Mitsubishi Lancer Workshop Service Repair Manual 2004 (5 000+ Pages 254MB Searchable Bookmarked iPad-ready)

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2004 Codes Chassis Code: CS (Global platform) Engine Code Common Gasoline: 4G15 (1.5L I4 SOHC) Engine Code Common Gasoline Performance: 4G63...

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Type: Car

Vendor:

Sku: 317206

Tags: 2004 Car Cars Lancer Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Year:

Codes

Chassis Code:

CS (Global platform)

Engine Code Common Gasoline:

4G15 (1.5L I4 SOHC)

Engine Code Common Gasoline Performance:

4G63 (2.0L I4 SOHC/DOHC)

Engine Code Common Diesel:

4D68 (2.0L I4 SOHC Diesel)

👋 Introduction

Market Position

Market Segment:

Compact car, often positioned as an affordable and reliable option with sporty variants.

Competitive Analysis

Competitors 2004:

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

Key Features Vehicle

Platform:

Global platform shared with other Mitsubishi models, known for its robustness.

Performance Variants:

The Lancer platform has a strong heritage in performance, with variants like the Ralliart and the legendary Lancer Evolution (though the 2004 Evo is likely a separate manual).

Manual Value Proposition

Target Audience:

Mitsubishi Lancer owners, independent repair shops, automotive technicians, and DIY mechanics.

Benefit To Owner:

Enables owners to perform routine maintenance and repairs, understand vehicle systems, and potentially save on repair costs.

Benefit To Technician:

Provides official factory specifications, procedures, and diagnostic information for accurate and efficient repairs.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive factory service and repair procedures for the 2004 Mitsubishi Lancer.

Page Count

Page Count:

5000+

Manual Type

Manual Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Digital PDF

Features

Searchable:

Bookmarked:

Ipad Ready:

Printable:

File Size

File Size Mb:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, component inspection, timing belt/chain, seals, gaskets, lubrication.

Fuel System:

Fuel pump, injectors, lines, fuel tank, evaporative emissions (EVAP) system.

Cooling System:

Radiator, water pump, thermostat, hoses, fan operation, coolant specifications.

Ignition System:

Spark plugs, coils, ignition timing, sensors (crankshaft, camshaft position).

Exhaust System:

Manifolds, catalytic converter, mufflers, pipes, O2 sensors.

Transmission Manual:

Clutch, gearbox overhaul, shift linkage, bearings, seals, fluid specifications.

Transmission Automatic:

Torque converter, planetary gears, valve body, solenoids, fluid specifications, control modules.

Drivetrain:

Driveshafts, CV joints, differential, wheel bearings, hub assemblies.

Suspension Front:

Struts, control arms, ball joints, bushings, sway bar, alignment specifications.

Suspension Rear:

Shock absorbers, trailing arms, control links, bushings, alignment specifications.

Steering System:

Power steering pump, rack and pinion, tie rods, steering column, fluid.

Brake System Hydraulic:

Master cylinder, brake lines, calipers, wheel cylinders, brake fluid specifications.

Brake System Parking:

Cable operation, mechanism, adjustment.

Wheels And Tires:

Tire pressures, rotation, wheel installation, bolt patterns.

Body Exterior:

Panels, doors, hood, trunk, bumpers, trim, glass, sunroof.

Body Interior:

Seats, dashboard, trim panels, HVAC controls, sound deadening.

HVAC System:

Blower motor, evaporator, condenser, refrigerant, controls, ducting.

Electrical System Charging:

Alternator, battery, charging circuit diagnostics.

Electrical System Starting:

Starter motor, ignition switch, wiring.

Lighting System:

Headlights, taillights, interior lights, fuses, relays, bulbs.

Instrument Panel:

Gauges, warning lights, indicators, driver information display.

Audio System:

Radio, speakers, antenna, wiring.

Power Accessories:

Power windows, locks, mirrors, seats, sunroof, wiper motors.

ECU ECM:

Engine Control Unit (ECU) / Powertrain Control Module (PCM) diagnostics, sensor inputs, actuator outputs, wiring diagrams.

ABS System:

Anti-lock Braking System components, sensors, hydraulic unit, diagnostics.

Srs Airbag System:

Airbag modules, sensors, control unit, seatbelt pre-tensioners, diagnostics.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad/rotor replacement.

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation, wiring schematics for fault finding.

Repair Major Engine:

Engine removal and installation, cylinder head service, piston and connecting rod service, crankshaft service, timing component replacement.

Repair Major Transmission:

Transmission removal and installation, clutch replacement, internal transmission component repair (manual and automatic).

Repair Brakes:

Brake caliper overhaul, master cylinder replacement, brake line repair, ABS component replacement.

Repair Suspension:

Component replacement (struts, shocks, ball joints, bushings), suspension alignment procedures and specifications.

Repair Steering:

Power steering pump replacement, rack and pinion overhaul/replacement, tie rod end replacement.

Repair Electrical:

Component replacement (alternator, starter, sensors), wiring harness repair, diagnostic connector usage.

Repair Body:

Door panel removal, bumper replacement, glass replacement, trim piece installation/removal.

HVAC Service:

Refrigerant handling, compressor replacement, evaporator/condenser service, leak detection.

Airbag Service:

Airbag module replacement, sensor recalibration, system safety precautions.

Technical Depth

Depth:

Extensive, from basic maintenance to complete engine and transmission rebuilds.

Diagrams:

Includes detailed exploded views, wiring diagrams, and system schematics.

📊 Manual Specifications

File Format

File Format:

Print Quality

Resolution:

High-resolution, optimized for digital viewing and printing.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine Gasoline 1.5L

Engine Code:

Configuration:

Inline-4 Cylinder, SOHC

Displacement Cc:

Bore Mm:

Stroke Mm:

Compression Ratio:

9.5:1 (approximate)

Horsepower Ps Rpm:

90-100 PS @ 6000 RPM (market dependent)

Torque Nm Rpm:

130-140 Nm @ 4000 RPM (market dependent)

Fuel System:

Multi-point Fuel Injection (MPI)

Primary Engine Gasoline 2.0L

Engine Code:

Configuration:

Inline-4 Cylinder, SOHC (standard trims) or DOHC (performance trims like Ralliart/Evo).

Displacement Cc:

Compression Ratio:

9.8:1 (SOHC), 8.5:1 (DOHC Turbo for Evo variants)

Horsepower Ps Rpm:

135-160 PS (SOHC), 270+ PS (DOHC Turbo for Evo variants)

Torque Nm Rpm:

180-200 Nm (SOHC), 370+ Nm (DOHC Turbo for Evo variants)

Fuel System:

Multi-point Fuel Injection (MPI) or Electronic Fuel Injection (EFI) for turbocharged variants.

Primary Engine Diesel

Engine Code:

Configuration:

Inline-4 Cylinder, SOHC, Turbocharged (common)

Displacement Cc:

Horsepower Ps Rpm:

70-80 PS (market dependent)

Torque Nm Rpm:

140-160 Nm (market dependent)

Fuel System:

Direct Injection (DI) or Indirect Injection (IDI) with Turbocharger.

🔧 Transmission

Standard

Manual Transmission:

5-speed Manual Transmission

Optional

Automatic Transmission:

4-speed Automatic Transmission (common on non-performance variants).

All Wheel Drive:

Available on specific performance variants (e.g., Ralliart, Evo).

Features

Clutch Type Manual:

Dry single plate clutch.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 (typical specification, always verify with manual)

Transmission Fluid Automatic:

Mitsubishi Diaqueen SPII / ATF-SP II M (or equivalent, always verify with manual)

📐 Dimensions

Exterior

Length Mm:

4490 (approximate, varies by trim/region)

Width Mm:

1740 (approximate)

Height Mm:

1445 (approximate)

Wheelbase Mm:

Front Track Mm:

1470 (approximate)

Rear Track Mm:

1460 (approximate)

Weights

Curb Weight Kg:

1150 - 1350 kg (depending on engine, transmission, and trim)

Gross Vehicle Weight Kg:

1700 - 1850 kg (typical range)

Towing Capacity Kg:

Not officially specified for most markets, generally not recommended.

Cargo

Trunk Volume Liters:

405 (approximate)

Wheels Tires

Wheel Bolt Pattern:

4x114.3 mm (common)

Wheel Size:

15-inch or 16-inch (common)

Tire Sizes Common:

195/60R15, 205/50R16 (market dependent)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star (driver), 5-star (passenger) for 2004 model in US tests.

IIHS Front Offset:

Good (for models equipped with side airbags and curtain airbags).

Active Features

Standard or Optional depending on trim and market.

Electronic Brakeforce Distribution (often paired with ABS).

Traction Control:

Optional on some trims.

Passive Features

Airbags Front:

Driver and Passenger Frontal Airbags (standard).

Airbags Side:

Optional front side-impact airbags, optional curtain airbags on some trims.

Seatbelts:

3-point front and rear seatbelts with pretensioners and load limiters for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System Features:

AM/FM radio, CD player (single disc or in-dash changer), optional cassette player. Basic speaker setup (4-6 speakers).

Display Type:

Analog gauges with basic LCD/digital display for odometer, trip meter, and warning lights.

Driver Assistance

Cruise Control:

Optional on higher trim levels.

Keyless Entry:

Optional on many trims.

Connectivity

Bluetooth:

Not standard for this model year.

Usb Port:

Not standard for this model year.

🔧 Maintenance

Service Intervals Oil Filter

Oil Change Interval Gasoline:

Every 7,500 miles or 6 months (typical, varies by driving conditions and oil type).

Oil Filter Part Number Example:

MD348583 (for 4G15/4G63, but always verify)

Engine Oil Type Gasoline:

API SN, ILSAC GF-5, SAE 5W-30 (common, but check manual for specific viscosity and API rating)

Engine Oil Capacity Gasoline 1.5L:

Approx. 3.7 Liters (with filter change)

Engine Oil Capacity Gasoline 2.0L:

Approx. 4.0 Liters (with filter change)

Service Intervals Other

Timing Belt Replacement Interval:

Every 60,000 miles or 4 years (for models with a timing belt). Some 4G63 variants might have a timing chain. Verify specific engine. Crucial interval to prevent catastrophic engine damage.

Air Filter Replacement Interval:

Every 15,000 - 30,000 miles or as needed based on conditions.

Spark Plug Replacement Interval:

Every 60,000 miles (typically for platinum or iridium plugs).

Brake Fluid Change Interval:

Every 2-3 years or as recommended.

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent phosphate-based OAT, pink colored).

Coolant Capacity:

Approx. 5.5 - 6.0 Liters (depending on engine and radiator size).

Known Issues

Common Issue Ignition:

Spark plug blow-out (especially on early models/specific engines), ignition coil failure.

Common Issue Suspension:

Worn front control arm bushings, noisy sway bar links, premature rear shock absorber failure.

Common Issue Engine:

Timing belt issues if not replaced on schedule (major failure risk), minor oil leaks from valve cover gasket.

Common Issue Transmission:

Automatic transmission can be prone to harsh shifting or solenoid issues if fluid is neglected. Manual clutch wear is typical over time.

Common Issue Electrical:

Window regulator failures, power mirror motor issues, gauge cluster illumination problems.

Common Issue Corrosion:

Rust can be an issue on underbody components and wheel wells in certain climates. Body panel rust can occur over time.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Heritage:

Mitsubishi Motors has a long history in automotive manufacturing, dating back to its origins in 1917. Known for innovation and performance, particularly with the Lancer Evolution line.

Model Evolution

Lancer Lineage:

The Lancer nameplate has been used by Mitsubishi since 1973, evolving through numerous generations and body styles (sedan, coupe, wagon). The 2004 model belongs to the seventh generation (CS/CT chassis).

Production

Production Period Generation:

2000-2007 (CS/CT Generation)

Manufacturing Locations:

Primary manufacturing in Japan (Okazaki Plant). Also produced in other global facilities under license or joint ventures (e.g., Netherlands, Colombia, Taiwan).

🏆 Awards & Recognition

Recognitions

Recognition Lancer Evolution:

The Lancer Evolution (Evo) variants are highly acclaimed in the automotive world, particularly for their rally heritage and performance capabilities, winning numerous awards and accolades in motorsport and enthusiast publications.

Recognition Standard Lancer:

Standard Lancer models typically received positive reviews for value, reliability, and practicality within their segment, though not as frequently awarded as performance variants.