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: CSA (Lancer), CSX (Evolution) 👋 Introduction Market Position Segment: Compact sedan and hatchback (Lancer), Performance compact sedan (Lancer Evolution) Competitive Analysis Competitors: For Lancer: Honda Civic, Toyota Corolla, Mazda3, Ford Focus. For Lancer Evolution: Subaru WRX STI, Volkswagen Golf R, Audi S3. Key Features Lancer Attributes: Reliability, fuel efficiency, practicality, affordable performance options. Lancer Evolution Attributes: All-wheel drive (AWD) with Active Center Differential (ACD), turbocharged engines, advanced suspension, performance-oriented chassis, rally heritage. Manual Value Proposition User Benefit: Enables DIY maintenance, diagnostics, and repairs, saving costs and maximizing vehicle uptime. 📋 Manual Details Coverage Areas Regions Covered: Global (may vary slightly by specific market; manual typically covers common international specifications) Page Count Estimated Page Count: Extensive, likely 1500+ pages (typical for a complete service manual covering multiple variants) Manual Type Type: Complete Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, emissions control, exhaust system, cooling system, lubrication system Transmission Drivetrain: Manual transmission, Automatic transmission, Clutch system, Drive shafts, Axles, Differentials (including ACD for Evolution) Chassis Suspension Steering: Front suspension, Rear suspension, Shock absorbers, Springs, Steering system, Power steering Brakes: Front brakes, Rear brakes, Parking brake, Anti-lock Braking System (ABS), Brake fluid specifications Electrical Electronics: Battery, Charging system, Starting system, Lighting system, Gauges and instruments, Wiper/washer system, Power windows, Central locking, Audio system, ECU, Powertrain Control Module (PCM), Body Control Module (BCM) Body Chassis: Body construction, Exterior panels, Doors, Hood, Trunk lid, Bumpers, Interior trim, Seating systems, Glass and seals Heating Ventilation Air Conditioning: HVAC system, Air conditioning (A/C) compressor, Refrigerant, Blower motor, Controls, Cabin filter Procedures Included Maintenance: Routine checks, Oil changes, Filter replacements, Spark plug replacement, Fluid level checks and top-offs Troubleshooting: Diagnostic procedures for various systems, Fault code interpretation (OBD-II), Symptom-based troubleshooting guides Repair Rebuild: Engine overhaul, Transmission repair/rebuild, Brake caliper replacement, Suspension component replacement, Electrical component diagnosis and replacement Installation Replacement: Component replacement (e.g., alternator, starter, fuel pump), Accessory installation guidance Specifications Data: Torque specifications, Gapping procedures, Alignment specifications, Electrical diagrams, Component data Technical Depth Depth: Comprehensive (covers basic maintenance to full mechanical and electrical system overhauls and diagnostics) 📊 Manual Specifications File Format Digital Format: PDF Searchability: Likely searchable text-based PDF for efficient information retrieval Print Quality Printability: Printable pages for workshop use Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Lancer Engine Code Lancer: 4G64 (2.4L) Engine Type Lancer: Inline-4, SOHC, 16-valve Displacement Lancer: 2351 cc (2.4 Liters) Horsepower Lancer: Approx. 135-160 hp (depending on specific market/tune) Torque Lancer: Approx. 145-155 lb-ft (depending on specific market/tune) Lancer Evolution Engine Engine Code Evolution: 4G63T Engine Type Evolution: Inline-4, DOHC, 16-valve, Turbocharged and Intercooled Displacement Evolution: 1997 cc (2.0 Liters) Horsepower Evolution: Approx. 270-285 hp (depending on Evolution VII/VIII/IX specifications) Torque Evolution: Approx. 255-275 lb-ft (depending on Evolution VII/VIII/IX specifications) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Recommended Fuel: Unleaded gasoline (87 octane for Lancer, 91+ octane for Lancer Evolution) Performance Acceleration 0 60 Lancer: Approx. 8.5-9.5 seconds Acceleration 0 60 Evolution: Approx. 4.5-5.5 seconds 🔧 Transmission Standard Lancer Type Lancer: 5-speed Manual Optional Lancer Type Lancer: 4-speed Automatic Standard Evolution Type Evolution: 5-speed Manual (Early) / 6-speed Manual (Later Evolution models) Optional Evolution Type Evolution: Limited availability of automatic transmissions in certain markets/trims for Evolution models. Features Evolution Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD), front helical limited-slip differential (LSD), rear mechanical LSD (on most performance variants). 📐 Dimensions Exterior Length: Approx. 4475-4625 mm (Lancer Sedan), Approx. 4300-4350 mm (Lancer Sportback), Approx. 4360-4430 mm (Lancer Evolution, depending on wing/body kit) Width: Approx. 1740-1770 mm Height: Approx. 1415-1445 mm (Lancer Sedan/Sportback), Approx. 1450-1490 mm (Lancer Evolution) Wheelbase: Approx. 2630-2635 mm Weights Curb Weight: Approx. 1300-1450 kg (Lancer), Approx. 1450-1550 kg (Lancer Evolution) Cargo Trunk Capacity: Approx. 390-420 Liters (Lancer Sedan), Approx. 340-370 Liters (Lancer Sportback) 🛡️ Safety Features Ratings NHTSA Front Crash Test Driver: Good (for 2004 Lancer models, typically) NHTSA Front Crash Test Passenger: Good (for 2004 Lancer models, typically) IIHS Frontal Offset: Good (for 2004 Lancer models, typically) Active Features ABS: Standard on most trims, enhanced on Evolution. Traction Control: Available on select Lancer trims, standard and advanced on Evolution (e.g., AYC - Active Yaw Control). Electronic Stability Control: Available on some later models or specific trims, less common on early 2004 models. Passive Features Airbags: Frontal airbags standard, side airbags and curtain airbags available on higher trims. Seatbelts: 3-point seatbelts with pretensioners and load limiters. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional premium audio systems with more speakers. Display Screen: Basic digital display for clock/radio, no large central touchscreens on most models....
Front suspension, Rear suspension, Shock absorbers, Springs, Steering system, Power steering
Brakes:
Front brakes, Rear brakes, Parking brake, Anti-lock Braking System (ABS), Brake fluid specifications
Electrical Electronics:
Battery, Charging system, Starting system, Lighting system, Gauges and instruments, Wiper/washer system, Power windows, Central locking, Audio system, ECU, Powertrain Control Module (PCM), Body Control Module (BCM)
Body Chassis:
Body construction, Exterior panels, Doors, Hood, Trunk lid, Bumpers, Interior trim, Seating systems, Glass and seals
Limited availability of automatic transmissions in certain markets/trims for Evolution models.
Features
Evolution Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD), front helical limited-slip differential (LSD), rear mechanical LSD (on most performance variants).
📐 Dimensions
Exterior
Length:
Approx. 4475-4625 mm (Lancer Sedan), Approx. 4300-4350 mm (Lancer Sportback), Approx. 4360-4430 mm (Lancer Evolution, depending on wing/body kit)
Width:
Approx. 1740-1770 mm
Height:
Approx. 1415-1445 mm (Lancer Sedan/Sportback), Approx. 1450-1490 mm (Lancer Evolution)
Wheelbase:
Approx. 2630-2635 mm
Weights
Curb Weight:
Approx. 1300-1450 kg (Lancer), Approx. 1450-1550 kg (Lancer Evolution)
Available on select Lancer trims, standard and advanced on Evolution (e.g., AYC - Active Yaw Control).
Electronic Stability Control:
Available on some later models or specific trims, less common on early 2004 models.
Passive Features
Airbags:
Frontal airbags standard, side airbags and curtain airbags available on higher trims.
Seatbelts:
3-point seatbelts with pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio systems with more speakers.
Display Screen:
Basic digital display for clock/radio, no large central touchscreens on most models.
Driver Assistance
Cruise Control:
Available on many Lancer trims, standard on Evolution.
Keyless Entry:
Available on higher trims.
Connectivity
Bluetooth:
Rarely standard for 2004, likely an aftermarket addition.
Aux Input:
Rarely standard for 2004, likely an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. For Evolution, more frequent changes may be recommended, especially under spirited driving.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 60,000-100,000 miles (96,000-160,000 km) for standard ignition, potentially less for performance plugs in Evolution.
Timing Belt Replacement:
Every 60,000-105,000 miles (96,000-168,000 km) or 7 years, depending on engine (4G64 usually uses a belt, 4G63T uses a belt). Crucial for 4G63T as it's an interference engine.
Fluid Specifications
Engine Oil Specification:
API SM/SN, ILSAC GF-4/GF-5. Viscosity: 5W-30 or 5W-40 (depending on climate and engine). Consult manual for specific recommendations.
Coolant Specification:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol based coolant with deionized water, typically a 50/50 mix). Check manual for color/type.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 75W-85.
Transmission Fluid Automatic:
Mitsubishi DiaQueen SP III Automatic Transmission Fluid (or equivalent Dexron III/Mercon compatible fluid). Check manual for precise type.
Head gasket failures (especially if modified or poorly maintained), turbocharger wear, piston ring land failure (on high mileage or heavily modified engines).
Suspension Steering:
Worn control arm bushings, ball joints, and tie rod ends over time; potential for strut leaks.
Transmission Clutch:
Clutch wear (especially in performance models); transmission synchro wear on manual transmissions.
Electrical:
Alternator failure, window regulator issues, minor sensor failures.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation (Japan)
Model Evolution
Generation:
Seventh Generation Lancer (CS/CT platform), with Evolution VII/VIII/IX variants derived from this platform.
Production Period:
2000-2007 (CS platform)
Production
Manufacturing Locations:
Japan, Australia, USA (for specific models/assembly plants)
Evolution Significance:
The Lancer Evolution is a legendary homologation special derived from rally racing, renowned for its performance and technology.
🏆 Awards & Recognition
Recognitions
Lancer Evolution Awards:
Consistently praised by automotive media for its handling, performance, and value in the performance compact segment. Often featured in 'Best Performance Cars' lists.
Lancer Awards:
Received positive reviews for affordability, reliability, and practicality in its class.
Certifications
Emissions Certification:
Meets EPA and CARB emissions standards for the model year.