🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer

Year:

2004

Chassis Code:

CS/CT

Factory Service Manual Identifier:

Likely a specific internal Mitsubishi designation, not publicly provided.

👋 Introduction

Segment:

Compact car / Small family car.

Target Audience:

Value-conscious buyers seeking reliability, practicality, and affordable ownership.

Key Competitors 2004:

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

Model Strengths:

Reliability, fuel efficiency, sporty handling (especially on performance variants), affordability, practical interior space.

Manual Value Proposition:

Provides professional-level repair and maintenance guidance, enabling DIY enthusiasts and professional mechanics to service and repair the vehicle effectively, saving time and money.

📋 Manual Details

Geographic Coverage:

Global (typically covers models sold in North America, Europe, and Asia, with potential regional variations noted within the manual).

Estimated Page Count:

1500-2500 pages (typical for a comprehensive factory FSM for this era).

Manual Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, disassembly, inspection, assembly, timing belt/chain, pistons, rings, bearings, cylinder heads, valve train, lubrication system.

Engine Performance And Controls:

Fuel injection system (MPI), ignition system, emission control systems (catalytic converter, EGR), engine management system (ECU/ECM), diagnostic trouble codes (DTCs), sensor testing.

Transmission Manual:

Disassembly, assembly, inspection, gear ratios, clutch system, shifting mechanisms, service procedures.

Transmission Automatic:

Disassembly, assembly, inspection, torque converter, valve body, planetary gear sets, transmission control module (TCM), diagnostic procedures.

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, driveshafts, CV joints, differentials, wheel bearings, propeller shaft (AWD).

Brakes:

Hydraulic system, disc brakes (front and rear), drum brakes (rear on some models), ABS (Anti-lock Braking System) components, bleeding procedures, master cylinder, wheel cylinders, calipers, pads, rotors.

Suspension:

Front and rear suspension systems (McPherson strut, multi-link), shock absorbers, springs, control arms, ball joints, bushings, alignment specifications.

Steering:

Power steering system (hydraulic), steering rack, tie rods, steering column, wheel alignment procedures, specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams.

Body And Interior:

Body panels, doors, hood, trunk lid, glass, upholstery, trim components, seat removal, dashboard removal, sound insulation.

HVAC:

Heating, Ventilation, and Air Conditioning system components, refrigerant system, blower motor, evaporator, condenser, climate controls, diagnostic procedures.

Safety Systems:

Airbag system (SRS), seat belt mechanisms, diagnostics and servicing of safety components.

Preventive Maintenance:

Oil and filter changes, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, air filter replacement, tire rotation.

Troubleshooting:

Diagnostic flowcharts, common symptoms, pinpoint tests for electrical and mechanical issues, fault code interpretation.

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major vehicle systems.

Diagnostic Procedures:

OBD-II system, scan tool usage, live data analysis, component testing using multimeters and oscilloscopes.

Calibration And Adjustment:

Wheel alignment, timing adjustments (if applicable), throttle body cleaning and relearn procedures, power steering assist adjustments.

Depth:

Comprehensive (covers everything from basic fluid checks and filter changes to complete engine and transmission overhauls and complex electrical diagnostics).

Diagnostic Capabilities:

Advanced diagnostics including wiring diagrams, pinouts, component resistance values, voltage checks, and troubleshooting flowcharts.

Rebuild Instructions:

Detailed specifications and procedures for rebuilding major components like engines, transmissions, and differentials.

📊 Manual Specifications

File Type:

PDF

Searchability:

Typically searchable text within the PDF for quick information retrieval.

Image Resolution:

High-resolution images and diagrams, suitable for printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Access Method:

Instant download to computer, tablet, or smartphone.

⚙️ Engine Specifications

Engine Code Common:

4G15 (1.5L), 4G13 (1.3L - less common in some markets), 4G93 (1.8L - optional on some trims), 4G94 (2.0L - common on GT models), 4G63T (2.0L Turbo - Lancer Evolution, not typically covered in standard Lancer manuals unless specified).

Engine Description:

Inline 4-cylinder, SOHC or DOHC, naturally aspirated or turbocharged (Evolution).

Horsepower Range:

Approx. 90 HP (1.3L) to 160 HP (2.0L NA). Evolution models significantly higher.

Torque Range:

Approx. 120 Nm (1.3L) to 180 Nm (2.0L NA).

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI).

Fuel Type:

Unleaded Gasoline (Octane rating as specified by manufacturer, typically 87-91 RON/AKI).

🔧 Transmission

Transmission Type Standard:

5-speed manual transmission.

Transmission Type Optional:

4-speed automatic transmission.

All Wheel Drive:

Available on certain trims, often designated as AWD or 4WD, typically featuring a viscous coupling or active center differential.

📐 Dimensions

Length:

Approx. 4490-4520 mm (depending on variant).

Width:

Approx. 1740-1770 mm.

Height:

Approx. 1415-1445 mm.

Wheelbase:

Approx. 2630 mm.

Curb Weight:

Approx. 1200-1350 kg (depending on engine and transmission).

🛡️ Safety Features

NHTSA Front Impact Driver:

Likely 'Good' (IIHS rating for similar era models).

NHTSA Front Impact Passenger:

Likely 'Good'.

ABS:

Optional or standard depending on trim level.

Traction Control:

Optional or standard on higher trims.

Airbags:

Front airbags standard; side airbags optional on some trims.

Seatbelts:

3-point front and rear seat belts with pretensioners and load limiters (front).

💡 Technology Features

Audio System:

Factory AM/FM CD player with optional cassette, typically 4-6 speakers. Aftermarket head unit upgrades are common.

Climate Control:

Manual or automatic climate control depending on trim level.

Cruise Control:

Optional on most trims.

Bluetooth:

Not typically factory-equipped on this model year; aftermarket solutions available.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first.

Timing Belt Replacement:

For models with a timing belt (e.g., 4G15), recommend replacement every 60,000-100,000 miles (96,000-160,000 km) or 5-7 years.

Coolant Replacement:

Initial replacement at 60,000 miles, then every 30,000-45,000 miles or 2-3 years.

Engine Oil Spec:

API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on climate).

Coolant Spec:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors).

Brake Fluid Spec:

DOT 3 or DOT 4.

Transmission Fluid Manual:

API GL-3 or GL-4, SAE 75W-85 or 75W-90.

Transmission Fluid Automatic:

Mitsubishi DiaQueen ATF-J2 or equivalent Dexron III/Mercon compatible fluid.

Common Wear Items:

CV joints, wheel bearings, exhaust system components, ignition coils, oxygen sensors.

Potential Electrical Gremlins:

Check wiring harness connections, particularly in the engine bay and under the dash. Occasional issues with window regulators and door lock actuators.

Engine Performance Issues:

Carbon buildup on intake valves (especially on direct-injected variants, less common on this generation MPI), fuel injector clogging, worn spark plugs.

📚 Vehicle History

Mitsubishi Motors:

Japanese automotive manufacturer with a long history of producing reliable and often sporty vehicles, known for rally heritage with the Lancer Evolution.

Lancer Lineage:

The Lancer nameplate has been used by Mitsubishi since 1973, evolving through multiple generations. The 2004 model represents the eighth generation (CS/CT).

Production Years Eighth Gen:

2000-2007 (with facelifts).

Manufacturing Locations:

Japan, and various international assembly plants.

🏆 Awards & Recognition

Safety Awards:

While specific awards vary, the Lancer generally performed adequately in safety tests for its class and era. IIHS and NHTSA ratings from the period are the best indicators.

Consumer Reports Reliability:

Reliability ratings for this generation were generally good to excellent, contributing to its popularity.

Emissions Compliance:

Compliant with EPA and CARB emissions standards for the 2004 model year (USA market).