🏷️ Basic Information

Make:

Mitsubishi

Model:

Colt Lancer

Product Type:

Workshop Service Repair Manual

Product Name:

1996-2007 Mitsubishi Colt Lancer Workshop Service Repair Manual

👋 Introduction

Positioning:

The Mitsubishi Colt Lancer of this era was positioned as a reliable, economical, and practical compact car, often appealing to budget-conscious buyers and those seeking a dependable daily driver. It competed directly with vehicles like the Honda Civic, Toyota Corolla, Nissan Sentra, and Ford Focus.

Strengths:

Known for its straightforward mechanicals, generally good reliability, and affordable parts availability. Often offered a sporty feel, particularly in certain trim levels (e.g., Evolution variants, though this manual likely covers standard models).

Weaknesses:

Interior materials could sometimes feel less premium than competitors. Some engine variants might have been perceived as underpowered compared to certain rivals. Rust could be an issue in certain climates.

Design:

Characterized by a relatively simple and functional design language, evolving through different generations within the covered period. The later models adopted a more aerodynamic and contemporary appearance.

Engine Options:

A range of efficient four-cylinder gasoline engines, typically in the 1.3L, 1.5L, and 1.8L displacements, with some markets receiving 2.0L options. Diesel engines were also available in some regions.

Transmission Options:

Available with both manual and automatic transmissions, offering a choice for different driving preferences.

📋 Manual Details

Applicable Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Global Market Coverage:

Covers models sold internationally under the Mitsubishi Lancer and Colt nameplates, as well as potentially rebadged variants in certain markets (e.g., Proton Wira/Persona in some regions).

Estimated Page Count:

1500+

Type:

Comprehensive Workshop Service and Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, including disassembly, inspection, assembly, torque specifications, timing belt/chain replacement, piston and ring replacement, valve train servicing, cylinder head repair, and oil pump operation.

Fuel System:

Fuel injection system diagnosis and repair, fuel pump testing, fuel pressure regulator, injectors, throttle body cleaning and adjustment, fuel tank removal and installation, and evaporative emission control (EVAP).

Engine Management And Ignition:

ECU diagnosis, sensor testing (MAF, MAP, O2, TPS, ECT), ignition coil testing, spark plug replacement, distributorless ignition systems (DIS) troubleshooting, and engine control module (ECM) parameters.

Cooling System:

Radiator service, thermostat replacement, water pump overhaul, fan clutch/electric fan operation, coolant type and capacity specifications, and troubleshooting overheating issues.

Exhaust System:

Catalytic converter replacement, muffler and exhaust pipe servicing, exhaust manifold gasket replacement, and oxygen sensor replacement procedures.

Transmission Manual:

Clutch system diagnosis and repair, clutch disc and pressure plate replacement, flywheel resurfacing, transmission fluid type and capacity, gear shift linkage adjustment, and internal transmission component inspection.

Transmission Automatic:

Automatic transmission fluid type and capacity, torque converter service, transmission control module (TCM) diagnosis, shift solenoid testing, and general automatic transmission troubleshooting.

Drivetrain And Axles:

Front-wheel drive (FWD) axle shaft replacement, CV joint boot repair and replacement, differential servicing, and driveshaft maintenance (for AWD variants, if applicable).

Suspension System:

Strut and shock absorber replacement, ball joint inspection and replacement, control arm bushing service, coil spring replacement, sway bar link maintenance, and wheel bearing replacement.

Steering System:

Power steering pump diagnosis and replacement, steering rack and pinion repair, tie rod end replacement, steering column lubrication, and power steering fluid specifications.

Brake System:

Front and rear brake pad and rotor replacement, brake caliper servicing, brake line and hose replacement, brake fluid type and bleeding procedures, parking brake adjustment, and ABS system diagnosis (if equipped).

Electrical System And Wiring:

Complete wiring diagrams for all vehicle systems, fuse box locations and identification, relay testing, starter motor and alternator testing and replacement, battery maintenance, and grounding point identification.

Lighting System:

Headlight, taillight, brake light, turn signal, and interior light bulb replacement procedures, headlight aiming, and exterior lighting circuit troubleshooting.

HVAC System:

Air conditioning (AC) system diagnosis and refrigerant handling, blower motor replacement, cabin air filter replacement, heater core service, and temperature control system troubleshooting.

Body And Chassis:

Door panel removal, exterior trim replacement, hood and trunk latch servicing, bumper removal and installation, glass replacement, and basic body panel repair guidance.

Interior Components:

Seat removal and installation, dashboard panel removal, center console access, and interior trim piece replacement.

Preventative Maintenance:

Detailed oil change procedures, filter replacement schedules (oil, air, fuel, cabin), fluid level checks and top-offs, tire rotation and pressure recommendations, spark plug replacement intervals, and belt inspection.

Troubleshooting Guides:

Systematic diagnostic procedures for common drivability issues, electrical faults, starting problems, braking concerns, and HVAC malfunctions, often including symptom-based troubleshooting trees.

Component Replacement:

Step-by-step instructions for replacing virtually every major and minor component on the vehicle, from alternators and starters to sensors, actuators, and body panels.

Diagnostic Procedures:

Guidance on using diagnostic tools, reading trouble codes (OBD-I/OBD-II depending on year), and interpreting sensor data for effective fault diagnosis.

Rebuilding And Overhaul:

Detailed instructions for engine and transmission rebuilds, including specifications for machining, clearances, and assembly sequences.

Torque Specifications:

Comprehensive list of all critical torque values for engine, chassis, and drivetrain fasteners, essential for proper assembly and safety.

Wiring Diagrams:

High-quality, detailed wiring schematics for all electrical systems, aiding in troubleshooting and repair of electrical faults.

Depth:

Extremely High - Covers everything from basic fluid changes and filter replacements to complete engine and transmission overhauls, complex electrical diagnostics, and body repair.

Target Audience:

Professional mechanics, experienced DIY enthusiasts, and automotive technical schools.

📊 Manual Specifications

Format Details:

Likely a searchable PDF document, allowing for quick navigation and keyword searches. Optimized for digital viewing and printing.

Quality:

High-resolution scans or original digital files ensuring clarity of text, diagrams, and illustrations.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Variants Covered:

Likely covers a range of inline 4-cylinder gasoline engines, including but not limited to: 4G13 (1.3L), 4G15 (1.5L), 4G91/4G92 (1.5L/1.6L, SOHC/DOHC), 4G93 (1.8L, SOHC/DOHC), 4G94 (2.0L). Diesel engines (e.g., 4D68) may also be covered depending on market scope.

Horsepower Range:

Approx. 75 HP (1.3L) to 140 HP (2.0L DOHC) for standard gasoline models. High-performance variants (like non-EVO RS/GSR) could exceed this.

Torque Range:

Approx. 100 Nm to 180 Nm, varying significantly with engine displacement and tuning.

Fuel Delivery:

Electronic Fuel Injection (EFI). Early models might have had carbureted variants, but EFI became standard across most markets within this period.

Fuel Type:

Unleaded gasoline (Octane rating recommendations will be in the manual, typically 91 RON or higher).

Engine Codes Common:

4G1x, 4G9x series (e.g., 4G13, 4G15, 4G91, 4G92, 4G93, 4G94).

Timing Mechanism:

Both timing belt and timing chain variants exist depending on the specific engine. The manual will detail procedures for both.

Emission Controls:

Catalytic converter, oxygen sensors (lambda sensors), evaporative emission control (EVAP) system, exhaust gas recirculation (EGR) system (on some models).

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission (MT).

Optional Transmission:

4-speed Automatic Transmission (AT) or CVT (Continuously Variable Transmission) on some models.

Drivetrain:

Front-Wheel Drive (FWD) is standard. All-Wheel Drive (AWD) or Four-Wheel Drive (4WD) was available on specific performance variants (e.g., Lancer Evolution) or select regular models in certain markets, though this manual may focus on FWD variants unless specified otherwise.

Clutch Type:

Dry, single-plate clutch, hydraulically actuated.

Manual Transmission Fluid:

GL-4 or GL-5 hypoid gear oil, SAE 75W-90 viscosity is common, but specific viscosity and API classification will be detailed in the manual. Capacity typically around 2.0-2.5 liters.

Automatic Transmission Fluid:

Specific ATF fluid (e.g., DIAQueen ATF SP-II M or equivalent) will be recommended. Capacity typically around 5.0-7.0 liters for a complete fluid change.

📐 Dimensions

Length:

Varies by generation and body style (sedan/hatchback), generally between 4200 mm and 4500 mm.

Width:

Varies by generation and body style, typically around 1700 mm.

Height:

Varies by generation and body style, typically around 1400 mm to 1450 mm.

Curb Weight:

Approximately 1050 kg to 1300 kg, depending on engine and transmission.

Gross Vehicle Weight Rating:

Will be specified in the manual, typically around 1500-1700 kg.

Wheel Bolt Pattern:

Commonly 4x114.3 mm (4-lug) or 5x114.3 mm (5-lug), depending on the specific model and year.

Tire Sizes:

Commonly 175/70R14, 185/65R14, 195/60R15, or 205/50R16, depending on trim level and optional wheel packages.

🛡️ Safety Features

Crash Test Data:

Specific ratings from organizations like NHTSA or IIHS for the 1996-2007 models would require specific year-by-year checks, but generally, vehicles of this era had moderate safety performance. The manual itself might not contain crash test results but will detail safety system components.

Active Safety Features:

Anti-lock Braking System (ABS) often optional or standard on higher trims. Traction Control System (TCS) may have been available on certain performance or luxury variants.

Passive Safety Features:

Front airbags for driver and passenger. Seatbelt pre-tensioners. Reinforced body structure (Zone Body construction). Side impact door beams.

💡 Technology Features

Infotainment System:

Basic AM/FM radio with CD player or cassette tape player. Some higher trim levels might have offered more advanced audio systems with more speakers. Navigation systems were rare in this segment and era.

Driver Assistance Features:

Limited by modern standards. Features like ABS and potentially TCS were the primary electronic aids. Cruise control was common on many trims.

Connectivity Options:

Very basic. Often included power windows and locks on higher trims. No Bluetooth or smartphone integration in models from the earlier part of this range.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 6-12 months, whichever comes first. Severe driving conditions may require more frequent changes.

Air Filter Replacement:

Recommended every 15,000-30,000 miles (24,000-48,000 km) or annually, depending on driving environment.

Spark Plug Replacement:

Intervals vary by spark plug type (copper, platinum, iridium). Typically 30,000-100,000 miles. Manual will specify exact type and interval.

Timing Belt Replacement:

Critical service item. Generally recommended every 60,000-90,000 miles (96,000-145,000 km) or 5-7 years, as failure can cause catastrophic engine damage. Manual will provide the precise interval.

Engine Oil Type:

API SG, SH, or SJ certified. Viscosity grade typically SAE 5W-30 or 10W-30, with recommendations varying based on climate. Manual will provide exact specification.

Coolant Type:

Ethylene glycol based antifreeze. Mitsubishi recommends specific coolant (e.g., DIAQUEEN SUPER LONG LIFE COOLANT) or equivalent with a 50/50 mix with deionized water. Conventional green coolant is also likely acceptable if meeting standards.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify exact requirement.

Common Wear Items:

Clutch wear, brake component wear (pads, rotors, calipers), suspension bushings and ball joints, CV joint boots, exhaust system components (muffler, pipes), and accessory belts.

Engine Specific Concerns:

Timing belt failure on interference engines if not replaced on schedule. Oil leaks from valve cover gaskets or oil pan gaskets. Potential for carbon buildup in engines with high mileage or infrequent oil changes.

Electrical Concerns:

Alternator failure, starter motor issues, and occasional power window regulator failures. Corrosion on ground points can cause intermittent electrical issues.

Transmission Concerns:

Automatic transmission shifting issues due to low fluid or worn solenoids. Manual transmission clutch wear. Synchro ring wear in manual transmissions on high-mileage examples.

📚 Vehicle History

Mitsubishi History:

Mitsubishi Motors, a division of the Mitsubishi conglomerate, has a long history in automotive manufacturing, known for both reliable economy cars and groundbreaking performance vehicles (like the Lancer Evolution series).

Lancer Generations Covered:

This manual likely covers the 6th generation (1995-2000) and 7th generation (2000-2007) of the Mitsubishi Lancer. These generations saw significant design evolutions and technological updates.

Production Period:

1996-2007 for the specific models covered by this manual. The Lancer nameplate itself has a much longer history dating back to 1973.

Manufacturing Locations:

Primarily manufactured in Japan by Mitsubishi Motors Corporation, with production facilities also located in various international markets through joint ventures or licensed manufacturing (e.g., Netherlands, Australia, South Korea, Philippines, South Africa, Brazil).

🏆 Awards & Recognition

Awards:

While specific awards for the standard Colt Lancer models of this period are not widely publicized, Mitsubishi vehicles from this era were often recognized for value and reliability in their respective segments by consumer automotive publications.

Consumer Ratings:

Generally received fair to good ratings for reliability and value in consumer surveys from the period. The Lancer Evolution variants, however, consistently received high praise for performance.