2004-2005 Mitsubishi Lancer/Lancer Wagon Service and Repair Manual

This 2004–2005 Mitsubishi Lancer / Lancer Wagon Workshop Manual Covers

• Complete factory workshop procedures
• Scheduled servicing and maintenance
• Engine overhaul and repair
• Manual and automatic transmission servicing
• Electrical diagnostics
• Factory wiring diagrams
• Suspension and steering repairs
• Brake system servicing
• Body repairs
• Diagnostic troubleshooting
• Technical specifications
• Component testing

Engine Options

Petrol

• 1.3L 4G13 SOHC Inline-4
• 1.5L 4G15 SOHC Inline-4
• 1.6L 4G18 SOHC Inline-4
• 1.8L 4G93 DOHC GDI Inline-4 (selected markets)
• 2.0L 4G94 SOHC Inline-4
• 2.4L 4G69 SOHC MIVEC Inline-4 (Ralliart/selected markets)

Transmission Options

• 5-speed manual transmission
• 4-speed automatic transmission
• INVECS-II automatic transmission (selected models)

Engine and Drivetrain Repair Coverage

• Complete engine overhaul procedures
• Engine removal and installation
• Cylinder head servicing
• Timing belt replacement
• Valve train inspection
• Fuel injection diagnostics
• Ignition system servicing
• Electronic throttle diagnostics (where equipped)
• Cooling system repairs
• Engine lubrication servicing
• Intake and exhaust repairs
• EVAP system diagnostics
• Emissions control servicing
• Clutch replacement procedures
• Manual transmission overhaul
• Automatic transmission servicing
• Differential servicing
• Driveshaft servicing
• CV joint replacement

Chassis, Steering and Suspension

• Front MacPherson strut suspension
• Rear multi-link suspension
• Steering rack servicing
• Hydraulic power steering diagnostics
• Wheel alignment specifications
• Wheel bearing replacement
• Ball joint servicing
• Control arm replacement
• Stabiliser bar servicing
• Shock absorber replacement

Braking Systems

• Hydraulic brake system servicing
• Front disc brake overhaul
• Rear disc/drum brake servicing
• ABS diagnostics (where equipped)
• Electronic Brakeforce Distribution (EBD) diagnostics
• Brake master cylinder overhaul
• Brake booster servicing
• Parking brake adjustment
• Wheel speed sensor diagnostics
• Brake hydraulic system bleeding

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine ECU diagnostics
• Charging system testing
• Starting system diagnostics
• Alternator servicing
• Starter motor overhaul
• Battery testing
• Lighting system wiring
• Instrument cluster diagnostics
• Power window servicing
• Central locking diagnostics
• Power mirror wiring
• Audio system wiring
• Immobiliser diagnostics
• Relay testing
• Connector pin-outs
• Ground point locations
• Electrical circuit testing

Air Conditioning and HVAC

• Air conditioning diagnostics
• Heater system servicing
• Compressor replacement
• Condenser servicing
• Evaporator repairs
• Refrigerant circuit testing
• HVAC control diagnostics
• Blower motor servicing
• Heater core replacement

Body, Interior and Restraint Systems

• SRS airbag diagnostics
• Seat belt pretensioner servicing
• Dashboard removal
• Door trim removal
• Window regulator servicing
• Tailgate servicing (Wagon)
• Exterior lighting repairs
• Interior trim servicing
• Door lock servicing
• Exterior mirror repairs

Diagnostics and Troubleshooting

• Factory diagnostic procedures
• Engine performance diagnostics
• Fuel system diagnostics
• Ignition system testing
• Automatic transmission diagnostics
• ABS troubleshooting
• SRS fault diagnosis
• Electrical circuit testing
• Sensor testing procedures
• Actuator testing
• Factory diagnostic flowcharts

Common Error Codes Covered

Engine Codes

• P0101 — Mass Air Flow Sensor Range/Performance
• P0113 — Intake Air Temperature Circuit High Input
• P0125 — Insufficient Coolant Temperature for Closed Loop Fuel Control
• P0171 — System Too Lean (Bank 1)
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0301 — Cylinder 1 Misfire Detected
• P0302 — Cylinder 2 Misfire Detected
• P0303 — Cylinder 3 Misfire Detected
• P0304 — Cylinder 4 Misfire Detected
• P0335 — Crankshaft Position Sensor Circuit Malfunction
• P0340 — Camshaft Position Sensor Circuit Malfunction
• P0420 — Catalyst System Efficiency Below Threshold
• P0442 — EVAP System Small Leak Detected
• P0455 — EVAP System Large Leak Detected
• P0505 — Idle Air Control System Malfunction
• P0606 — ECM/PCM Processor Fault

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0715 — Input Speed Sensor Circuit
• P0720 — Output Speed Sensor Circuit
• P0730 — Incorrect Gear Ratio
• P0743 — Torque Converter Clutch Solenoid Circuit
• P0753 — Shift Solenoid A Electrical

ABS and Chassis Codes

• C1015 — Front Right Wheel Speed Sensor Circuit
• C1020 — Front Left Wheel Speed Sensor Circuit
• C1210 — Brake Pressure Sensor Fault
• C2116 — ABS Pump Motor Circuit Fault

Network Communication Codes

• U1100 — CAN Communication Line Error
• U1101 — CAN Timeout Communication

Body Control Codes

• B1206 — Driver Door Lock Circuit Malfunction
• B1213 — Passenger Door Lock Circuit Malfunction
• B2404 — Blower Motor Circuit Malfunction

Plus many additional Mitsubishi-specific diagnostic codes.

Fuse Box Diagram

• Engine compartment fuse box layout
• Passenger compartment fuse box layout
• Fuse identification chart
• Relay locations
• Fuse amperage ratings
• Protected circuit identification
• Power distribution diagrams

Wiring Diagrams

• Engine management wiring
• Fuel injection wiring
• Ignition system wiring
• Automatic transmission wiring
• ABS wiring
• SRS wiring
• Air conditioning wiring
• Lighting circuits
• Instrument cluster wiring
• Power windows
• Central locking
• Audio system wiring
• Connector views
• Ground point diagrams
• Component location diagrams

Serpentine Belt and Timing System Information

• Timing belt replacement procedures
• Camshaft timing specifications
• Crankshaft timing procedures
• Timing mark illustrations
• Timing belt tensioner inspection
• Accessory drive belt routing
• Drive belt tension specifications
• Timing component inspection

Torque Specifications

• Cylinder head bolt torque
• Main bearing cap torque
• Connecting rod bolt torque
• Crankshaft pulley torque
• Camshaft sprocket torque
• Flywheel torque
• Wheel nut torque
• Brake caliper torque
• Suspension fastener torque
• Steering component torque
• Engine mount torque
• Spark plug torque

Maintenance and Service Information

• Factory maintenance schedules
• Engine oil specifications
• Manual transmission oil specifications
• Automatic transmission fluid specifications
• Coolant specifications
• Brake fluid specifications
• Power steering fluid specifications
• Spark plug replacement intervals
• Air filter servicing
• Cabin air filter replacement
• Timing belt replacement intervals
• Cooling system maintenance
• Brake inspection procedures
• Tyre rotation procedures
• Battery maintenance

Who Is This Manual For?

• New Zealand automotive workshops
• Independent repair garages
• Automotive technicians
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions