Mitsubishi Lancer 2004 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2004 Codes Platform Code: CS/CT 👋 Introduction Market Position Segment: Compact Car / Economy Sedan Target Audience: Budget-conscious consumers, first-time car...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Year:

Codes

Platform Code:

CS/CT

👋 Introduction

Market Position

Segment:

Compact Car / Economy Sedan

Target Audience:

Budget-conscious consumers, first-time car buyers, small families.

Competitive Analysis

Key Competitors:

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

Key Features

Value Proposition:

Affordable pricing, reliable mechanicals, decent fuel economy, available AWD (on some variants).

Trim Levels Overview:

ES, LS, GTS, OZ Rally, SE (Varies by market).

📋 Manual Details

Coverage Areas

Regions Covered:

Global (specific regional variations may exist but core repair procedures are universal)

Page Count

Estimated Pages:

1500-2000+

Manual Type

Type:

Service Repair Manual (SRM) / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul, timing belt replacement, fuel injection systems, ignition systems, cooling system, lubrication system, emissions control.

Transmission:

Manual (5-speed) and Automatic (4-speed INVECS-II) transmission service, repair, diagnostics, fluid changes, clutch service, torque converter, valve body operation.

Drivetrain:

Front-wheel drive (FWD) and All-Wheel Drive (AWD) systems, differential service, CV joints, driveshafts, transfer case (if applicable to AWD models).

Suspension:

Front MacPherson struts, rear multi-link suspension, coil springs, shock absorbers, control arms, bushings, wheel alignment procedures and specifications.

Steering:

Power steering system diagnostics and repair, steering rack, tie rods, power steering pump, fluid specifications.

Brakes:

Front disc brakes, rear drum or disc brakes, ABS system diagnostics, brake fluid specifications, bleeding procedures, rotor and pad replacement, parking brake.

Electrical:

Comprehensive wiring diagrams for all circuits, starter, alternator, battery, lighting systems, power windows, power locks, interior and exterior electronics, fuses, relays, ECUs.

HVAC:

Air conditioning system service, refrigerant, compressor, evaporator, condenser, heater core, blower motor, climate control module.

Body And Chassis:

Body panel removal and installation, interior trim, glass replacement, door mechanisms, chassis specifications, corrosion protection.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement.

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides for common problems, electrical system diagnosis.

Repair:

Detailed step-by-step repair procedures for all major components and systems, including torque specifications and special tool requirements.

Disassembly And Assembly:

Complete instructions for dismantling and reassembling engines, transmissions, suspension components, and body parts.

Diagnostics:

On-board diagnostics (OBD-II) system explanation, diagnostic tool usage, sensor data interpretation.

Technical Depth

Depth:

Comprehensive (covers everything from basic fluid changes to complete engine and transmission rebuilds).

📊 Manual Specifications

File Format

Quality:

High-resolution scans, searchable text (OCR'd where possible), printable pages.

Print Quality

Printability:

Designed for printing key sections or entire manual.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

4G15 (1.5L SOHC)

Displacement 1:

1468 cc

Horsepower 1:

92 hp @ 5500 rpm

Torque 1:

130 Nm @ 3500 rpm

Engine Code 2:

4G19 (1.6L SOHC/DOHC)

Displacement 2:

1584 cc

Horsepower 2:

99 - 105 hp @ 5800-6000 rpm

Torque 2:

137 - 143 Nm @ 3000-4000 rpm

Engine Code 3:

4G63 (2.0L SOHC/DOHC - Naturally Aspirated)

Displacement 3:

1997 cc

Horsepower 3:

114 - 135 hp @ 5000-6000 rpm

Torque 3:

170 - 176 Nm @ 4000-4500 rpm

Engine Code 4:

4G63T (2.0L DOHC Turbocharged - Ralliart/Evolution variants)

Displacement 4:

1997 cc

Horsepower 4:

261 hp @ 6500 rpm (Ralliart), 271 hp @ 6500 rpm (Evo VIII)

Torque 4:

343 Nm @ 3500 rpm (Ralliart), 370 Nm @ 3000 rpm (Evo VIII)

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

Injection Type:

Multi-point Fuel Injection (MPI)

Ignition System:

Electronic ignition with coil-on-plug (COP) or distributor-based systems (depending on engine variant).

Engine Management

ECU Type:

Engine Control Unit (ECU) specific to engine and transmission configuration.

🔧 Transmission

Standard

Type 1:

5-speed Manual Transmission

Optional

Type 2:

4-speed Automatic Transmission (INVECS-II with Sport Mode)

Features

AWD System:

Active Center Differential (ACD) with mechanical Limited-Slip Differential (LSD) on Evolution models; viscous coupling AWD on some Ralliart variants.

Fluid Specifications

Manual Trans Fluid:

API GL-3 or GL-4 SAE 75W-85 gear oil. Consult manual for specific Mitsubishi recommendations (e.g., DiaQueen).

Automatic Trans Fluid:

Mitsubishi DiaQueen SPIII (or equivalent Dexron III/Mercon).

📐 Dimensions

Exterior

Wheelbase:

2630 mm (103.5 in)

Length:

4480 - 4490 mm (176.4 - 176.8 in)

Width:

1740 mm (68.5 in)

Height:

1445 - 1470 mm (56.9 - 57.9 in)

Weights

Curb Weight:

1150 - 1450 kg (approx.)

Gross Vehicle Weight:

Varies by model and configuration.

Wheels And Tires

Bolt Pattern:

4x100 (most models), 5x114.3 (Performance/AWD variants)

Typical Tire Sizes:

185/65R14, 195/60R15, 205/50R16, 235/45R17 (Evo VIII).

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated by NHTSA for 2004 in all configurations, but generally considered good for its class.

IIHS Ratings:

Similar to NHTSA, specific ratings may vary. Generally good for its era.

Active Features

Available (standard on higher trims and performance models).

Traction Control:

Available (often linked with AWD systems or higher trim levels).

Passive Features

Airbags:

Front airbags standard, side airbags available on select models.

Seatbelts:

3-point height-adjustable front seatbelts with pre-tensioners.

Body Structure:

Reinforced Impact Safety Evolution (RISE) body construction for improved crashworthiness.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, with available premium sound systems and CD changers on higher trims.

Navigation:

Optional factory navigation system available on select models and markets.

Driver Assistance

Cruise Control:

Available on most trim levels.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors standard on mid to high trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first. Consult manual for specific driving conditions.

Engine Coolant Flush:

Every 30,000 - 45,000 miles (48,000 - 72,000 km) or 2-3 years.

Transmission Fluid Change:

Manual: Check level regularly, replacement less frequent but recommended every 60,000-100,000 miles. Automatic: Every 30,000-60,000 miles depending on use.

Spark Plug Replacement:

100,000 miles for iridium plugs, potentially sooner for conventional plugs (refer to engine type).

Timing Belt Replacement:

Crucial for interference engines (e.g., 4G63). Typically 60,000 - 90,000 miles or 5-7 years. Failure can cause catastrophic engine damage.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or 5W-40 synthetic or semi-synthetic oil meeting API SL or SN specifications. Check manual for specific viscosity and API rating.

Engine Oil Capacity:

Approx. 4.0-4.5 liters (4.2-4.8 US quarts) with filter, depending on engine.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant Type:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent Ethylene Glycol based coolant with a 50/50 mix with deionized water.

Known Issues

Engine:

Timing belt failure (if not replaced on schedule), oil consumption on higher mileage units, minor oil leaks from valve cover gaskets.

Suspension:

Worn control arm bushings, premature strut wear, occasional rattling from rear suspension components.

Electrical:

Window regulator failures, intermittent power window issues, dashboard warning light illumination (often sensor related).

Exhaust:

Rusting exhaust components over time.

📚 Vehicle History

Brand Heritage

Mitsubishi History:

Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer, has a long history dating back to 1917, known for robust engineering and rally heritage.

Model Evolution

Lancer Generations:

The 2004 Lancer is part of the 8th generation (CS/CT platform, 2000-2007) of the Lancer lineage, which began in 1973.

Evolution Variant:

The Lancer Evolution VIII (CT9A chassis) represents a high-performance variant, renowned for its motorsport success in the World Rally Championship (WRC).

Production

Manufacturing Locations:

Primarily Japan, with assembly also occurring in other countries depending on the market.

Production Years For Cs Ct Platform:

2000-2007

🏆 Awards & Recognition

Recognitions

Performance Awards:

Lancer Evolution models are highly acclaimed for their rally heritage and performance credentials, often winning performance tests and comparisons.

Value Awards:

The standard Lancer models have often been recognized for their affordability and value for money in the compact car segment.