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Mitsubishi Lancer 2004 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2004 Codes Platform Code: CS/CT 👋 Introduction Market Position Segment: Compact Car / Economy Sedan Target Audience: Budget-conscious consumers, first-time car buyers, small families. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Mazda3, Nissan Sentra. Key Features Value Proposition: Affordable pricing, reliable mechanicals, decent fuel economy, available AWD (on some variants). Trim Levels Overview: ES, LS, GTS, OZ Rally, SE (Varies by market). 📋 Manual Details Coverage Areas Regions Covered: Global (specific regional variations may exist but core repair procedures are universal) Page Count Estimated Pages: 1500-2000+ Manual Type Type: Service Repair Manual (SRM) / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, timing belt replacement, fuel injection systems, ignition systems, cooling system, lubrication system, emissions control. Transmission: Manual (5-speed) and Automatic (4-speed INVECS-II) transmission service, repair, diagnostics, fluid changes, clutch service, torque converter, valve body operation. Drivetrain: Front-wheel drive (FWD) and All-Wheel Drive (AWD) systems, differential service, CV joints, driveshafts, transfer case (if applicable to AWD models). Suspension: Front MacPherson struts, rear multi-link suspension, coil springs, shock absorbers, control arms, bushings, wheel alignment procedures and specifications. Steering: Power steering system diagnostics and repair, steering rack, tie rods, power steering pump, fluid specifications. Brakes: Front disc brakes, rear drum or disc brakes, ABS system diagnostics, brake fluid specifications, bleeding procedures, rotor and pad replacement, parking brake. Electrical: Comprehensive wiring diagrams for all circuits, starter, alternator, battery, lighting systems, power windows, power locks, interior and exterior electronics, fuses, relays, ECUs. HVAC: Air conditioning system service, refrigerant, compressor, evaporator, condenser, heater core, blower motor, climate control module. Body And Chassis: Body panel removal and installation, interior trim, glass replacement, door mechanisms, chassis specifications, corrosion protection. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement. Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides for common problems, electrical system diagnosis. Repair: Detailed step-by-step repair procedures for all major components and systems, including torque specifications and special tool requirements. Disassembly And Assembly: Complete instructions for dismantling and reassembling engines, transmissions, suspension components, and body parts. Diagnostics: On-board diagnostics (OBD-II) system explanation, diagnostic tool usage, sensor data interpretation. Technical Depth Depth: Comprehensive (covers everything from basic fluid changes to complete engine and transmission rebuilds). 📊 Manual Specifications File Format Quality: High-resolution scans, searchable text (OCR'd where possible), printable pages. Print Quality Printability: Designed for printing key sections or entire manual. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 4G15 (1.5L SOHC) Displacement 1: 1468 cc Horsepower 1: 92 hp @ 5500 rpm Torque 1: 130 Nm @ 3500 rpm Engine Code 2: 4G19 (1.6L SOHC/DOHC) Displacement 2: 1584 cc Horsepower 2: 99 - 105 hp @ 5800-6000 rpm Torque 2: 137 - 143 Nm @ 3000-4000 rpm Engine Code 3: 4G63 (2.0L SOHC/DOHC - Naturally Aspirated) Displacement 3: 1997 cc Horsepower 3: 114 - 135 hp @ 5000-6000 rpm Torque 3: 170 - 176 Nm @ 4000-4500 rpm Engine Code 4: 4G63T (2.0L DOHC Turbocharged - Ralliart/Evolution variants) Displacement 4: 1997 cc Horsepower 4: 261 hp @ 6500 rpm (Ralliart), 271 hp @ 6500 rpm (Evo VIII) Torque 4: 343 Nm @ 3500 rpm (Ralliart), 370 Nm @ 3000 rpm (Evo VIII) Performance Fuel Type: Unleaded Gasoline Fuel System Injection Type: Multi-point Fuel Injection (MPI) Ignition System: Electronic ignition with coil-on-plug (COP) or distributor-based systems (depending on engine variant). Engine Management ECU Type: Engine Control Unit (ECU) specific to engine and transmission configuration. 🔧 Transmission Standard Type 1: 5-speed Manual Transmission Optional Type 2: 4-speed Automatic Transmission (INVECS-II with Sport Mode) Features AWD System: Active Center Differential (ACD) with mechanical Limited-Slip Differential (LSD) on Evolution models; viscous coupling AWD on some Ralliart variants. Fluid Specifications Manual Trans Fluid: API GL-3 or GL-4 SAE 75W-85 gear oil. Consult manual for specific Mitsubishi recommendations (e.g., DiaQueen). Automatic Trans Fluid: Mitsubishi DiaQueen SPIII (or equivalent Dexron III/Mercon). 📐 Dimensions Exterior Wheelbase: 2630 mm (103.5 in) Length: 4480 - 4490 mm (176.4 - 176.8 in) Width: 1740 mm (68.5 in) Height: 1445 - 1470 mm (56.9 - 57.9 in) Weights Curb Weight: 1150 - 1450 kg (approx.) Gross Vehicle Weight: Varies by model and configuration. Wheels And Tires Bolt Pattern: 4x100 (most models), 5x114.3 (Performance/AWD variants) Typical Tire Sizes: 185/65R14, 195/60R15, 205/50R16, 235/45R17 (Evo VIII). 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated by NHTSA for 2004 in all configurations, but generally considered good for its class. IIHS Ratings: Similar to NHTSA, specific ratings may vary. Generally good for its era. Active Features ABS: Available (standard on higher trims and performance models). Traction Control: Available (often linked with AWD systems or...
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Mitsubishi Lancer 2004 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Year:
2004
Codes
Platform Code:
CS/CT
👋 Introduction
Market Position
Segment:
Compact Car / Economy Sedan
Target Audience:
Budget-conscious consumers, first-time car buyers, small families.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Mazda3, Nissan Sentra.
Key Features
Value Proposition:
Affordable pricing, reliable mechanicals, decent fuel economy, available AWD (on some variants).
Trim Levels Overview:
ES, LS, GTS, OZ Rally, SE (Varies by market).
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specific regional variations may exist but core repair procedures are universal)
Page Count
Estimated Pages:
1500-2000+
Manual Type
Type:
Service Repair Manual (SRM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, timing belt replacement, fuel injection systems, ignition systems, cooling system, lubrication system, emissions control.
Transmission:
Manual (5-speed) and Automatic (4-speed INVECS-II) transmission service, repair, diagnostics, fluid changes, clutch service, torque converter, valve body operation.
Drivetrain:
Front-wheel drive (FWD) and All-Wheel Drive (AWD) systems, differential service, CV joints, driveshafts, transfer case (if applicable to AWD models).
Suspension:
Front MacPherson struts, rear multi-link suspension, coil springs, shock absorbers, control arms, bushings, wheel alignment procedures and specifications.
Steering:
Power steering system diagnostics and repair, steering rack, tie rods, power steering pump, fluid specifications.
Brakes:
Front disc brakes, rear drum or disc brakes, ABS system diagnostics, brake fluid specifications, bleeding procedures, rotor and pad replacement, parking brake.
Electrical:
Comprehensive wiring diagrams for all circuits, starter, alternator, battery, lighting systems, power windows, power locks, interior and exterior electronics, fuses, relays, ECUs.
HVAC:
Air conditioning system service, refrigerant, compressor, evaporator, condenser, heater core, blower motor, climate control module.
Body And Chassis:
Body panel removal and installation, interior trim, glass replacement, door mechanisms, chassis specifications, corrosion protection.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides for common problems, electrical system diagnosis.
Repair:
Detailed step-by-step repair procedures for all major components and systems, including torque specifications and special tool requirements.
Disassembly And Assembly:
Complete instructions for dismantling and reassembling engines, transmissions, suspension components, and body parts.
Diagnostics:
On-board diagnostics (OBD-II) system explanation, diagnostic tool usage, sensor data interpretation.
Technical Depth
Depth:
Comprehensive (covers everything from basic fluid changes to complete engine and transmission rebuilds).
📊 Manual Specifications
File Format
Quality:
High-resolution scans, searchable text (OCR'd where possible), printable pages.
Print Quality
Printability:
Designed for printing key sections or entire manual.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4G15 (1.5L SOHC)
Displacement 1:
1468 cc
Horsepower 1:
92 hp @ 5500 rpm
Torque 1:
130 Nm @ 3500 rpm
Engine Code 2:
4G19 (1.6L SOHC/DOHC)
Displacement 2:
1584 cc
Horsepower 2:
99 - 105 hp @ 5800-6000 rpm
Torque 2:
137 - 143 Nm @ 3000-4000 rpm
Engine Code 3:
4G63 (2.0L SOHC/DOHC - Naturally Aspirated)
Displacement 3:
1997 cc
Horsepower 3:
114 - 135 hp @ 5000-6000 rpm
Torque 3:
170 - 176 Nm @ 4000-4500 rpm
Engine Code 4:
4G63T (2.0L DOHC Turbocharged - Ralliart/Evolution variants)
Displacement 4:
1997 cc
Horsepower 4:
261 hp @ 6500 rpm (Ralliart), 271 hp @ 6500 rpm (Evo VIII)
Torque 4:
343 Nm @ 3500 rpm (Ralliart), 370 Nm @ 3000 rpm (Evo VIII)
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Ignition System:
Electronic ignition with coil-on-plug (COP) or distributor-based systems (depending on engine variant).
Engine Management
ECU Type:
Engine Control Unit (ECU) specific to engine and transmission configuration.
🔧 Transmission
Standard
Type 1:
5-speed Manual Transmission
Optional
Type 2:
4-speed Automatic Transmission (INVECS-II with Sport Mode)
Features
AWD System:
Active Center Differential (ACD) with mechanical Limited-Slip Differential (LSD) on Evolution models; viscous coupling AWD on some Ralliart variants.
Fluid Specifications
Manual Trans Fluid:
API GL-3 or GL-4 SAE 75W-85 gear oil. Consult manual for specific Mitsubishi recommendations (e.g., DiaQueen).
Automatic Trans Fluid:
Mitsubishi DiaQueen SPIII (or equivalent Dexron III/Mercon).
📐 Dimensions
Exterior
Wheelbase:
2630 mm (103.5 in)
Length:
4480 - 4490 mm (176.4 - 176.8 in)
Width:
1740 mm (68.5 in)
Height:
1445 - 1470 mm (56.9 - 57.9 in)
Weights
Curb Weight:
1150 - 1450 kg (approx.)
Gross Vehicle Weight:
Varies by model and configuration.
Wheels And Tires
Bolt Pattern:
4x100 (most models), 5x114.3 (Performance/AWD variants)
Typical Tire Sizes:
185/65R14, 195/60R15, 205/50R16, 235/45R17 (Evo VIII).
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated by NHTSA for 2004 in all configurations, but generally considered good for its class.
IIHS Ratings:
Similar to NHTSA, specific ratings may vary. Generally good for its era.
Active Features
ABS:
Available (standard on higher trims and performance models).
Traction Control:
Available (often linked with AWD systems or higher trim levels).
Passive Features
Airbags:
Front airbags standard, side airbags available on select models.
Seatbelts:
3-point height-adjustable front seatbelts with pre-tensioners.
Body Structure:
Reinforced Impact Safety Evolution (RISE) body construction for improved crashworthiness.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, with available premium sound systems and CD changers on higher trims.
Navigation:
Optional factory navigation system available on select models and markets.
Driver Assistance
Cruise Control:
Available on most trim levels.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors standard on mid to high trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first. Consult manual for specific driving conditions.
Engine Coolant Flush:
Every 30,000 - 45,000 miles (48,000 - 72,000 km) or 2-3 years.
Transmission Fluid Change:
Manual: Check level regularly, replacement less frequent but recommended every 60,000-100,000 miles. Automatic: Every 30,000-60,000 miles depending on use.
Spark Plug Replacement:
100,000 miles for iridium plugs, potentially sooner for conventional plugs (refer to engine type).
Timing Belt Replacement:
Crucial for interference engines (e.g., 4G63). Typically 60,000 - 90,000 miles or 5-7 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 synthetic or semi-synthetic oil meeting API SL or SN specifications. Check manual for specific viscosity and API rating.
Engine Oil Capacity:
Approx. 4.0-4.5 liters (4.2-4.8 US quarts) with filter, depending on engine.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent Ethylene Glycol based coolant with a 50/50 mix with deionized water.
Known Issues
Engine:
Timing belt failure (if not replaced on schedule), oil consumption on higher mileage units, minor oil leaks from valve cover gaskets.
Suspension:
Worn control arm bushings, premature strut wear, occasional rattling from rear suspension components.
Electrical:
Window regulator failures, intermittent power window issues, dashboard warning light illumination (often sensor related).
Exhaust:
Rusting exhaust components over time.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer, has a long history dating back to 1917, known for robust engineering and rally heritage.
Model Evolution
Lancer Generations:
The 2004 Lancer is part of the 8th generation (CS/CT platform, 2000-2007) of the Lancer lineage, which began in 1973.
Evolution Variant:
The Lancer Evolution VIII (CT9A chassis) represents a high-performance variant, renowned for its motorsport success in the World Rally Championship (WRC).
Production
Manufacturing Locations:
Primarily Japan, with assembly also occurring in other countries depending on the market.
Production Years For Cs Ct Platform:
2000-2007
🏆 Awards & Recognition
Recognitions
Performance Awards:
Lancer Evolution models are highly acclaimed for their rally heritage and performance credentials, often winning performance tests and comparisons.
Value Awards:
The standard Lancer models have often been recognized for their affordability and value for money in the compact car segment.
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