🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer

Year:

2004

Chassis Code:

CS_A (Sedan/Sportback)

Engine Code Common:

4G63 (2.0L Turbo for Evolution, 4G94 2.4L, 4G18 1.6L, 4G93 1.8L)

Vin Code Generation:

J

👋 Introduction

Segment:

Compact sedan/hatchback

Target Audience:

Enthusiast owners, DIY mechanics, independent repair shops.

Key Competitors:

Honda Civic, Toyota Corolla, Mazda3, Subaru Impreza.

Strengths Vehicle:

Reliability, performance (especially in performance variants like the GT and Evolution), practicality, affordable maintenance.

Value Proposition Manual:

Provides detailed, accurate repair and maintenance information to empower owners and save on repair costs.

📋 Manual Details

Regions Covered:

Global (specific markets may have minor variations)

Estimated Page Count:

1500+

Type:

Full Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, lubrication, cooling system, starting and charging system, engine control systems (ECU).

Transmission Drivetrain:

Manual transmission, automatic transmission, clutch, drive shafts, differentials, axles, transfer case (AWD models).

Suspension Steering:

Front suspension (MacPherson strut), rear suspension (Multi-link), power steering system, steering column, steering linkage.

Brakes:

Front disc brakes, rear disc brakes (some base models may have rear drums), anti-lock braking system (ABS), parking brake.

Electrical Electronics:

Battery, alternator, starter motor, lighting system, dashboard instruments, power windows, power locks, wipers, horn, audio system, engine control module (ECM), body control module (BCM), airbag system (SRS), wiring diagrams for all circuits.

Body Chassis:

Body panels, doors, hood, trunk lid, bumpers, interior trim, seats, glass, chassis components, corrosion protection.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair, refrigerant handling.

Emissions Control:

Emissions control systems, evaporative emission control (EVAP), catalytic converter, oxygen sensors.

Maintenance Tasks:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt replacement, coolant flushes, brake pad replacement, tire rotation.

Repair Procedures:

Engine overhaul, transmission repair/rebuild, clutch replacement, suspension component replacement, brake caliper/rotor replacement, electrical component diagnosis and repair, body panel repair, HVAC system repair.

Troubleshooting Diagnostics:

Diagnostic trouble codes (DTCs) interpretation, fault finding procedures, symptom-based troubleshooting guides.

Component Replacement:

Detailed step-by-step instructions for replacing virtually all mechanical and electrical components.

Specifications Data:

Torque specifications for all fasteners, diagnostic specifications, repair times (R&R times).

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds. Includes detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for quick information retrieval.

Quality:

High-resolution scans with clear text and diagrams.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options 2004:

1.6L (4G18), 1.8L (4G93), 2.0L Naturally Aspirated (4G63), 2.0L Turbocharged (4G63T - Evolution models).

Common Engine Displacement:

2.0 Liters

Horsepower Range:

Approx. 120 hp (1.6L) to 280 hp (Evolution VIII)

Torque Range:

Approx. 105 lb-ft (1.6L) to 275 lb-ft (Evolution VIII)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

Unleaded gasoline (Octane rating varies by engine, 91+ for turbocharged models).

Bore Stroke Common:

85.0 mm x 88.0 mm (4G63)

Compression Ratio Common:

9.0:1 (4G63 NA), 8.8:1 (4G63 Turbo)

Valvetrain:

SOHC or DOHC with MIVEC (Mitsubishi Innovative Valve timing Electronic Control system) on some variants.

🔧 Transmission

Transmission Options:

5-speed Manual Transmission (most models), 4-speed Automatic Transmission (some models).

AWD Option:

Available on GT and Evolution models (Super Active Yaw Control - SAYC).

Transmission Fluid Type Manual:

GL-4 or GL-5 gear oil (specification varies by transmission, consult manual for exact type and viscosity).

Transmission Fluid Type Automatic:

DIA QUEEN ATF-SP II M or equivalent.

Clutch Type:

Dry single plate clutch (manual transmission).

📐 Dimensions

Length:

Approx. 4470 mm (Sedan)

Width:

Approx. 1740 mm

Height:

Approx. 1415 mm (Sedan)

Wheelbase:

Approx. 2630 mm

Track Width Front:

Approx. 1500 mm

Track Width Rear:

Approx. 1500 mm

Wheelbase Evolution:

Approx. 2625 mm

Curb Weight Range:

Approx. 1250 kg - 1500 kg (depending on trim and drivetrain)

Gross Vehicle Weight Rating Gvwr:

Consult specific model documentation.

🛡️ Safety Features

NHTSA Front Crash Test Rating:

4 Stars (Driver), 5 Stars (Passenger) for some configurations.

IIHS Frontal Offset Rating:

Good (for models tested).

ABS:

Standard on most models, optional on base trims.

Traction Control:

Available on some higher trim levels and Evolution models.

Airbags:

Front driver and passenger airbags standard. Side airbags and curtain airbags optional on some trims.

Seatbelts:

3-point ELR seatbelts with pre-tensioners and force limiters.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional premium audio systems, some models may have cassette player.

Navigation:

Rarely available, typically aftermarket or dealer-installed on higher trims.

Cruise Control:

Available on most trim levels.

Headlights:

Halogen projector headlights on some trims, manual or automatic leveling.

Auxiliary Input:

Not standard, often requires aftermarket adapter for modern devices.

🔧 Maintenance

Oil Change Interval:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions. Consult manual for specific recommendation.

Air Filter Replacement:

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

Spark Plug Replacement:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type.

Timing Belt Replacement:

60,000 - 90,000 miles (96,000 - 145,000 km) for engines equipped with a timing belt. Highly critical for 4G63 and 4G94 engines.

Engine Oil Capacity 2.0L:

Approx. 4.5 liters (with filter) - SAE 5W-30 or 10W-30, API SJ/SL.

Coolant Capacity:

Approx. 6.0 liters - Mixture of distilled water and Mitsubishi Super Long Life Coolant (or equivalent). Ensure proper freeze protection.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

Refer to manual for specific type, often ATF.

Engine Common:

Some models may experience head gasket issues, especially if driven hard or poorly maintained. Catalytic converter failure. Oil leaks from valve cover gasket and oil pan.

Transmission Common:

Manual transmission synchro wear, clutch wear. Automatic transmission clutch pack wear and solenoid issues on higher mileage vehicles.

Suspension Common:

Worn suspension bushings, ball joints, and wheel bearings, especially on AWD models and higher mileage cars.

Electrical Common:

Alternator failure, power window motor issues, occasional wiring harness issues.

📚 Vehicle History

Parent Company:

Mitsubishi Motors Corporation

Generation:

8th Generation (2000-2007)

Design Philosophy:

Sporty styling, practical interior, driver-focused dynamics.

Performance Variants:

Notable for the highly successful Lancer Evolution (performance rally homologation special) series.

Manufacturing Locations:

Japan, and various international assembly plants.

🏆 Awards & Recognition

Rally Heritage:

Significant success in the World Rally Championship (WRC) with Lancer Evolution models.

Performance Awards:

Lancer Evolution models frequently praised for handling and performance by automotive journalists.

Safety Awards:

Achieved good safety ratings from organizations like NHTSA and IIHS for its time.