In a famitsu article (i have to find it, i think to save it from somewhere in HardDisk) i remember that the journalist say "playable version of Bio Hazard 4". It was December 2002 and game was playable (amazing).

In this German Article, they talk about 40%: 
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Neue Infos zu Biohazard 4[/i:dc369ec74a][/b:dc369ec74a]
20.11.02 - Wie Capcom in der aktuellen Famitsu Cube &amp; Advance mitteilt, ist noch nicht entschieden, auf wie vielen DVDs Biohazard 4 ausgeliefert wird.  Der Entwicklungsstand liegt derzeit bei 40 %. Release: TBA.
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[b:dc369ec74a]Here:[/b:dc369ec74a][/i:dc369ec74a]
Production Studio 4 Announcements. Capcom Co., Ltd. (via Internet Archive). 14 November 2002. Archived from the original on 16 November 2002. Retrieved 17 July 2010. "The game the whole world has been waiting for will finally be unveiled. The story takes place deep inside the very heart of Umbrella, the evil company responsible for the progenitor virus. The main character of Resident Evil 2, Leon S. Kennedy, is back in the game. What will Umbrella have in store for him this time? That "surprise" will push Leon to the very limits of his being for one purpose...the STRUGGLE to survive. Director / Hiroshi Shibata"

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Another news of 2002:[/i:dc369ec74a][/b:dc369ec74a]
Resident Evil 4
Director: Hiroshi Shibata
Release date: "200X"

The next installment in the Resident Evil franchise stars RE2's Leon S. Kennedy and takes players into the very core of the Umbrella Company. Ditching the pre-rendered backgrounds and static cameras, it will run in full blow 3D this time around. 

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Other news of 2002:[/b:dc369ec74a][/i:dc369ec74a]
The first footage RE4, show above, is all in real-time and, although it's hard to make out exactly what is going on, it is unbelievably detailed. It seems Capcom is trying its hardest to reproduce the beautiful visuals we've seen with the GameCube remakes in real-time. From the robust lighting model to the gorgeous animation, it looks like the team is succeeding. Control will undoubtedly feel the biggest impact with the move to 3D, and with any luck will leap forward with improvement. The announced release date of 200X seems to indicate the title may not find its way to stores until at least 2004.

BTW: This link is for all news about Resident Evil 4 on Ign.com 
http://uk.cube.ign.com/objects/015/015821_articles.html

Amazing old screen about Bio Hazard 4 in 2002:
http://uk.media.cube.ign.com/media/015/015821/imgs_23.html
http://uk.media.cube.ign.com/media/015/015821/imgs_22.html
http://uk.media.cube.ign.com/media/015/015821/imgs_21.html

4- Yeah, i know. 
We have to find some ex-developer of Production Studio 4, maybe he have Resident Evil betas of 2002 or later.

5- Yeah, but for that maybe is better a new website, with a link to BioFlames (that's always good!)
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All info about Bio Hazard 4, from Wikipedia:[/b:dc369ec74a]
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The game's new title was revealed as Devil May Cry in November 2000,[23] and development on Resident Evil 4 started over at the end of 2001.[24]

The first official announcement of the game was made in November 2002, as one of five games exclusively developed for the Nintendo GameCube by Capcom Production Studio 4.[1][25] This revision, commonly dubbed the "fog version", was directed by Hiroshi Shibata[26] and was 40 percent finished at that time.[27] The game saw Leon S. Kennedy infiltrating the Umbrella headquarters in Europe and featured traditional Resident Evil monsters such as zombies.[9][28][29] During the course of the new story which was again written by Sugimura's scenario creation company Flagship,[30] Leon became infected with the Progenitor Virus and possessed a hidden power in his left hand.[9][31][32] The producer of the final version also pointed out that Ashley did not appear back then, though there was a different girl who was never revealed to the public.[9]
 
 This screenshot of a canceled version depicts Leon fighting the hook man. Though this earlier revision still used fixed camera angles while exploring environments, the battles already employed the over-the-shoulder view seen in the final build.

Nevertheless, it was decided to start development over again.[9] At E3 2003, another revision was revealed that is widely known as the "hook man version" now, though officially titled Maboroshi no Biohazard 4 (&#24187;&#12398;&#12300;&#12496;&#12452;&#12458;&#12495;&#12470;&#12540;&#12489;4&#12301;?, lit. "Hallucination Biohazard 4") on the Biohazard 4 Secret DVD.[33] During Mikami's introduction of the trailer, he assured that development was proceeding very smoothly and claimed the game to be the scarier than ever before, warning gamers with the quote "Don't pee your pants!"[33] The story was set in a haunted building where Leon contracted a bizarre disease and fought paranormal enemies, such as medieval suits of armor, living dolls, and a ghostlike man armed with a large hook.[28][33] The game had an otherworldly feel to it, containing elements like flashbacks and hallucinations that were marked by a bluish tint and a shaking camera.[9] It also displayed various gameplay mechanics that carried over to the final release, like the over-the-shoulder camera for aiming in battles.[33] Other features, such as dialogue choices, were removed later.[9] Though ultimately scrapped, five minutes of gameplay footage for this version were released on the Biohazard 4 Secret DVD, a Japanese preorder bonus given out in January 2005.[34] After this attempt, the last canceled revision featured zombies again, but was discontinued before it was shown to the public as the developers felt it was too formulaic.[9]

Following that, it was decided to change the game's genre to reinvent the series.[28] Mikami took over directorial duties from Shibata and began working on the version that was released.[35] In a later interview, he mentioned that he was put under enormous pressure by Capcom, threatened with the series' cancellation if the game had not sold well.[36]