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Mitsubishi Colt -Lancer 1992-1995 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Colt / Lancer Model Codes: CC (Colt), CA (Lancer) Generation: Sixth Generation (CB/CC/CD) Codes Chassis Codes: CC, CA 👋 Introduction Market Position Market...
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Mitsubishi Colt -Lancer 1992-1995 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Colt / Lancer
Model Codes:
CC (Colt), CA (Lancer)
Generation:
Sixth Generation (CB/CC/CD)
Codes
Chassis Codes:
CC, CA
👋 Introduction
Market Position
Market Segment:
Compact car, subcompact car (depending on region and specific model variant), affordable and reliable transportation
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Nissan Sentra, Ford Escort, Mazda 323/Familia, Hyundai Elantra
Key Features
Vehicle Strengths:
Reliability, fuel efficiency, practicality, value for money, nimble handling
Manual Value Proposition
Target Audience:
DIY mechanics, independent repair shops, classic car enthusiasts
Benefits:
Empowers owners to perform maintenance and repairs, reduces repair costs, ensures proper vehicle upkeep, aids in diagnosing issues accurately
📋 Manual Details
Coverage Areas
Regions Covered:
Global (North America, Europe, Asia, Oceania) - specific market variations may exist
Page Count
Estimated Page Count:
800-1200 (typical for comprehensive service manuals of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Print (likely bound paperback or spiral-bound)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (4G1x, 4G9x series), fuel injection, ignition, exhaust, emissions control, manual transmission, automatic transmission, drivetrain components (CV joints, axles)
Chassis:
Suspension (front MacPherson strut, rear multi-link or torsion beam), steering (rack and pinion, power assist), braking system (disc/drum, ABS diagnostics), wheels and tires
Body And Interior:
Body construction and repair, interior trim, HVAC system, seating, body hardware (doors, hood, trunk), glass, exterior lighting, safety systems (seat belts, airbags - early models)
Electrical:
Wiring diagrams, starter system, charging system, lighting system, instrumentation, instrument cluster, body control modules (BCM - early integration), power accessories (windows, locks), fuse and relay locations
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, spark plug service, belt tensioning, tire rotation
Diagnostics And Troubleshooting:
Fault diagnosis for all major systems, reading diagnostic trouble codes (DTCs), troubleshooting flowcharts, symptom-based repair guidance
Mechanical Repairs:
Engine overhaul (top-end, bottom-end), transmission rebuild, brake caliper and rotor replacement, suspension component replacement (shocks, struts, bushings), steering rack repair
Electrical Repairs:
Component testing (alternator, starter, sensors), wiring harness repair, diagnostic connector usage, basic ECU troubleshooting
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, troubleshooting, component removal/installation, and detailed mechanical/electrical system overhauls. Includes torque specifications, clearances, and diagnostic procedures.
📊 Manual Specifications
File Format
Print Quality:
Professional print, clear diagrams and text (typical of factory manuals)
Binding Type
Binding:
Likely staple-bound, perfect bound, or spiral-bound for durability in a workshop environment
Paper Type
Paper Quality:
Durable paper stock, resistant to shop grime and handling
⚙️ Engine Specifications
Primary Engine
Engine Codes:
4G13 (1.3L), 4G15 (1.5L), 4G91 (1.5L DOHC), 4G92 (1.6L DOHC MIVEC), 4G63 (2.0L DOHC - performance variants)
Performance
Horsepower Range:
60 - 140 HP (approx., depending on engine variant)
Torque Range:
75 - 130 lb-ft (approx., depending on engine variant)
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI) for most variants, Carbureted on some base models in certain markets
Fuel Type:
Unleaded Gasoline (Octane rating as per market/owner's manual)
Cooling System
Coolant Type:
Ethylene Glycol based, typically a green color (refer to manual for specific spec, e.g., Mitsubishi DiaQueen SUPER LONG LIFE COOLANT)
Engine Management
ECU Type:
Electronic Control Unit (ECU) for fuel injection and ignition timing
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
3-speed or 4-speed Automatic Transmission
Features
Transmission Fluid Type:
ATF Dexron-III or equivalent (for automatic), Gear Oil SAE 75W-90 GL-4 (for manual)
Drivetrain
Drive Layout:
Front-Wheel Drive (FWD), Optional All-Wheel Drive (AWD) on select performance Lancer models
📐 Dimensions
Exterior
Body Styles:
3-door Hatchback, 5-door Hatchback, 4-door Sedan
Wheelbase:
2440 mm - 2500 mm (approx., depending on body style and market)
Length:
4000 mm - 4300 mm (approx., depending on body style)
Width:
1650 mm - 1700 mm (approx.)
Height:
1350 mm - 1450 mm (approx.)
Weights
Curb Weight:
950 - 1200 kg (approx.)
Gross Vehicle Weight Rating:
Not readily available without specific model trim, but typically around 1500-1700 kg
Wheels Tires
Wheel Bolt Pattern:
4x114.3 mm (4x4.5 inches)
Typical Tire Sizes:
175/70R13, 185/65R14, 195/55R15 (depending on trim and region)
🛡️ Safety Features
Ratings
Crash Test Results:
Not consistently rated by modern agencies like NHTSA/Euro NCAP for this specific era. Likely basic safety standards of the time.
Active Features
Active Safety Systems:
Optional Anti-lock Braking System (ABS) on higher trims, Power Assisted Brakes
Passive Features
Passive Safety Features:
Seat belts (front, possibly rear), optional driver airbag (late models/specific markets), reinforced safety cell construction
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette player, optional CD player on higher trims. Basic speaker setup.
Features:
Manual tuning, volume control, seek function. Limited to audio playback.
Driver Assistance
Assistance Systems:
Primarily manual driver input. Cruise control available on some higher trim levels/markets.
Connectivity
Connectivity Features:
None in the modern sense (no Bluetooth, USB, etc.). Antennas for radio reception.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months (whichever comes first), depending on driving conditions and oil type used.
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection, especially in dusty environments.
Spark Plug Replacement:
Every 30,000-60,000 miles for conventional plugs, longer for platinum/iridium (refer to manual for specific plug type).
Timing Belt Replacement:
Crucial interval, typically 60,000 miles or 4 years for 4G1x engines. 4G9x and 4G63 may differ. Failure can cause catastrophic engine damage (interference engine).
Fluid Specifications
Engine Oil Capacity:
3.5 - 4.5 liters (approx., depending on engine and oil filter)
Engine Oil Viscosity:
10W-30 or 10W-40 typically recommended, consult manual for ambient temperature suitability.
Transmission Fluid Capacity:
Manual: 2.0-2.5 liters; Automatic: 5.5-7.0 liters (approx., depending on model and drain/fill vs. overhaul)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron-II or III
Known Issues
Common Problems Powertrain:
Timing belt failure (critical maintenance item), water pump leaks, minor oil leaks from seals, clutch wear (manual transmission), automatic transmission solenoid issues.
Common Problems Chassis:
Worn suspension bushings (leading to knocking noises), premature CV joint wear, seized brake calipers (especially rear drums), power steering pump leaks.
Common Problems Electrical:
Corroded ground points, faulty alternator or voltage regulator, instrument cluster failures (dim lighting, inaccurate gauges), window regulator issues, central locking problems.
Common Maintenance Tasks
Items Covered:
Fuel filter replacement (often overlooked), distributor cap and rotor inspection/replacement, PCV valve service, thermostat replacement.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation
Model Evolution
Predecessor:
Mitsubishi Lancer (Fifth Generation - CB/CC)
Successor:
Mitsubishi Lancer (Seventh Generation - CS/CT)
Production
Production Years:
1992-1995
Major Manufacturing Locations:
Japan (Mizushima Plant), Australia, Colombia, South Africa, Taiwan
Market Context
Colt Nameplate:
The Colt nameplate was used primarily in Europe and Oceania, while Lancer was the dominant name globally. Essentially the same vehicle with regional branding.
🏆 Awards & Recognition
Recognitions
Awards Received:
While not receiving specific major 'Car of the Year' awards universally, the Lancer/Colt platform consistently earned recognition for its value, reliability, and sporty driving characteristics in its segment during its production years.
Ratings
Reliability Perception:
Generally considered a reliable vehicle with proper maintenance, especially with the 4G1x series engines. Performance variants (with 4G63) also have a strong reputation for durability if not heavily abused.
Certifications
Emission Standards:
Conforms to emissions standards of the period (e.g., EPA, Euro 1/2) depending on the market of sale. Manual covers diagnostic procedures related to emission control systems.
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