🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer

Year:

2004

Chassis Code:

CS_A (North America/Australia), CS_X (Europe/Asia)

👋 Introduction

Segment:

Compact Sedan/Hatchback

Target Audience:

Budget-conscious consumers, young drivers, economy-focused individuals.

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Mazda3, Nissan Sentra, Hyundai Elantra.

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

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

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.

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.

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:

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)

Image Resolution:

Variable, but typically sufficient for clear viewing of diagrams and text.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

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:

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

Fuel Type:

Unleaded Gasoline

Emission Control:

Multi-Point Fuel Injection (MPI), Catalytic Converter

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Tank Capacity:

50 Liters (approx. 13.2 US gallons)

🔧 Transmission

Transmission Type Standard:

5-Speed Manual

Transmission Type Optional:

4-Speed Automatic (INVECS-II)

Automatic Transmission Features:

Sportronic (manual shift mode on some variants), adaptive shift control.

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

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

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

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)

ABS:

Optional on most trims, standard on some higher trims.

Traction Control:

Rarely equipped on this generation.

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

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.

Cruise Control:

Available on LS, GTS, and higher trims.

Aux Input:

Not standard; aftermarket solutions likely required for modern device connectivity.

🔧 Maintenance

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.

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)

Common Issues Engine:

Oil consumption (especially on higher mileage 4G94 engines), occasional O2 sensor failures, thermostat issues.

Common Issues Transmission:

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 Origin:

Mitsubishi Motors Corporation, Japan.

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 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

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.