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2004 Mitsubushi LANCER/LANCER SPORTBACK/LANCER EVOLUTION Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Variant: Lancer Sportback, Lancer Evolution Model Year: 2004 Codes Chassis Codes: CY (Lancer), CZ (Lancer Evolution) Vin Prefix: JMB (Lancer), JMF (Lancer Evolution) 👋 Introduction Market Position Segment: Compact car segment, with the Evolution positioned as a performance-oriented, rally-bred sports sedan. Competitive Analysis Competitors Lancer: Honda Civic, Toyota Corolla, Mazda3, Nissan Sentra. Competitors Evolution: Subaru WRX STI, Volkswagen Golf R, Ford Focus RS (though the latter arrived later). Key Features Lancer Standard Features: Reliable commuter car, practical design, available in sedan and hatchback (Sportback) body styles. Key Features Evolution Performance Features: Symmetrical All-Wheel Drive (SAWC), turbocharged engine, active center differential (ACD), limited-slip differentials (LSD), performance suspension, and braking systems. Manual Value Proposition For Owners: Enables owners to perform maintenance, understand diagnostics, and tackle repairs confidently, saving on labor costs. For Mechanics: Provides definitive factory specifications, procedures, and troubleshooting guidance for efficient and accurate repairs. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair for all systems and components. Specific Models Covered: 2004 Mitsubishi Lancer, 2004 Mitsubishi Lancer Sportback, 2004 Mitsubishi Lancer Evolution Engine Variants Covered: All gasoline engines offered for the 2004 model year. Page Count Estimated Pages: Over 1500 pages (typical for comprehensive manuals of this era). Manual Type Type: Official Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, pistons, crankshaft, lubrication system, cooling system. Engine Performance: Fuel injection, ignition system, emission control systems, turbocharging (for Evolution). Transmission Manual: Manual transmission (5-speed and 6-speed for Evolution) disassembly, assembly, and overhaul. Transmission Automatic: Automatic transmission (if applicable) diagnosis and repair. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD - for Evolution) systems, drive shafts, differentials, hub assemblies. Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, alignment procedures. Steering: Power steering system, steering gear, steering column, diagnosis and repair. Brakes: Front and rear brake systems (disc brakes), ABS system, parking brake, hydraulic components. Electrical System Overview: Battery, charging system (alternator), starting system (starter motor). Lighting System: Headlights, taillights, interior lighting, wiring diagrams. Instrument Panel And Gauges: Speedometer, tachometer, warning lights, diagnostic trouble codes (DTCs). Comfort And Convenience: HVAC system, power windows, power locks, mirrors, remote keyless entry. Body And Frame: Body panel removal and installation, interior trim, exterior trim, doors, hood, trunk lid. Restraint Systems: Airbag system diagnosis and service procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections. Troubleshooting: Diagnostic flowcharts for common and complex issues, DTC interpretation. Component Repair And Overhaul: Detailed step-by-step instructions for disassembling, repairing, and reassembling major components. Wiring Diagrams: Complete electrical wiring schematics for all vehicle systems. Specification Tables: Torque specifications, clearances, fluid capacities, pressures, and other critical data. Technical Depth Depth: Professional-level repair and diagnostic information, suitable for both experienced technicians and dedicated DIY enthusiasts. Diagnostic Tools: Information on using specialized diagnostic tools (e.g., MUT-III) where applicable. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable pages allowing for physical reference. Print Quality Quality: Digital reproduction of original factory documentation, ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Lancer Engine Code: 4G63 (common in base models), 4G94 (in higher trims) Displacement: 2.0L (1997cc) or 2.4L (2351cc) Configuration: Inline 4-cylinder Aspiration: Naturally Aspirated Horsepower Est: 120-165 HP (depending on engine and trim) Torque Est: 130-170 lb-ft (depending on engine and trim) Primary Engine Lancer Evolution Engine Code: 4G63T (evolution variant) Displacement: 2.0L (1997cc) Configuration: Inline 4-cylinder Aspiration: Turbocharged and Intercooled Horsepower Est: 271 HP (for US spec Lancer Evolution VIII) Torque Est: 273 lb-ft (for US spec Lancer Evolution VIII) Fuel System Type: Electronic Fuel Injection (EFI) Required Octane: 87 Octane (Regular Unleaded) for standard Lancer, 91 Octane (Premium Unleaded) recommended for Lancer Evolution. 🔧 Transmission Standard Lancer: 5-speed Manual Transmission (5MT) Lancer Evolution: 6-speed Manual Transmission (GSR models) Optional Lancer: 4-speed Automatic Transmission (4AT) Lancer Evolution: 5-speed Manual Transmission (RS models - Ralliart Sport) or 6-speed Manual (GSR models). Features Evolution AWD System: Symmetrical All-Wheel Drive (SAWC) with Active Center Differential (ACD) and Helical Limited Slip Front Differential. Fluid Specifications Manual Type: GL-4 or GL-5 Gear Oil, 75W-90 viscosity (check specific fill for optimal performance). Fluid Specifications Automatic Type: Dexron III or equivalent ATF. 📐 Dimensions Exterior Lancer Length: Approx. 174.6 inches (Sedan), 177.2 inches (Sportback) Width: Approx. 67.1 inches Height: Approx. 56.7 inches (Sedan), 57.1 inches (Sportback) Exterior Lancer Evolution Length: Approx. 171.1 inches Width: Approx. 69.9 inches Height: Approx. 57.7 inches Wheelbase Lancer: Approx. 103.3 inches Lancer Evolution: Approx. 104.3 inches Cargo Lancer Sportback Volume Seats Up: Approx. 16.4 cu ft Volume Seats Down:...
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2004 Mitsubushi LANCER/LANCER SPORTBACK/LANCER EVOLUTION Service & Repair Manual-PDF
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Model Variant:
Lancer Sportback, Lancer Evolution
Model Year:
2004
Codes
Chassis Codes:
CY (Lancer), CZ (Lancer Evolution)
Vin Prefix:
JMB (Lancer), JMF (Lancer Evolution)
👋 Introduction
Market Position
Segment:
Compact car segment, with the Evolution positioned as a performance-oriented, rally-bred sports sedan.
Competitive Analysis
Competitors Lancer:
Honda Civic, Toyota Corolla, Mazda3, Nissan Sentra.
Competitors Evolution:
Subaru WRX STI, Volkswagen Golf R, Ford Focus RS (though the latter arrived later).
Key Features Lancer
Standard Features:
Reliable commuter car, practical design, available in sedan and hatchback (Sportback) body styles.
Key Features Evolution
Performance Features:
Symmetrical All-Wheel Drive (SAWC), turbocharged engine, active center differential (ACD), limited-slip differentials (LSD), performance suspension, and braking systems.
Manual Value Proposition
For Owners:
Enables owners to perform maintenance, understand diagnostics, and tackle repairs confidently, saving on labor costs.
For Mechanics:
Provides definitive factory specifications, procedures, and troubleshooting guidance for efficient and accurate repairs.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive service and repair for all systems and components.
Specific Models Covered:
2004 Mitsubishi Lancer, 2004 Mitsubishi Lancer Sportback, 2004 Mitsubishi Lancer Evolution
Engine Variants Covered:
All gasoline engines offered for the 2004 model year.
Page Count
Estimated Pages:
Over 1500 pages (typical for comprehensive manuals of this era).
Manual Type
Type:
Official Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, pistons, crankshaft, lubrication system, cooling system.
Engine Performance:
Fuel injection, ignition system, emission control systems, turbocharging (for Evolution).
Transmission Manual:
Manual transmission (5-speed and 6-speed for Evolution) disassembly, assembly, and overhaul.
Transmission Automatic:
Automatic transmission (if applicable) diagnosis and repair.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD - for Evolution) systems, drive shafts, differentials, hub assemblies.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, alignment procedures.
Steering:
Power steering system, steering gear, steering column, diagnosis and repair.
Brakes:
Front and rear brake systems (disc brakes), ABS system, parking brake, hydraulic components.
Electrical System Overview:
Battery, charging system (alternator), starting system (starter motor).
Lighting System:
Headlights, taillights, interior lighting, wiring diagrams.
Instrument Panel And Gauges:
Speedometer, tachometer, warning lights, diagnostic trouble codes (DTCs).
Comfort And Convenience:
HVAC system, power windows, power locks, mirrors, remote keyless entry.
Body And Frame:
Body panel removal and installation, interior trim, exterior trim, doors, hood, trunk lid.
Restraint Systems:
Airbag system diagnosis and service procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections.
Troubleshooting:
Diagnostic flowcharts for common and complex issues, DTC interpretation.
Component Repair And Overhaul:
Detailed step-by-step instructions for disassembling, repairing, and reassembling major components.
Wiring Diagrams:
Complete electrical wiring schematics for all vehicle systems.
Specification Tables:
Torque specifications, clearances, fluid capacities, pressures, and other critical data.
Technical Depth
Depth:
Professional-level repair and diagnostic information, suitable for both experienced technicians and dedicated DIY enthusiasts.
Diagnostic Tools:
Information on using specialized diagnostic tools (e.g., MUT-III) where applicable.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Printability:
Printable pages allowing for physical reference.
Print Quality
Quality:
Digital reproduction of original factory documentation, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine Lancer
Engine Code:
4G63 (common in base models), 4G94 (in higher trims)
Displacement:
2.0L (1997cc) or 2.4L (2351cc)
Configuration:
Inline 4-cylinder
Aspiration:
Naturally Aspirated
Horsepower Est:
120-165 HP (depending on engine and trim)
Torque Est:
130-170 lb-ft (depending on engine and trim)
Primary Engine Lancer Evolution
Engine Code:
4G63T (evolution variant)
Displacement:
2.0L (1997cc)
Configuration:
Inline 4-cylinder
Aspiration:
Turbocharged and Intercooled
Horsepower Est:
271 HP (for US spec Lancer Evolution VIII)
Torque Est:
273 lb-ft (for US spec Lancer Evolution VIII)
Fuel System
Type:
Electronic Fuel Injection (EFI)
Required Octane:
87 Octane (Regular Unleaded) for standard Lancer, 91 Octane (Premium Unleaded) recommended for Lancer Evolution.
🔧 Transmission
Standard
Lancer:
5-speed Manual Transmission (5MT)
Lancer Evolution:
6-speed Manual Transmission (GSR models)
Optional
Lancer:
4-speed Automatic Transmission (4AT)
Lancer Evolution:
5-speed Manual Transmission (RS models - Ralliart Sport) or 6-speed Manual (GSR models).
Features Evolution
AWD System:
Symmetrical All-Wheel Drive (SAWC) with Active Center Differential (ACD) and Helical Limited Slip Front Differential.
Fluid Specifications Manual
Type:
GL-4 or GL-5 Gear Oil, 75W-90 viscosity (check specific fill for optimal performance).
Fluid Specifications Automatic
Type:
Dexron III or equivalent ATF.
📐 Dimensions
Exterior Lancer
Length:
Approx. 174.6 inches (Sedan), 177.2 inches (Sportback)
Width:
Approx. 67.1 inches
Height:
Approx. 56.7 inches (Sedan), 57.1 inches (Sportback)
Exterior Lancer Evolution
Length:
Approx. 171.1 inches
Width:
Approx. 69.9 inches
Height:
Approx. 57.7 inches
Wheelbase
Lancer:
Approx. 103.3 inches
Lancer Evolution:
Approx. 104.3 inches
Cargo Lancer Sportback
Volume Seats Up:
Approx. 16.4 cu ft
Volume Seats Down:
Approx. 41.4 cu ft
Weights
Curb Weight Lancer Est:
Approx. 2700-3000 lbs
Curb Weight Lancer Evolution Est:
Approx. 3300-3500 lbs
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size Standard Lancer:
15-inch or 16-inch steel or alloy wheels
Wheel Size Evolution:
17-inch alloy wheels
🛡️ Safety Features
Ratings
NHTSA Front Impact Lancer:
4 Stars (driver), 4 Stars (passenger) - based on general testing for the generation.
IIHS Side Impact Lancer:
Good (for models equipped with side airbags).
Active Features
ABS:
Standard on most trims, mandatory on Evolution.
Traction Control:
Available on some Lancer models, standard and more advanced on Evolution.
Passive Features
Airbags:
Driver and front passenger airbags standard. Optional side airbags and curtain airbags on some Lancer trims.
Seatbelts:
3-point front and rear seatbelts with pretensioners and load limiters.
Structural Integrity
Reinforced Body:
RISE (Reinforced Impact Safety Evolution) body construction for improved crashworthiness.
💡 Technology Features
Infotainment Lancer
Audio System:
AM/FM stereo with CD player, typically 4 or 6 speakers.
Climate Control:
Manual or automatic climate control (depending on trim level).
Infotainment Lancer Evolution
Audio System Upgrade:
Upgraded Rockford Fosgate audio system available on higher trims.
Driver Assistance Lancer
Cruise Control:
Available on most trims.
Keyless Entry:
Remote keyless entry available.
Driver Assistance Lancer Evolution
Performance Displays:
Gauges for boost pressure, oil temperature (on some models), and ACD mode selection.
Connectivity Lancer
Auxiliary Input:
Not commonly available in 2004 models; aftermarket solutions may exist.
🔧 Maintenance
Service Intervals Lancer
Oil Change:
Every 3,750 miles or 6 months for severe driving, or 7,500 miles or 12 months for normal driving.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plugs Replacement:
Platinum-tipped plugs: 100,000 miles. Standard plugs: 30,000 miles.
Coolant Flush:
Every 30,000 miles or 24 months.
Fluid Specifications
Engine Oil:
API SG or SH, SAE 5W-30 (for most climates). Check owner's manual for specific recommendations.
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with deionized water, 50/50 mix).
Brake Fluid:
DOT 3 or DOT 4 (typically DOT 3 for this era).
Known Issues Lancer
Engine Mounts:
Can degrade over time, leading to vibration and harshness.
Alternator:
Failure can occur, especially with higher mileage vehicles.
Known Issues Lancer Evolution
Clutch Wear:
Aggressive driving can lead to accelerated clutch wear.
Timing Belt Tensioner:
Regular inspection and replacement is crucial to prevent catastrophic engine failure.
Ayc/Acd Pump:
The hydraulic pump for the Active Yaw Control (AYC) or Active Center Differential (ACD) can fail, impacting handling and traction.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Japanese automaker with a long history dating back to 1917, known for automotive manufacturing and diverse industrial interests.
Model Evolution Lancer
Generation Overview:
The 2004 model year represents the 8th generation (CS/CT chassis) of the Mitsubishi Lancer, introduced in 2000.
Model Evolution Lancer Sportback
Body Style Introduction:
The Sportback hatchback variant was introduced as part of this generation, offering increased practicality.
Model Evolution Lancer Evolution
Performance Lineage:
The Lancer Evolution is a highly acclaimed performance variant derived from the Lancer platform, originally built for Group A rallying homologation.
Specific Variant:
The 2004 model year corresponds to the Lancer Evolution VIII (CT9A chassis) in most markets.
Production
Manufacturing Location:
Primary production in Japan (Mizushima Plant).
Production Years Generation
8Th Gen Lancer:
2000-2007 (with facelifts in 2003 and 2005).
🏆 Awards & Recognition
Recognitions Lancer
General Reputation:
Praised for value and reliability within its segment.
Recognitions Lancer Evolution
Performance Accolades:
Consistently ranked among the top performance compacts by automotive publications for its handling and powertrain.
Rally Heritage:
Strong ties to World Rally Championship (WRC) success, contributing to its performance image.
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