2004 Mitsubishi Lancer/Lancer Sportback/Lancer Evolution Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Variant: Lancer Sportback, Lancer Evolution Model Year: 2004 Codes Chassis Codes: CSA (Lancer), CSX (Evolution) 👋 Introduction Market Position Segment: Compact...

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UGS: 532607

Mots clés: 2004 Car Cars Lancer Lancer Evolution Lancer Sportback Misc Mitsubishi

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Model Variant:

Lancer Sportback, Lancer Evolution

Model Year:

Codes

Chassis Codes:

CSA (Lancer), CSX (Evolution)

👋 Introduction

Market Position

Segment:

Compact sedan and hatchback (Lancer), Performance compact sedan (Lancer Evolution)

Competitive Analysis

Competitors:

For Lancer: Honda Civic, Toyota Corolla, Mazda3, Ford Focus. For Lancer Evolution: Subaru WRX STI, Volkswagen Golf R, Audi S3.

Key Features

Lancer Attributes:

Reliability, fuel efficiency, practicality, affordable performance options.

Lancer Evolution Attributes:

All-wheel drive (AWD) with Active Center Differential (ACD), turbocharged engines, advanced suspension, performance-oriented chassis, rally heritage.

Manual Value Proposition

User Benefit:

Enables DIY maintenance, diagnostics, and repairs, saving costs and maximizing vehicle uptime.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (may vary slightly by specific market; manual typically covers common international specifications)

Page Count

Estimated Page Count:

Extensive, likely 1500+ pages (typical for a complete service manual covering multiple variants)

Manual Type

Type:

Complete Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, emissions control, exhaust system, cooling system, lubrication system

Transmission Drivetrain:

Manual transmission, Automatic transmission, Clutch system, Drive shafts, Axles, Differentials (including ACD for Evolution)

Chassis Suspension Steering:

Front suspension, Rear suspension, Shock absorbers, Springs, Steering system, Power steering

Brakes:

Front brakes, Rear brakes, Parking brake, Anti-lock Braking System (ABS), Brake fluid specifications

Electrical Electronics:

Battery, Charging system, Starting system, Lighting system, Gauges and instruments, Wiper/washer system, Power windows, Central locking, Audio system, ECU, Powertrain Control Module (PCM), Body Control Module (BCM)

Body Chassis:

Body construction, Exterior panels, Doors, Hood, Trunk lid, Bumpers, Interior trim, Seating systems, Glass and seals

Heating Ventilation Air Conditioning:

HVAC system, Air conditioning (A/C) compressor, Refrigerant, Blower motor, Controls, Cabin filter

Procedures Included

Maintenance:

Routine checks, Oil changes, Filter replacements, Spark plug replacement, Fluid level checks and top-offs

Troubleshooting:

Diagnostic procedures for various systems, Fault code interpretation (OBD-II), Symptom-based troubleshooting guides

Repair Rebuild:

Engine overhaul, Transmission repair/rebuild, Brake caliper replacement, Suspension component replacement, Electrical component diagnosis and replacement

Installation Replacement:

Component replacement (e.g., alternator, starter, fuel pump), Accessory installation guidance

Specifications Data:

Torque specifications, Gapping procedures, Alignment specifications, Electrical diagrams, Component data

Technical Depth

Depth:

Comprehensive (covers basic maintenance to full mechanical and electrical system overhauls and diagnostics)

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely searchable text-based PDF for efficient information retrieval

Print Quality

Printability:

Printable pages for workshop use

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine Lancer

Engine Code Lancer:

4G64 (2.4L)

Engine Type Lancer:

Inline-4, SOHC, 16-valve

Displacement Lancer:

2351 cc (2.4 Liters)

Horsepower Lancer:

Approx. 135-160 hp (depending on specific market/tune)

Torque Lancer:

Approx. 145-155 lb-ft (depending on specific market/tune)

Lancer Evolution Engine

Engine Code Evolution:

4G63T

Engine Type Evolution:

Inline-4, DOHC, 16-valve, Turbocharged and Intercooled

Displacement Evolution:

1997 cc (2.0 Liters)

Horsepower Evolution:

Approx. 270-285 hp (depending on Evolution VII/VIII/IX specifications)

Torque Evolution:

Approx. 255-275 lb-ft (depending on Evolution VII/VIII/IX specifications)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

Unleaded gasoline (87 octane for Lancer, 91+ octane for Lancer Evolution)

Performance

Acceleration 0 60 Lancer:

Approx. 8.5-9.5 seconds

Acceleration 0 60 Evolution:

Approx. 4.5-5.5 seconds

🔧 Transmission

Standard Lancer

Type Lancer:

5-speed Manual

Optional Lancer

Type Lancer:

4-speed Automatic

Standard Evolution

Type Evolution:

5-speed Manual (Early) / 6-speed Manual (Later Evolution models)

Optional Evolution

Type Evolution:

Limited availability of automatic transmissions in certain markets/trims for Evolution models.

Features

Evolution Drivetrain:

All-Wheel Drive (AWD) with Active Center Differential (ACD), front helical limited-slip differential (LSD), rear mechanical LSD (on most performance variants).

📐 Dimensions

Exterior

Length:

Approx. 4475-4625 mm (Lancer Sedan), Approx. 4300-4350 mm (Lancer Sportback), Approx. 4360-4430 mm (Lancer Evolution, depending on wing/body kit)

Width:

Approx. 1740-1770 mm

Height:

Approx. 1415-1445 mm (Lancer Sedan/Sportback), Approx. 1450-1490 mm (Lancer Evolution)

Wheelbase:

Approx. 2630-2635 mm

Weights

Curb Weight:

Approx. 1300-1450 kg (Lancer), Approx. 1450-1550 kg (Lancer Evolution)

Cargo

Trunk Capacity:

Approx. 390-420 Liters (Lancer Sedan), Approx. 340-370 Liters (Lancer Sportback)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Driver:

Good (for 2004 Lancer models, typically)

NHTSA Front Crash Test Passenger:

Good (for 2004 Lancer models, typically)

IIHS Frontal Offset:

Good (for 2004 Lancer models, typically)

Active Features

Standard on most trims, enhanced on Evolution.

Traction Control:

Available on select Lancer trims, standard and advanced on Evolution (e.g., AYC - Active Yaw Control).

Electronic Stability Control:

Available on some later models or specific trims, less common on early 2004 models.

Passive Features

Airbags:

Frontal airbags standard, side airbags and curtain airbags available on higher trims.

Seatbelts:

3-point seatbelts with pretensioners and load limiters.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium audio systems with more speakers.

Display Screen:

Basic digital display for clock/radio, no large central touchscreens on most models.

Driver Assistance

Cruise Control:

Available on many Lancer trims, standard on Evolution.

Keyless Entry:

Available on higher trims.

Connectivity

Bluetooth:

Rarely standard for 2004, likely an aftermarket addition.

Aux Input:

Rarely standard for 2004, likely an aftermarket addition.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. For Evolution, more frequent changes may be recommended, especially under spirited driving.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Every 60,000-100,000 miles (96,000-160,000 km) for standard ignition, potentially less for performance plugs in Evolution.

Timing Belt Replacement:

Every 60,000-105,000 miles (96,000-168,000 km) or 7 years, depending on engine (4G64 usually uses a belt, 4G63T uses a belt). Crucial for 4G63T as it's an interference engine.

Fluid Specifications

Engine Oil Specification:

API SM/SN, ILSAC GF-4/GF-5. Viscosity: 5W-30 or 5W-40 (depending on climate and engine). Consult manual for specific recommendations.

Coolant Specification:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol based coolant with deionized water, typically a 50/50 mix). Check manual for color/type.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 or 75W-85.

Transmission Fluid Automatic:

Mitsubishi DiaQueen SP III Automatic Transmission Fluid (or equivalent Dexron III/Mercon compatible fluid). Check manual for precise type.

Brake Fluid Specification:

DOT 3 or DOT 4.

Known Issues

Engine 4G64:

Occasional oil consumption, potential PCV valve issues.

Engine 4G63T:

Head gasket failures (especially if modified or poorly maintained), turbocharger wear, piston ring land failure (on high mileage or heavily modified engines).

Suspension Steering:

Worn control arm bushings, ball joints, and tie rod ends over time; potential for strut leaks.

Transmission Clutch:

Clutch wear (especially in performance models); transmission synchro wear on manual transmissions.

Electrical:

Alternator failure, window regulator issues, minor sensor failures.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mitsubishi Motors Corporation (Japan)

Model Evolution

Generation:

Seventh Generation Lancer (CS/CT platform), with Evolution VII/VIII/IX variants derived from this platform.

Production Period:

2000-2007 (CS platform)

Production

Manufacturing Locations:

Japan, Australia, USA (for specific models/assembly plants)

Evolution Significance:

The Lancer Evolution is a legendary homologation special derived from rally racing, renowned for its performance and technology.

🏆 Awards & Recognition

Recognitions

Lancer Evolution Awards:

Consistently praised by automotive media for its handling, performance, and value in the performance compact segment. Often featured in 'Best Performance Cars' lists.

Lancer Awards:

Received positive reviews for affordability, reliability, and practicality in its class.

Certifications

Emissions Certification:

Meets EPA and CARB emissions standards for the model year.