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Mitsubishi Colt Lancer 1996-2003 All Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer / Colt Production Years: 1996-2003 Codes Chassis Codes: CJ2A, CK2A, CM2A, CK4A, CK6A, CP9A (Evolution models), CA4A, CB4A, CC4A (earlier generations overlapping)...
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Type: Car
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Sku: 82036
Mitsubishi Colt Lancer 1996-2003 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer / Colt
Production Years:
1996-2003
Codes
Chassis Codes:
CJ2A, CK2A, CM2A, CK4A, CK6A, CP9A (Evolution models), CA4A, CB4A, CC4A (earlier generations overlapping)
Engine Codes:
4G92, 4G93, 4G94, 4G63 (Evolution models)
👋 Introduction
Market Position
Segment:
Compact/Small Family Car
Target Audience:
DIY mechanics, car enthusiasts, independent repair shops.
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Mazda 323/Familia, Subaru Impreza.
Key Features
Value Proposition:
Affordable, reliable, and often engaging to drive, particularly performance variants like the Evolution.
Dvp Focus:
Empowering owners to maintain and repair their vehicles, saving on labor costs and ensuring proper upkeep.
📋 Manual Details
Coverage Areas
Covered Regions:
Global (specifically targeting markets where Colt and Lancer were sold under these names, common in Europe, Asia, Australia, and North America for certain generations)
Page Count
Estimated Page Count:
1500-2500+ (estimated for a comprehensive PDF service manual covering multiple engine and body variants)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul procedures for all listed engine variants (e.g., 4G92 SOHC/DOHC, 4G93 SOHC/DOHC, 4G94 SOHC, 4G63 Naturally Aspirated and Turbocharged for Evo models).
Transmission:
Manual and Automatic transmission repair, clutch service, drivetrain components (CV joints, driveshafts).
Fuel System:
Fuel injection systems (MPI), fuel pump, injectors, pressure regulation, fuel tank and lines, emissions control systems.
Ignition System:
Ignition coils, spark plugs, ignition control modules, distributors (if applicable), timing.
Cooling System:
Radiator, thermostat, water pump, coolant hoses, fan assembly, pressure cap, heater core.
Lubrication System:
Oil pump, oil filter, oil pan, oil pressure diagnostics, oil cooler (if equipped).
Exhaust System:
Manifold, catalytic converter, muffler, exhaust pipes, oxygen sensors.
Brakes:
Hydraulic system, ABS (if equipped), brake pads, rotors, calipers, master cylinder, brake lines, parking brake.
Suspension:
Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), wheel alignment specifications.
Steering:
Power steering system, steering rack/gearbox, steering column, tie rod ends.
Electrical System:
Battery, alternator, starter motor, wiring diagrams, lighting system, fuses, relays, power windows, mirrors, central locking.
Body And Chassis:
Body panel repair, door mechanisms, interior trim, glass replacement, rust prevention, jacking points.
HVAC:
Air conditioning system service, heater core, blower motor, climate control unit.
Safety Systems:
Airbag system diagnostics and replacement (where applicable).
Procedures Included
Maintenance:
Scheduled maintenance items, fluid changes (oil, coolant, brake, transmission), filter replacements, belt inspections/replacements.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-I/OBD-II where applicable).
Repair:
Step-by-step repair instructions for all major mechanical and electrical components.
Overhaul:
Complete engine and transmission rebuild procedures, including torque specifications and clearances.
Adjustment:
Valve adjustments, clutch adjustments, brake adjustments.
Installation:
Component installation and removal procedures for key parts.
Technical Depth
Depth:
Comprehensive, covering everything from basic owner-level maintenance to full engine and transmission rebuilds, including electrical system diagnostics with wiring diagrams.
📊 Manual Specifications
File Format
Format Type:
PDF
Searchability:
Typically searchable text-based PDF for efficient information retrieval.
Print Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
1.3L (4G92), 1.5L (4G91/4G93), 1.6L (4G92), 1.8L (4G93/4G94), 2.0L Turbocharged (4G63 - Evolution models).
Performance
Typical Horsepower Range:
70-120 hp (naturally aspirated), 270-280 hp (Evolution models).
Typical Torque Range:
110-170 Nm (naturally aspirated), 350-370 Nm (Evolution models).
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI), Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating typically 91 RON minimum for NA, 98 RON recommended for Evo)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission
Features
Drivetrain:
Front-Wheel Drive (FWD) standard; All-Wheel Drive (AWD) available on Evolution models and some specific market variants.
Clutch Type:
Dry single-plate clutch (manual transmission)
📐 Dimensions
Exterior
Typical Length:
4300-4450 mm (varies by body style/generation)
Typical Width:
1690-1770 mm (varies by body style/generation)
Typical Height:
1400-1450 mm (sedan), 1430-1470 mm (hatchback)
Wheelbase:
2500-2620 mm (varies by generation)
Weights
Curb Weight:
1050-1300 kg (varies by engine and trim)
🛡️ Safety Features
Ratings
Crash Test Data:
Information available from various independent testing agencies for specific model years and regions (e.g., Euro NCAP, IIHS). Often rated as average for its era.
Active Features
ABS:
Optional or standard on higher trims and specific markets. Anti-lock Braking System.
Traction Control:
Available on some higher-performance or AWD variants.
Passive Features
Airbags:
Driver and front passenger airbags standard on later models/higher trims.
Seatbelts:
Three-point inertia reel seatbelts front and rear.
💡 Technology Features
Infotainment
Head Unit:
Typically factory-fitted single-DIN or double-DIN AM/FM/Cassette or CD players. Aftermarket upgrades common.
Driver Assistance
Cruise Control:
Available on higher trim levels or as an optional extra.
Connectivity
Phone Integration:
Not present in factory systems of this era. Aftermarket Bluetooth kits available.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type (refer to manual for specifics).
Air Filter Replacement:
Every 20,000-40,000 km or as needed based on inspection.
Spark Plug Replacement:
Every 40,000-100,000 km, depending on spark plug type (copper, platinum, iridium).
Timing Belt Replacement:
Typically 80,000-100,000 km or 5-7 years for 4G9x engines. 4G63 (Evo) also requires regular replacement. Critical component to prevent engine damage.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, Viscosity SAE 10W-30 or 10W-40 (check manual for specific engine and climate).
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (MS-9790) or equivalent. Green or pink color.
Transmission Fluid Manual:
API GL-3 or GL-4 SAE 75W-90 or 80W-90 Gear Oil.
Transmission Fluid Automatic:
Dexron III or equivalent ATF (Automatic Transmission Fluid).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine:
Oil consumption in some high-mileage engines, potential head gasket issues on certain 4G93/4G94 variants, ignition coil failures.
Transmission:
Wear in manual gearbox synchros (especially 5th gear), occasional automatic transmission solenoid issues.
Suspension:
Worn control arm bushings, worn shock absorbers/struts, creaks from sway bar links.
Electrical:
Corrosion on electrical connectors, issues with power window motors, intermittent dashboard warning lights.
Body:
Rusting, particularly around wheel arches, sill panels, and rear quarter panels, especially in regions with road salt.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation
Model Evolution
Generation Overview:
This period covers the 6th and 7th generations of the Mitsubishi Lancer globally. The 'Colt' name was often used for the Lancer in specific markets (e.g., Europe) during parts of this era, or for distinct smaller models like the Mitsubishi Colt (not a Lancer variant).
Key Variants:
Lancer GLXi, Lancer GSR, Lancer Evolution (IV, V, VI, VII) - highly acclaimed rally homologation specials.
Production
Manufacturing Locations:
Japan (Okazaki Plant), and various international assembly plants depending on market.
🏆 Awards & Recognition
Recognitions
Rally Success:
The Lancer Evolution models were legendary in the World Rally Championship (WRC), achieving significant success and contributing to the model's performance image.
General Reputation:
Praised for reliability and value in standard trims, and performance pedigree in Evolution variants.
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