🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2004 Codes Chassis Code: CS_A (North America/Australia), CS_X (Europe/Asia) 👋 Introduction Market Position Segment: Compact Sedan/Hatchback Target Audience: Budget-conscious consumers, young drivers, economy-focused individuals. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Mazda3, Nissan Sentra, Hyundai Elantra. Key Features Platform: Mitsubishi's 'Project Global' platform, shared with other contemporary Mitsubishi models. Drivetrain Options: Primarily Front-Wheel Drive (FWD), with some markets offering All-Wheel Drive (AWD) as an option (often on higher trims or performance variants). Trim Levels: ES (base), LS, OZ Rally Edition (sporty trim), GTS, SE, Ralliart (performance-oriented). 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: RAR/PDF (Downloadable) Primary Market: North America, Europe, Asia (depending on specific model variant covered) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, component replacement for 4G9 series engines (4G93, 4G94) and potentially 4G1 series (4G18) depending on region. Engine Electrical: Ignition system, fuel injection system (MPI), starting and charging system, ECU diagnosis, sensor data. Transmission Manual: Clutch system, gearbox disassembly/assembly, gear shift mechanism, fluid specifications. Transmission Automatic: Torque converter operation, valve body diagnosis, planetary gear sets, electronic control, fluid specifications. Drivetrain: Front-wheel drive (FWD) and all-wheel drive (AWD) system (if applicable for specific variants), drive shafts, CV joints, differential. Suspension: Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, sway bars, alignment specifications. Steering: Power steering system (hydraulic or electric depending on trim), steering rack, tie rods, steering column. Brakes: Front and rear disc brakes, ABS system (if equipped), brake fluid type, bleeding procedures, component replacement (pads, rotors, calipers). Body And Chassis: Body panel removal/installation, door mechanisms, interior trim, underbody components, frame specifications. HVAC: Air conditioning system, heater core, blower motor, climate control panel, refrigerant type and capacity. Electrical Accessories: Lighting system, power windows, central locking, wipers, horn, mirrors, fuses and relays. Dashboard And Instruments: Instrument cluster removal/installation, warning lights, gauge operation. Safety Systems: Airbag system (SRS) diagnosis and component replacement (cautionary notes will be prominent), seatbelt mechanisms. Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacements. Diagnostic Procedures: Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams for electrical system diagnosis. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for all major systems. Rebuild Procedures: Detailed instructions for engine and transmission major overhauls, including torque specifications and clearances. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, including ABS, SRS, ECU, lighting, and accessories. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagnostics Level: Advanced, including OE-level diagnostic procedures and potential use of scan tools (though not explicitly for specific scan tool models). 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely searchable text within the PDF (depends on scan quality) Printability: Printable pages Compression: RAR (WinRAR or compatible unarchiver required) Print Quality Image Resolution: Variable, but typically sufficient for clear viewing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: 4G94 Engine Type 1: Inline-4, SOHC, 16-valve Displacement 1: 2.0 Liters (1997 cc) Bore X Stroke 1: 86.0 mm x 86.0 mm Compression Ratio 1: 9.5:1 Horsepower 1: 120-135 hp @ 5500-6000 rpm (varies by market and trim) Torque 1: 131-135 lb-ft @ 4000 rpm (varies by market and trim) Engine Code 2 Engine Code 2: 4G93 Engine Type 2: Inline-4, DOHC, 16-valve, MIVEC (on some performance variants) Displacement 2: 1.8 Liters (1834 cc) Horsepower 2: 135-150 hp (with MIVEC) Torque 2: 122-127 lb-ft Performance Fuel Type: Unleaded Gasoline Emission Control: Multi-Point Fuel Injection (MPI), Catalytic Converter Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Tank Capacity: 50 Liters (approx. 13.2 US gallons) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Optional Transmission Type Optional: 4-Speed Automatic (INVECS-II) Features Automatic Transmission Features: Sportronic (manual shift mode on some variants), adaptive shift control. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (refer to manual for exact specification) Automatic Transmission Fluid: Diamond SP-III or equivalent (refer to manual for exact specification) 📐 Dimensions Exterior Length: 4495 mm (Sedan) / 4150 mm (Hatchback) Width: 1740 mm Height: 1445 mm (Sedan) / 1420 mm (Hatchback) Wheelbase: 2630 mm Ground Clearance: Approx. 150 mm Weights Curb Weight Min: Approx. 1250 kg (depending on trim and drivetrain) Gross Vehicle Weight: Varies by model/trim, refer to manual Towing Capacity: Not specified/recommended for most variants. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (2004 model year, specific test results may vary) NHTSA Front Impact Passenger: Good (2004 model year, specific test results may vary) IIHS Side Impact Driver: Acceptable (2004 model year, specific test results may vary) IIHS Side Impact Rear Passenger: Acceptable (2004 model year,...
Sportronic (manual shift mode on some variants), adaptive shift control.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (refer to manual for exact specification)
Automatic Transmission Fluid:
Diamond SP-III or equivalent (refer to manual for exact specification)
📐 Dimensions
Exterior
Length:
4495 mm (Sedan) / 4150 mm (Hatchback)
Width:
1740 mm
Height:
1445 mm (Sedan) / 1420 mm (Hatchback)
Wheelbase:
2630 mm
Ground Clearance:
Approx. 150 mm
Weights
Curb Weight Min:
Approx. 1250 kg (depending on trim and drivetrain)
Gross Vehicle Weight:
Varies by model/trim, refer to manual
Towing Capacity:
Not specified/recommended for most variants.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (2004 model year, specific test results may vary)
NHTSA Front Impact Passenger:
Good (2004 model year, specific test results may vary)
IIHS Side Impact Driver:
Acceptable (2004 model year, specific test results may vary)
IIHS Side Impact Rear Passenger:
Acceptable (2004 model year, specific test results may vary)
IIHS Roof Strength:
Acceptable (2004 model year, specific test results may vary)
Active Features
ABS:
Optional on most trims, standard on some higher trims.
Traction Control:
Rarely equipped on this generation.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags optional on some trims.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters for front occupants.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player with 4 or 6 speakers depending on trim. Premium Rockford Fosgate audio system available on some higher trims.
Navigation:
Not typically offered from the factory on this generation of Lancer.
Driver Assistance
Cruise Control:
Available on LS, GTS, and higher trims.
Connectivity
Aux Input:
Not standard; aftermarket solutions likely required for modern device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6 months, depending on driving conditions (refer to manual for exact recommendation).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually.
Spark Plug Replacement:
Every 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium-tipped plugs (refer to manual for specific type).
Timing Belt Replacement:
For engines with a timing belt (e.g., 4G18), typically every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years. **Note:** The 4G94 engine uses a timing chain, which is generally maintenance-free unless internal issues arise.
Fluid Specifications
Engine Oil Type:
API SM/SN or ILSAC GF-4/GF-5, SAE 5W-30 or 10W-30 (check manual for specific viscosity and API rating).
Coolant Type:
Mitsubishi Genuine Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based, OAT (Organic Acid Technology) type, pre-diluted.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification)
Automatic transmission 'flare' or hesitant shifting (potential solenoid or valve body issues), clutch wear in manual transmissions.
Common Issues Suspension:
Worn front control arm bushings, noisy sway bar links, premature rear shock absorber failure on some models.
Common Issues Electrical:
Power window regulators failing, dashboard illumination issues, blower motor resistor failure.
Common Issues Body:
Rust on wheel arches and rocker panels, especially in areas with road salt.
📚 Vehicle History
Brand Heritage
Brand Origin:
Mitsubishi Motors Corporation, Japan.
Model Evolution
Generation Timeline:
The 2004 Lancer is part of the seventh generation (CS/CT) Lancer family, which debuted globally in late 2000. This generation saw significant redesign and platform updates compared to its predecessors.
Performance Variants:
This generation introduced the Lancer Ralliart, a more performance-oriented model, and the highly sought-after Lancer Evolution (Evo VII), though the latter is a separate model and not covered by this specific service manual for the standard Lancer.
Production
Production Years:
2002-2007 (for the CS generation in North America, with facelifts occurring).
Manufacturing Locations:
Primarily Mizushima Plant, Kurashiki, Okayama, Japan; also produced in other Mitsubishi global facilities.
🏆 Awards & Recognition
Recognitions
Year Award 1:
2004
Award Name 1:
Car and Driver - 10Best (The Lancer Evolution, not this standard model, was a frequent recipient, highlighting the performance lineage.)
Year Award 2:
2004
Award Name 2:
Insurance Institute for Highway Safety (IIHS) Top Safety Pick for some configurations, indicating good crash test performance for its class.
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