1970, Mitsubishi Motors has a strong history in motorsports, particularly rallying with the Lancer Evolution.

Model Evolution

Lancer Lineage:

The Lancer nameplate has been used since 1973, evolving through various generations and body styles. The Evolution (Evo) variant, introduced in 1992, transformed it into a performance icon.

Production

Evo Viii Production Years:

2003-2005

Lancer Sportback Generation:

Part of the seventh generation Lancer (CS/CT platform).

🏆 Awards & Recognition

Recognitions

Evolution Motorsport Legacy:

The Lancer Evolution platform is legendary in world rally championships (WRC), with multiple driver and manufacturer titles.

Performance Car Awards:

The Evolution VIII received numerous accolades from automotive publications for its performance, handling, and value proposition in the sports sedan segment.