2004 Mitsubushi LANCER/LANCER SPORTBACK/LANCER EVOLUTION Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Variant: Lancer Evolution Year: 2004 Codes Chassis Codes: CS_A (Lancer), CT_A (Lancer Evolution) 👋 Introduction Market Position Segment: Compact/Subcompact Sedan and Hatchback, Performance Sedan (Evolution) Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Mazda3, Subaru Impreza (WRX for Evolution) Key Features Model Appeal: Affordable transportation with reliable engines, practical hatchback option (Sportback), and high-performance enthusiast variant (Evolution). Manual Value Target Audience: DIY mechanics, independent repair shops, and owners seeking to understand and maintain their vehicle. 📋 Manual Details Coverage Areas Engine: All gasoline engines for 2004 Lancer, Lancer Sportback, and Lancer Evolution models Transmission: Manual and Automatic Transmissions Drivetrain: Front-Wheel Drive (FWD), All-Wheel Drive (AWD) for Evolution models Body And Chassis: Body panels, frame, suspension, steering, brakes, exhaust, fuel system Electrical System: Wiring diagrams, lighting, ignition, starting, charging, accessories, ECUs Heating Ventilation And Air Conditioning: HVAC system operation and repair Interior: Seating, trim, airbags, dashboard Troubleshooting: Diagnostic procedures and common issues Page Count Estimated Pages: 1500+ Manual Type Type: Complete Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system Engine Management: Fuel injection, ignition timing, emissions control, sensor diagnostics, ECU functions Powertrain Controls: Transmission control module (TCM), electronic control unit (ECU) integration Braking System: Hydraulic system, ABS, EBD, brake pad/rotor replacement, caliper service Suspension And Steering: Struts, shocks, control arms, tie rods, power steering system, alignment specifications Electrical Diagnostics: Wiring diagrams, component testing, circuit tracing, diagnostic trouble codes (DTCs) Body And Trim: Door mechanisms, interior panels, exterior trim, glass replacement Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug service, timing belt/chain inspection Component Replacement: Alternator, starter motor, water pump, fuel pump, radiator, battery Engine Overhaul: Complete engine rebuild procedures for all covered engines Transmission Service: Fluid changes, filter replacement, clutch service (manual), torque converter service (automatic) Brake Service: Brake fluid flush and bleed, rotor and pad replacement, caliper overhaul Diagnostic Troubleshooting: Step-by-step diagnostic flowcharts for various symptoms Alignment And Balancing: Wheel alignment procedures and specifications, tire balancing Airbag System Service: Safety precautions and replacement procedures for airbag components Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Type: PDF Searchable: Yes (text-based PDF) Resolution: High-resolution for clear diagrams and text Print Quality Printability: Printable (allows users to print specific sections or the entire manual) Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Standard Lancer: 2.0L 4G63 SOHC MPI Inline-4 Optional Lancer: 2.4L 4G64 DOHC MPI Inline-4 (some markets) Evolution Engine: 2.0L 4G63T DOHC Turbocharged MPI Inline-4 Performance Lancer Horsepower: 120 hp @ 5500 rpm (2.0L), 135 hp @ 5500 rpm (2.4L) Torque: 130 lb-ft @ 3500 rpm (2.0L), 150 lb-ft @ 3500 rpm (2.4L) Performance Evolution Horsepower: 271 hp @ 6500 rpm (GSR), 287 hp @ 6500 rpm (MR) Torque: 273 lb-ft @ 3500 rpm (GSR), 289 lb-ft @ 3500 rpm (MR) Fuel System Type: Multi-Point Fuel Injection (MPI) Octane Rating: 87 octane recommended for Lancer, 91+ octane premium required for Lancer Evolution Engine Codes Lancer Gasoline: 4G63, 4G64 Lancer Turbocharged: 4G63T 🔧 Transmission Standard Lancer: 5-speed Manual Evolution: 5-speed Manual (GSR), 6-speed Manual (MR) Optional Lancer: 4-speed Automatic Features Evolution AWD: Active Center Differential (ACD), Active Yaw Control (AYC) on some models Fluid Specification Manual Transmission Fluid: API GL-4, SAE 75W-90 (e.g., DiaQueen LSD Gear Oil for AYC units) Automatic Transmission Fluid: DIAQUEEN ATF SP-III or equivalent 📐 Dimensions Exterior Lancer Sedan Length: 174.0 in (4420 mm) Width: 67.1 in (1705 mm) Height: 56.5 in (1435 mm) Exterior Lancer Sportback Length: 174.8 in (4440 mm) Exterior Lancer Evolution Length: 176.0 in (4470 mm) Width: 69.7 in (1770 mm) Height: 57.1 in (1450 mm) Wheelbase Lancer All Models: 103.3 in (2625 mm) Cargo Lancer Sportback Volume: Approximately 13.7 cu ft (seats up) Weights Curb Weight Lancer: Approx. 2700-2900 lbs (depending on trim and engine) Curb Weight Evolution: Approx. 3200-3350 lbs (depending on trim) Towing Capacity: Not Recommended 🛡️ Safety Features Ratings NHTSA Front Impact: 4-Star (Driver), 4-Star (Passenger) for Lancer Sedan (2004 model year specific) IIHS Front Impact: Good (for Lancer Sedan, 2004 model year specific) Active Features ABS: Standard on most trims, standard on Evolution Traction Control: Optional on some Lancer trims, standard on Evolution Electronic Brakeforce Distribution: Standard on Evolution, optional on some Lancer trims Passive Features Airbags: Front airbags standard; optional side airbags on some Lancer trims. Seatbelts: 3-point front and rear seatbelts, pretensioners for front seats. Child Seat Anchors: LATCH (Lower Anchors and Tethers for CHildren) system 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with speaker options (4-6 speakers typically). Optional premium audio systems available on higher...
87 octane recommended for Lancer, 91+ octane premium required for Lancer Evolution
Engine Codes
Lancer Gasoline:
4G63, 4G64
Lancer Turbocharged:
4G63T
🔧 Transmission
Standard
Lancer:
5-speed Manual
Evolution:
5-speed Manual (GSR), 6-speed Manual (MR)
Optional
Lancer:
4-speed Automatic
Features
Evolution AWD:
Active Center Differential (ACD), Active Yaw Control (AYC) on some models
Fluid Specification
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (e.g., DiaQueen LSD Gear Oil for AYC units)
Automatic Transmission Fluid:
DIAQUEEN ATF SP-III or equivalent
📐 Dimensions
Exterior Lancer Sedan
Length:
174.0 in (4420 mm)
Width:
67.1 in (1705 mm)
Height:
56.5 in (1435 mm)
Exterior Lancer Sportback
Length:
174.8 in (4440 mm)
Exterior Lancer Evolution
Length:
176.0 in (4470 mm)
Width:
69.7 in (1770 mm)
Height:
57.1 in (1450 mm)
Wheelbase
Lancer All Models:
103.3 in (2625 mm)
Cargo Lancer Sportback
Volume:
Approximately 13.7 cu ft (seats up)
Weights
Curb Weight Lancer:
Approx. 2700-2900 lbs (depending on trim and engine)
Curb Weight Evolution:
Approx. 3200-3350 lbs (depending on trim)
Towing Capacity:
Not Recommended
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-Star (Driver), 4-Star (Passenger) for Lancer Sedan (2004 model year specific)
IIHS Front Impact:
Good (for Lancer Sedan, 2004 model year specific)
Active Features
ABS:
Standard on most trims, standard on Evolution
Traction Control:
Optional on some Lancer trims, standard on Evolution
Electronic Brakeforce Distribution:
Standard on Evolution, optional on some Lancer trims
Passive Features
Airbags:
Front airbags standard; optional side airbags on some Lancer trims.
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seats.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with speaker options (4-6 speakers typically). Optional premium audio systems available on higher trims.
Navigation:
Rarely offered, and if so, typically a dealer-installed accessory or aftermarket unit.
Driver Assistance
Cruise Control:
Available on most models.
Keyless Entry:
Available on higher trims.
Connectivity
Power Windows Locks Mirrors:
Standard on most trims.
Immobilizer:
Standard engine immobilizer for anti-theft.
🔧 Maintenance
Service Intervals Oil Change
Engine Oil And Filter:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use); 7,500 miles (12,000 km) or 12 months (normal use).
Service Intervals Air Filter
Engine Air Filter:
Every 30,000 miles (48,000 km)
Service Intervals Spark Plugs
Spark Plugs:
Every 60,000 miles (96,000 km) for standard spark plugs; iridium plugs may have longer intervals (refer to manual).
Service Intervals Timing Belt
Timing Belt:
Crucial for 4G63/4G64 engines. Inspect every 30,000 miles (48,000 km), replace every 60,000 miles (96,000 km) or 5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SJ or higher, SAE 5W-30 recommended for most conditions. Check manual for specific viscosity and API rating.
Coolant:
Mitsubishi DIANLLE coolant (Long Life) or equivalent (50/50 mix of ethylene glycol and distilled water)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
ATF SPIII or DEXRON-III equivalent
Known Issues
Turbocharger Failure:
Common on high-mileage or poorly maintained Evolution models due to heat and oil degradation. Regular oil changes and proper cool-down are vital.
Engine Oil Consumption:
Some 4G6x engines can exhibit increased oil consumption with age; piston ring wear is a potential cause.
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear over time, leading to clunking noises and steering issues.
Exhaust Manifold Cracks:
The cast iron exhaust manifold on Evolution models can develop cracks due to thermal cycling.
Clutch Wear:
Heavy use, especially in performance driving, can accelerate clutch wear on manual transmission models.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Japanese automaker with a long history in automotive manufacturing, known for innovation in performance and technology (e.g., rally heritage).
Model Evolution
Lancer Seventh Generation:
The 2004 model represents the third year of the seventh generation Lancer (CS/CT platform), known for its more European styling and improved chassis.
Lancer Evolution Vii:
The Lancer Evolution VII, introduced for the 2004 model year in certain markets, continued the lineage of high-performance rally-bred sedans, featuring advanced all-wheel-drive systems and turbocharged power.
Production
Manufacturing Location:
Japan (Primary), also assembled in other global locations.
🏆 Awards & Recognition
Recognitions
Lancer Evolution Legacy:
Consistently praised by automotive journalists and enthusiasts for its rally-bred performance, handling, and affordability in the performance sedan segment.
Lancer Sportback Practicality:
Appreciated for its versatility and practicality as a compact hatchback.