Mitsubishi Lancer 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2004 Codes Chassis Code: CS/CT Series Chassis Code Specific: CS3A (sedan), CS5A (sedan), CS6A (sedan), CT9A (Evolution) 👋 Introduction Market Position...

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Type: Car

Vendor:

Sku: 357676

Tags: 2004 Car Cars Lancer Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Year:

Codes

Chassis Code:

CS/CT Series

Chassis Code Specific:

CS3A (sedan), CS5A (sedan), CS6A (sedan), CT9A (Evolution)

👋 Introduction

Market Position

Segment:

Compact car, sporty sedan/hatchback.

Target Audience:

Enthusiasts, DIY mechanics, professional workshops seeking official dealer-level documentation.

Competitive Analysis

Competitors:

Honda Civic, Toyota Corolla, Subaru Impreza, Mazda3.

Key Features

Vehicle Selling Points:

Sporty handling, available AWD (Evolution), practical design, good value.

Manual Value:

Provides dealership-level repair information, saving significant costs on maintenance and repairs.

📋 Manual Details

Coverage Areas

General Coverage:

All workshop procedures, diagnostics, repair, maintenance, and component replacement for the 2004 Mitsubishi Lancer.

Page Count

Estimated Pages:

1500-2500+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system, emission control system, engine management.

Engine Performance:

Engine tuning, performance diagnostics, power output troubleshooting.

Transmission Manual:

Manual transmission (W5MG1, W151, W1A2) removal, installation, overhaul, clutch system.

Transmission Automatic:

Automatic transmission (F4A42, F5A51) removal, installation, overhaul, torque converter, shift control.

Drivetrain:

Front-wheel drive, All-wheel drive (AWD) system for Evolution models, differentials, drive shafts, CV joints.

Suspension:

Front and rear suspension systems, shock absorbers, springs, control arms, steering knuckle, alignment specifications.

Steering:

Power steering system, steering rack, tie rod ends, steering column, wheel balancing.

Brakes:

Hydraulic brake system, ABS system, brake calipers, rotors, pads, lines, master cylinder, parking brake.

Electrical System:

Battery, charging system, starting system, ignition system, lighting, instrumentation, accessories.

Body And Interior:

Body panels, doors, hood, trunk, interior trim, seats, HVAC system, dashboard, glass, weatherstripping.

Heating Ventilation Air Conditioning:

HVAC system components, refrigerant, operation, troubleshooting.

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel filter, fuel pressure regulator.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors.

Manual Coverage

Procedures Included:

Complete engine rebuild, transmission overhaul, brake system bleeding and repair, suspension component replacement, electrical system diagnostics and repair, body panel alignment and repair.

Procedures Included

Troubleshooting:

Step-by-step troubleshooting guides for common and complex issues across all vehicle systems.

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, spark plug replacement, belt replacement.

Diagnostics:

OBD-II diagnostic procedures, reading trouble codes, sensor testing, circuit testing.

Technical Depth

Depth:

Comprehensive, covering from basic DIY maintenance to advanced professional-level repairs and diagnostics.

Detail Level:

Detailed step-by-step instructions, torque specifications, wiring diagrams, exploded views, and diagnostic flowcharts.

📊 Manual Specifications

File Format

Searchability:

Fully searchable PDF text, allowing for quick access to specific information.

Print Quality

Image Resolution:

High-resolution diagrams and images for clarity.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Ls:

4G63 (2.0L Turbocharged - Evolution models)

Engine Code Na 1:

4G15 (1.5L SOHC MPI)

Engine Code Na 2:

4G64 (2.4L SOHC MPI)

Engine Code Na 3:

4G63 (2.0L Naturally Aspirated SOHC MPI - some markets)

Performance

Horsepower 4G63 Turbo:

271-280 hp (depending on specific Evolution model and market)

Torque 4G63 Turbo:

273-282 lb-ft (depending on specific Evolution model and market)

Horsepower 4G64 Na:

135 hp @ 5500 rpm

Torque 4G64 Na:

137 lb-ft @ 3500 rpm

Horsepower 4G15 Na:

105 hp @ 6000 rpm

Torque 4G15 Na:

106 lb-ft @ 3500 rpm

Fuel System

Injection Type:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (91+ octane recommended for 4G63 Turbo)

🔧 Transmission

Standard

Standard Transmission Na:

5-speed Manual

Standard Transmission Evolution:

6-speed Manual (Getrag W5MG1)

Optional

Optional Transmission Na:

4-speed Automatic (F4A42)

Features

AWD System:

Active All-Wheel Drive (AYC - Active Yaw Control) on Evolution models.

📐 Dimensions

Exterior

Wheelbase:

104.3 inches (2650 mm)

Length:

177.4 inches (4505 mm) for Sedan, 170.1 inches (4320 mm) for Evolution

Width:

67.7 inches (1720 mm) for Sedan, 69.5 inches (1765 mm) for Evolution

Height:

56.7 inches (1440 mm) for Sedan, 57.9 inches (1470 mm) for Evolution

Weights

Curb Weight Range:

2600 - 3100 lbs (approximate, varies by trim and drivetrain)

Gross Vehicle Weight Rating:

Varies by model, typically around 4000-4200 lbs

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

4-star rating for driver, 4-star rating for front passenger (2004 models)

IIHS Front Offset Crash Test:

Active Features

Standard on most trims, optional on base models.

Traction Control:

Available on certain trims, standard on Evolution.

Passive Features

Airbags Front:

Driver and front passenger airbags standard.

Airbags Side:

Optional front side-impact airbags on some trims.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium sound system.

Navigation:

Not typically available on standard models, optional on higher trims in some markets.

Driver Assistance

Cruise Control:

Available on most trim levels.

Connectivity

Auxiliary Input:

Not standard, may require aftermarket modification.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 to 5,000 miles (6,000 to 8,000 km) or 6 months, whichever comes first (refer to manual for specific engine/oil type).

Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km).

Spark Plug Replacement:

Iridium-tipped plugs: 60,000-100,000 miles (96,000-160,000 km). Platinum-tipped plugs: 30,000-60,000 miles (48,000-96,000 km).

Timing Belt Replacement:

For 4G63/4G64 engines, typically 60,000 miles (96,000 km) or 5 years. Crucial for 4G63 Turbo.

Fluid Specifications

Engine Oil Viscosity:

5W-30 or 10W-30 API Service SJ or SL (refer to manual for exact specification).

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with deionized water).

Transmission Fluid Manual:

API GL-4 SAE 75W-85 or 75W-90 gear oil.

Transmission Fluid Automatic:

DIA QUEEN ATF-SP III or equivalent ATF.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Engine 4G63 Turbo:

Head gasket failures, turbocharger wear, oil consumption, piston ring issues if not maintained properly.

Suspension:

Worn bushings, front strut mounts, premature wear of control arm components.

Body And Interior:

Paint chipping (especially on bumpers and hoods), interior trim creaks, power window regulator failures.

Electrical:

Alternator failures, starter motor issues, fuel pump failures.

📚 Vehicle History

Brand Heritage

Brand Focus:

Mitsubishi has a long history in motorsports, particularly with rally racing, which influenced models like the Lancer Evolution.

Model Evolution

Seventh Generation:

The 2004 Lancer belongs to the seventh generation (2000-2007), representing a significant redesign with a more global platform.

Evolution Lineage:

The Lancer Evolution (Evo) series, starting with the Evo I in 1992, is a performance icon, with the Evo VIII being the primary variant for the 2004 model year in many markets.

Production

Production Location:

Primarily Japan (Mizushima Plant), with some assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Evolution Reputation:

Consistently praised by automotive journalists for its performance, handling, and AWD system, especially the Lancer Evolution VIII.

General Lancer:

Recognized for reliability and value in the compact segment.