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Mitsubishi Colt Ralliart 2006-2012 Repair Service Manual

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The Colt Ralliart Z20 Series represents a potent entry in the performance compact segment, building upon a rich rally heritage. Produced between 2006 and 2012, this model offers a spirited...
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SKU: 70457
Mitsubishi Colt Ralliart 2006-2012 Repair Service ManualMitsubishi Colt Ralliart 2006-2012 Repair Service ManualMitsubishi Colt Ralliart 2006-2012 Repair Service ManualMitsubishi Colt Ralliart 2006-2012 Repair Service Manual
The Colt Ralliart Z20 Series represents a potent entry in the performance compact segment, building upon a rich rally heritage. Produced between 2006 and 2012, this model offers a spirited driving experience characterized by its turbocharged 1.5-liter 4G15T engine, delivering approximately 150-163 PS and 200-210 Nm of torque. Its agile handling, sport-tuned suspension, and upgraded braking systems, all built on the Project Global Small Platform, make it a compelling choice for enthusiasts seeking dynamic performance in a compact package. The Ralliart designation signifies factory-enhanced capabilities, including a sportier aerodynamic body kit and often sport seats, further emphasizing its performance-oriented design. This comprehensive workshop repair and service manual provides detailed technical information for the Colt Ralliart, covering model years 2006 through 2012. It serves as an essential resource for owners, technicians, and mechanics, offering in-depth guidance on all major vehicle systems, including engine mechanical and electrical components, transmission, drivetrain, suspension, steering, brakes, and HVAC. The manual details routine and scheduled maintenance procedures, troubleshooting faulty systems, and step-by-step repair and component replacement instructions. It also includes crucial technical specifications, diagnostic procedures, wiring diagrams, and information on special tools, ensuring thorough understanding and effective maintenance of the vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Colt Ralliart
Generation:
Z20 Series (Specific to Ralliart variants)
Codes
Platform:
Mitsubishi Project Global Small Platform (Shared with Smart Forfour)
👋 Introduction
Market Position
Segment:
Hot Hatch / Performance Compact
Target Audience:
Enthusiasts seeking performance in a compact, affordable package.
Competitive Analysis
Key Competitors:
Ford Fiesta ST, Vauxhall Corsa VXR, Renault Clio RS, Volkswagen Polo GTI (depending on market).
Key Features
Performance Enhancements:
Turbocharged engine, sport-tuned suspension, upgraded brakes, aerodynamic body kit, sport seats.
Handling:
Sharp and agile handling due to compact dimensions and performance tuning.
Engine Responsiveness:
Punchy acceleration characteristic of its turbocharged engine.
Brand Heritage
Ralliart Legacy:
Continuation of Mitsubishi's performance tuning division, Ralliart, known for rally heritage and performance vehicles.
📋 Manual Details
Coverage Areas
Covered Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Page Count
Estimated Pages:
Thousands (typical for a comprehensive workshop manual)
Manual Type
Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, component replacement, timing belt/chain, seals, gaskets, cylinder head, block assembly, lubrication system.
Engine Electrical:
Ignition system, fuel injection system (ECI Multi), starter, alternator, ECU diagnostics, sensors, actuators, wiring diagrams.
Transmission:
Manual transmission (e.g., F5M43-2-C303, depending on specific Ralliart model), clutch system, gears, shafts, seals, maintenance, removal/installation.
Drivetrain:
Front-wheel drive system, differential, CV joints, drive shafts, wheel bearings.
Suspension:
Front struts, rear shock absorbers, springs, control arms, anti-roll bars, bushings, alignment procedures, troubleshooting.
Steering:
Power steering system, pump, rack and pinion, tie rods, steering column, troubleshooting.
Brakes:
Front and rear disc brakes, calipers, pads, rotors, master cylinder, brake lines, ABS system, parking brake, bleeding procedures.
Electrical Body:
Lighting system (headlights, taillights, interior), power windows, door locks, mirrors, wipers, horn, fuses, relays, body control module (BCM).
HVAC:
Air conditioning system, heater, blower motor, controls, refrigerant, troubleshooting.
Chassis Body:
Frame, body panels, doors, hood, trunk lid, bumpers, interior trim, sound deadening, rust prevention.
Diagnostics:
OBD-II fault codes, diagnostic procedures for various systems, troubleshooting flowcharts.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-ups, tire rotations, spark plug replacement.
Scheduled Maintenance:
Detailed schedules for 10,000km, 20,000km, etc., including specific component checks and replacements.
Troubleshooting Fault Finding:
Step-by-step diagnostic guides for common and uncommon issues across all vehicle systems.
Repair Rebuild:
Comprehensive instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Component Replacement:
Detailed guides for replacing major and minor components like alternators, water pumps, brake calipers, etc.
Specifications Settings:
Torque specifications for all fasteners, alignment angles, valve clearances (if applicable), diagnostic parameter settings.
Technical Depth
Depth:
From basic owner maintenance tasks to complex engine and transmission rebuilds, including electrical system diagnostics.
Diagnostic Tools:
References to specific Mitsubishi diagnostic tools (e.g., MUT-III) and generic OBD-II scanners.
Wiring Diagrams:
Detailed, system-specific wiring schematics with component identification and wire colors.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable for quick access to information.
Resolution:
High-resolution for clear diagrams and text.
Printable:
Yes, printable pages.
Print Quality
Quality Description:
Professional quality, clear technical illustrations and diagrams.
Binding Type
Binding Description:
Not applicable for PDF download, but would typically be perfect bound or spiral bound for a physical copy.
Paper Type
Paper Description:
Not applicable for PDF download.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G15T (Turbocharged inline-4)
Displacement:
1.5 Liters (1468 cc)
Configuration:
Inline 4-cylinder, DOHC, 16-valve
Aspiration:
Turbocharged with Intercooler
Performance
Horsepower:
Approximately 150-163 PS (110-119 kW) depending on market and specific tune.
Torque:
Approximately 200-210 Nm (148-155 lb-ft) depending on market and specific tune.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (ECI Multi) with Turbocharging
Fuel Type:
Unleaded Petrol (Octane rating typically 95 RON or higher recommended)
Engine Management
ECU Type:
Engine Control Unit (ECU) with integrated engine management functions.
Cooling System
Cooling Type:
Water-cooled with thermostatically controlled fan and pressurized radiator system.
Lubrication System
Oil Capacity:
Approx. 4.0 - 4.3 Liters (with filter change)
Oil Type:
API SN/SP, ACEA A3/B4, or higher; viscosity typically 5W-30 or 5W-40 (refer to owner's manual for exact specification).
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Gear Ratios:
Specific ratios vary by gearbox code, typically designed for sporty performance.
Clutch Type:
Hydraulically operated, dry single plate clutch.
Features
Performance Tuning:
Close-ratio gearing for enhanced acceleration.
Maintenance
Fluid Type:
Manual Transmission Fluid (MTF) GL-4, viscosity typically 75W-80 or 75W-90 (refer to manual for exact specification).
Fluid Capacity:
Approx. 2.0 - 2.3 Liters
📐 Dimensions
Exterior
Length:
Approx. 3810 - 3850 mm
Width:
Approx. 1690 - 1720 mm
Height:
Approx. 1475 - 1500 mm
Wheelbase:
Approx. 2500 mm
Ground Clearance:
Typically lowered for sportier stance, around 130-140 mm.
Weights
Curb Weight:
Approx. 1100 - 1180 kg
Gross Vehicle Weight:
Varies, consult vehicle placard.
Towing Capacity:
Not typically specified or recommended for this performance model.
🛡️ Safety Features
Ratings
Euro Ncap:
Typically 4 or 5 stars for the standard Colt model; Ralliart variants share the same structural safety but performance modifications do not affect crash test ratings.
Active Features
ABS:
Anti-lock Braking System standard on Ralliart models.
Ebd:
Electronic Brakeforce Distribution standard.
TCS:
Traction Control System (TCS) may be standard or optional depending on market and year.
Esp:
Electronic Stability Program (ESP) or similar stability control systems may be present.
Passive Features
Airbags:
Front airbags (driver and passenger), side airbags, curtain airbags (depending on trim and market).
Seatbelts:
3-point seatbelts with pre-tensioners, ISOFIX child seat anchors.
Body Structure:
Reinforced safety cell structure.
💡 Technology Features
Infotainment
Audio System:
Factory-installed CD player with radio, likely with basic speaker system. Higher trims may have upgraded audio or optional navigation.
Display:
Minimal in-dash display for audio and basic vehicle information. No large touchscreen infotainment systems typical of later models.
Driver Assistance
Parking Sensors:
Optional on some higher trim levels.
Cruise Control:
Available on many models, particularly those with manual transmission.
Connectivity
Usb Aux Input:
Unlikely to be standard, but some aftermarket head units or later model year updates might include these.
Bluetooth:
Generally not standard; may be an optional accessory or aftermarket fitment.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 km (or 12 months), whichever comes first, under normal driving conditions (refer to manual for severe conditions).
Air Filter Replacement:
Typically every 30,000 km or as needed based on inspection.
Spark Plug Replacement:
Typically Iridium spark plugs at 100,000 km intervals, but confirm exact type and interval.
Brake Fluid Change:
Typically every 2-3 years, regardless of mileage.
Fluid Specifications
Engine Coolant:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent (pink colored, ethylene glycol-based with demineralized water).
Brake Fluid:
DOT 3 or DOT 4, preferably low viscosity (LV) for ABS systems.
Known Issues
Turbocharger Wear:
As with many turbocharged cars, turbocharger longevity can be affected by maintenance practices, especially oil changes and ensuring proper cool-down periods.
Suspension Wear:
Bushings and shock absorbers can experience wear over time, particularly given the car's performance-oriented nature.
Intermittent Electrical Faults:
Wiring harness issues or sensor failures can lead to intermittent electrical problems, often resolvable with detailed diagnostics.
Clutch Wear:
Aggressive driving can accelerate clutch wear, requiring eventual replacement of the clutch disc, pressure plate, and release bearing.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Long history in automotive manufacturing, particularly known for rally success and durable vehicles.
Model Evolution
Colt Lineage:
The Colt nameplate has a long history, evolving through various generations and platforms. The Z20 Colt was a significant departure, focusing on a more modern and global platform.
Ralliart Introduction:
Ralliart versions were introduced to provide a factory-tuned, sportier variant of the standard Colt, leveraging Mitsubishi's performance expertise.
Production
Manufacturing Location:
Primarily produced in Japan and supplied to various global markets.
Production Period:
2006-2012 for the specific Ralliart generation covered by this manual.
🏆 Awards & Recognition
Recognitions
General Colt Reviews:
The standard Colt received mixed reviews, often praised for its handling and practicality but criticized for engine refinement in lower trims. The Ralliart variant was generally well-received by enthusiasts for its performance value.
Ralliart Tuning:
Ralliart's involvement typically meant a higher degree of performance validation and tuning compared to standard models.
Ratings
Reliability:
Generally considered reliable when properly maintained, with specific issues usually related to wear and tear rather than inherent design flaws.
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