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2004 Mitsubishi Lancer/Lancer Evolution XIII (Evo 8)/Lancer SportBack Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer / Lancer Evolution XIII (Evo 8) / Lancer Sportback Year: 2004 Codes Chassis Codes: CT9A (Evo VIII), CS (Standard Lancer/Sportback) 👋 Introduction Market Position Segment: Compact Sport Sedan/Hatchback (Lancer/Sportback) and Performance Compact Sedan (Lancer Evolution) Competitive Analysis Competitors: Standard Lancer: Honda Civic, Toyota Corolla, Mazda3. Lancer Evolution VIII: Subaru Impreza WRX STI, Ford Focus RS (limited markets), BMW M3 (aspirational). Key Features Standard Lancer: Reliable, practical, affordable, available as sedan and hatchback (Sportback). Lancer Evolution Viii: Iconic rally-bred performance, advanced AWD system (Super Active Center Differential - ACD, Active Yaw Control - AYC), potent turbocharged 4G63 engine, high-performance braking. 📋 Manual Details Coverage Areas Regions Covered: Global (applicable to 2004 models across major markets) Page Count Estimated Pages: 1500-2000+ Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (4G63, 4G69), Transmission (Manual, Automatic, Twin Clutch SST for some Evo variants), Drivetrain (AWD, FWD), Exhaust System, Fuel System, Cooling System Chassis: Suspension (Front MacPherson strut, Rear Multi-link), Steering System (Power Steering), Braking System (ABS, EBD, Brembo for Evo), Wheels and Tires Electrical: Battery, Charging System, Ignition System, Lighting, Instrumentation, HVAC Controls, Power Accessories, ECU Diagnostics, Wiring Diagrams Body: Body Panels, Doors, Windows, Seats, Interior Trim, Bumpers, Exterior Trim, Paint and Corrosion Climate Control: HVAC system, AC compressor, heater core, blower motor, refrigerant system. Fuel And Emissions: Fuel pump, injectors, fuel filter, EVAP system, catalytic converter, oxygen sensors. Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Inspection/Replacement, Fluid Checks and Top-offs Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Service, Electrical Component Diagnosis and Replacement, Body Panel Repair Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting, Fault Isolation Techniques, Electrical System Diagnostics Engine Mechanical: Cylinder head removal and reassembly, piston and connecting rod installation, crankshaft removal, valve timing, engine balancing. Drivetrain Component Replacement: CV joints, driveshafts, differential service (front and rear), ACD/AYC unit service. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications) Diagnostic Procedures: Detailed DTC lookup tables, circuit diagrams, component testing procedures, sensor data interpretation. 📊 Manual Specifications File Format Digital Format: PDF (typically) Print Quality Quality: High-resolution scans or original manufacturer files, ensuring clarity of diagrams and text Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Lancer Non Evo: 2.0L DOHC 16-valve (4G63 or 4G69 depending on market/trim) Lancer Evo Viii: 2.0L DOHC 16-valve Turbocharged Intercooled MIVEC (4G63T) Performance Lancer Non Evo Hp: Approx. 120-160 hp (depending on engine variant and market) Lancer Non Evo Torque: Approx. 130-150 lb-ft Lancer Evo Viii Hp: 271 hp (USDM spec, SAE net) Lancer Evo Viii Torque: 273 lb-ft (USDM spec, SAE net) Fuel System Fuel Type: Unleaded Gasoline (Premium Unleaded required for Evo VIII) Injection: Electronic Fuel Injection (EFI) with Sequential Port Injection 🔧 Transmission Standard Lancer Non Evo: 5-speed Manual Transmission Lancer Evo Viii: 6-speed Manual Transmission (Getrag) Optional Lancer Non Evo: 4-speed Automatic Transmission Features Lancer Evo Viii AWD: Super Active Center Differential (ACD), Active Yaw Control (AYC) on specific models/trims for enhanced handling. 📐 Dimensions Exterior Wheelbase: Approx. 104.3 inches (2650 mm) Length: Approx. 177.7 inches (4515 mm) for Sedan, 177.0 inches (4495 mm) for Evo VIII Width: Approx. 67.3 inches (1710 mm) for Standard Lancer, 70.1 inches (1780 mm) for Evo VIII Height: Approx. 57.3 inches (1455 mm) for Standard Lancer, 56.1 inches (1425 mm) for Evo VIII Weights Curb Weight: Approx. 2800-3100 lbs (Standard Lancer), 3200-3400 lbs (Evo VIII) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4-star (for relevant models/tests) NHTSA Frontal Passenger: 4-star (for relevant models/tests) IIHS Front Small Overlap: Good (for applicable years/models tested) Active Features ABS: Standard on most models, enhanced on Evo VIII Ebd: Electronic Brakeforce Distribution (standard on many models) Traction Control: Available on some Lancer models, standard on Evo VIII Passive Features Airbags: Frontal airbags, optional side airbags Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Aftermarket head unit common, factory units often included CD/MP3 player and basic radio. Driver Assistance ABS: Standard on most, enhanced with EBD. AWD Control: ACD and AYC are key technological highlights of the Evo VIII. Connectivity Connectivity Features: Limited by modern standards; primarily focused on audio input (cassette, CD). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, depending on driving conditions and oil type. Refer to manual for specific recommendations. Timing Belt Replacement: For 4G63 engine, typically 60,000 to 100,000 miles (100,000 to 160,000 km). Crucial for preventing catastrophic engine damage. Fluid Specifications Engine Oil: API SG/SH/SJ or ACEA A2/A3 certified. Viscosity typically 5W-30 or 10W-30. Refer to manual for exact specs...
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2004 Mitsubishi Lancer/Lancer Evolution XIII (Evo 8)/Lancer SportBack Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer / Lancer Evolution XIII (Evo 8) / Lancer Sportback
Year:
2004
Codes
Chassis Codes:
CT9A (Evo VIII), CS (Standard Lancer/Sportback)
👋 Introduction
Market Position
Segment:
Compact Sport Sedan/Hatchback (Lancer/Sportback) and Performance Compact Sedan (Lancer Evolution)
Competitive Analysis
Competitors:
Standard Lancer: Honda Civic, Toyota Corolla, Mazda3. Lancer Evolution VIII: Subaru Impreza WRX STI, Ford Focus RS (limited markets), BMW M3 (aspirational).
Key Features
Standard Lancer:
Reliable, practical, affordable, available as sedan and hatchback (Sportback).
Lancer Evolution Viii:
Iconic rally-bred performance, advanced AWD system (Super Active Center Differential - ACD, Active Yaw Control - AYC), potent turbocharged 4G63 engine, high-performance braking.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (applicable to 2004 models across major markets)
Page Count
Estimated Pages:
1500-2000+
Manual Type
Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63, 4G69), Transmission (Manual, Automatic, Twin Clutch SST for some Evo variants), Drivetrain (AWD, FWD), Exhaust System, Fuel System, Cooling System
Chassis:
Suspension (Front MacPherson strut, Rear Multi-link), Steering System (Power Steering), Braking System (ABS, EBD, Brembo for Evo), Wheels and Tires
Electrical:
Battery, Charging System, Ignition System, Lighting, Instrumentation, HVAC Controls, Power Accessories, ECU Diagnostics, Wiring Diagrams
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, Bumpers, Exterior Trim, Paint and Corrosion
Climate Control:
HVAC system, AC compressor, heater core, blower motor, refrigerant system.
Fuel And Emissions:
Fuel pump, injectors, fuel filter, EVAP system, catalytic converter, oxygen sensors.
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Inspection/Replacement, Fluid Checks and Top-offs
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Service, Electrical Component Diagnosis and Replacement, Body Panel Repair
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting, Fault Isolation Techniques, Electrical System Diagnostics
Engine Mechanical:
Cylinder head removal and reassembly, piston and connecting rod installation, crankshaft removal, valve timing, engine balancing.
Drivetrain Component Replacement:
CV joints, driveshafts, differential service (front and rear), ACD/AYC unit service.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications)
Diagnostic Procedures:
Detailed DTC lookup tables, circuit diagrams, component testing procedures, sensor data interpretation.
📊 Manual Specifications
File Format
Digital Format:
PDF (typically)
Print Quality
Quality:
High-resolution scans or original manufacturer files, ensuring clarity of diagrams and text
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Lancer Non Evo:
2.0L DOHC 16-valve (4G63 or 4G69 depending on market/trim)
Lancer Evo Viii:
2.0L DOHC 16-valve Turbocharged Intercooled MIVEC (4G63T)
Performance
Lancer Non Evo Hp:
Approx. 120-160 hp (depending on engine variant and market)
Lancer Non Evo Torque:
Approx. 130-150 lb-ft
Lancer Evo Viii Hp:
271 hp (USDM spec, SAE net)
Lancer Evo Viii Torque:
273 lb-ft (USDM spec, SAE net)
Fuel System
Fuel Type:
Unleaded Gasoline (Premium Unleaded required for Evo VIII)
Injection:
Electronic Fuel Injection (EFI) with Sequential Port Injection
🔧 Transmission
Standard
Lancer Non Evo:
5-speed Manual Transmission
Lancer Evo Viii:
6-speed Manual Transmission (Getrag)
Optional
Lancer Non Evo:
4-speed Automatic Transmission
Features
Lancer Evo Viii AWD:
Super Active Center Differential (ACD), Active Yaw Control (AYC) on specific models/trims for enhanced handling.
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.3 inches (2650 mm)
Length:
Approx. 177.7 inches (4515 mm) for Sedan, 177.0 inches (4495 mm) for Evo VIII
Width:
Approx. 67.3 inches (1710 mm) for Standard Lancer, 70.1 inches (1780 mm) for Evo VIII
Height:
Approx. 57.3 inches (1455 mm) for Standard Lancer, 56.1 inches (1425 mm) for Evo VIII
Weights
Curb Weight:
Approx. 2800-3100 lbs (Standard Lancer), 3200-3400 lbs (Evo VIII)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
4-star (for relevant models/tests)
NHTSA Frontal Passenger:
4-star (for relevant models/tests)
IIHS Front Small Overlap:
Good (for applicable years/models tested)
Active Features
ABS:
Standard on most models, enhanced on Evo VIII
Ebd:
Electronic Brakeforce Distribution (standard on many models)
Traction Control:
Available on some Lancer models, standard on Evo VIII
Passive Features
Airbags:
Frontal airbags, optional side airbags
Seatbelts:
Three-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Aftermarket head unit common, factory units often included CD/MP3 player and basic radio.
Driver Assistance
ABS:
Standard on most, enhanced with EBD.
AWD Control:
ACD and AYC are key technological highlights of the Evo VIII.
Connectivity
Connectivity Features:
Limited by modern standards; primarily focused on audio input (cassette, CD).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, depending on driving conditions and oil type. Refer to manual for specific recommendations.
Timing Belt Replacement:
For 4G63 engine, typically 60,000 to 100,000 miles (100,000 to 160,000 km). Crucial for preventing catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ACEA A2/A3 certified. Viscosity typically 5W-30 or 10W-30. Refer to manual for exact specs and capacity (approx. 4.5-5.0 quarts).
Transmission Fluid Manual:
API GL-4, SAE 75W-90 gear oil. Capacity approx. 2.0-2.5 liters.
Transmission Fluid Automatic:
Mitsubishi Genuine ATF SP-II or equivalent. Capacity approx. 7.0-8.0 liters.
Coolant:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Capacity approx. 7.0-8.5 liters.
Known Issues
Lancer Non Evo:
Occasional HVAC blower motor failure, minor electrical gremlins, exhaust manifold cracks (older models).
Lancer Evo Viii:
Turbocharger wear (if not maintained properly), clutch wear (performance driving), front differential wear, exhaust manifold cracking on early 4G63Ts, some AC system issues.
Part Numbers
Oil Filter Examples:
Mitsubishi MD347166, Wix 57060, Fram PH8170 (Verify for specific engine)
Spark Plugs Examples:
NGK BKR7E-11 (for Evo VIII, colder heat range recommended for tuning)
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Long history in automotive manufacturing, particularly known for reliable vehicles and motorsport success (rallying).
Model Evolution
Lancer Lineage:
The Lancer nameplate has been in continuous production since 1973, evolving through multiple generations. The 2004 model represents the eighth generation (CS platform).
Lancer Evolution History:
Born from Mitsubishi's World Rally Championship (WRC) program, the Evolution series is celebrated for its technological advancements and unparalleled performance in its class. The Evo VIII was a significant evolution, introducing the ACD and AYC systems more widely.
Production
Manufacturing Location:
Japan (primarily Mizushima Plant), with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Lancer Evolution Reputation:
Consistently praised by automotive journalists and enthusiasts for its handling, performance, and value in the sports compact segment. Often featured in 'Best Performance Cars' lists.
Ratings
Car And Driver 10Best:
Evo VIII frequently cited for its driving dynamics, though specific '10Best' inclusions may vary by year/rankings.
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