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Mitsubishi Colt 2002-2012 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Colt Generation Code: Z20 👋 Introduction Market Position Segment: Subcompact hatchback, known for its affordability, fuel efficiency, and practicality. Competitive Analysis Key Competitors:...
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Mitsubishi Colt 2002-2012 Factory Service Repair ManualMitsubishi Colt 2002-2012 Factory Service Repair ManualMitsubishi Colt 2002-2012 Factory Service Repair ManualMitsubishi Colt 2002-2012 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Colt
Generation Code:
Z20
👋 Introduction
Market Position
Segment:
Subcompact hatchback, known for its affordability, fuel efficiency, and practicality.
Competitive Analysis
Key Competitors:
Ford Fiesta, Opel Corsa, Volkswagen Polo, Peugeot 207, Toyota Yaris.
Key Features
Design Philosophy:
Compact exterior dimensions with surprisingly spacious interior packaging, emphasizing urban maneuverability and cost-effectiveness.
Reliability:
Generally considered a reliable vehicle with straightforward mechanicals, making maintenance accessible.
📋 Manual Details
Coverage Areas
Covered Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly procedures for engine components including cylinder head, block, pistons, crankshaft, camshafts, valves, and timing systems.
Engine Management:
Engine control unit (ECU) functions, sensor diagnostics (MAP, MAF, O2, TPS, CKP, CMP), fuel injection system operation, ignition system timing and control, emission control systems (EGR, EVAP).
Transmission Manual:
Service and repair procedures for manual transmissions, including clutch system, gear engagement, lubrication, and internal component inspection.
Transmission Automatic:
Diagnostic and repair procedures for automatic transmissions, including hydraulic control, torque converter operation, valve body servicing, and electronic controls.
Braking System:
Service and repair for hydraulic brake systems, including master cylinder, brake lines, calipers, wheel cylinders, and brake pad/shoe replacement. ABS and EBD system diagnostics.
Suspension Steering:
Repair and adjustment of front and rear suspension components (struts, shocks, control arms, ball joints), steering rack, power steering system, and wheel alignment procedures.
Electrical System:
Comprehensive wiring diagrams, component location charts, diagnostic procedures for lighting, charging system (alternator, battery), starting system, interior/exterior electronics, and body control modules.
HVAC System:
Refrigerant handling, compressor, condenser, evaporator, blower motor, climate control module diagnostics, and leak detection.
Body And Chassis:
Panel replacement, door mechanisms, glass, interior trim removal and installation, chassis components, and corrosion protection measures.
Procedures Included
Preventative Maintenance:
Detailed schedules for oil changes, filter replacements, fluid checks, belt inspections, and spark plug replacement.
Troubleshooting:
Systematic diagnostic flowcharts and symptom-based troubleshooting guides for common and intermittent issues.
Component Replacement:
Step-by-step instructions for replacing wear items and major components like alternators, starters, water pumps, radiators, and brake assemblies.
Diagnostic Procedures:
Guidance on using scan tools, interpreting diagnostic trouble codes (DTCs), and performing specific tests for various ECUs and sensors.
Rebuilding Procedures:
Detailed instructions for rebuilding major components such as engines, transmissions, and braking systems.
Technical Depth
Depth:
Comprehensive from basic maintenance to advanced diagnostics and full component rebuilds, suitable for both DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick access to information.
Print Quality
Resolution:
High resolution, ensuring clarity of diagrams, schematics, and images.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
4A91 (1.5L MIVEC), 4G15 (1.5L), 6A30 (1.3L)
Engine Displacement Range:
1.1L to 1.6L (depending on market and specific variant)
Engine Type:
Inline 3-cylinder and 4-cylinder, SOHC and DOHC, naturally aspirated gasoline engines. Some markets featured MIVEC (Mitsubishi Innovative Valve timing Electronic Control) for improved performance and efficiency.
Performance
Horsepower Range:
Approximately 65 hp to 115 hp (depending on engine variant)
Torque Range:
Approximately 95 Nm to 150 Nm (depending on engine variant)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (INVECS-II)
Features
Transmission Features:
Continuously Variable Transmission (CVT) also available on some variants, offering enhanced fuel economy.
📐 Dimensions
Exterior
Length Range:
Approx. 3,810 - 3,870 mm (varies by sub-model and year)
Width Range:
Approx. 1,680 - 1,700 mm
Height Range:
Approx. 1,530 - 1,570 mm
Wheelbase Range:
Approx. 2,450 - 2,470 mm
Weights
Curb Weight Range:
Approx. 1,000 - 1,150 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Euro NCAP awarded 4 stars for adult occupant protection on certain models, with variations based on equipment levels.
Active Features
ABS:
Anti-lock Braking System (ABS) available on most models, often with Electronic Brake-force Distribution (EBD).
Traction Control:
Traction Control System (TCS) available on higher trims or as an option.
Passive Features
Airbags:
Driver and front passenger airbags standard; side airbags and curtain airbags available on select models/trims.
Seatbelts:
Pre-tensioning front seatbelts with load limiters.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM radio with CD player; optional MP3 compatibility and upgraded speaker systems available.
Display:
Basic digital or analog displays for information; some models may feature multi-information displays.
Driver Assistance
Parking Sensors:
Rear parking sensors available on some higher trim levels.
Connectivity
Aux Input:
Auxiliary audio input jack often available on later models or as an accessory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km or 12 months, whichever comes first, depending on driving conditions.
Air Filter Replacement:
Recommended every 30,000 km or as needed based on inspection.
Spark Plug Replacement:
Varies by spark plug type; Iridium-tipped plugs typically recommend replacement around 80,000-100,000 km.
Fluid Specifications
Engine Oil Specification:
API SN/SP or ILSAC GF-5/GF-6, SAE 0W-20 or 5W-30 (refer to owner's manual for specific engine variant).
Coolant Specification:
Mitsubishi Genuine Super Long Life Coolant (SLLC) or equivalent OAT-based antifreeze/coolant.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4 SAE 75W-85 or 75W-90 gear oil.
Transmission Fluid Automatic:
Mitsubishi Genuine DIA QUEEN ATF SP-III or equivalent.
Known Issues
Common Wear Items:
Clutch wear, front suspension components (bushings, ball joints), exhaust system corrosion, occasional ignition coil failures.
Electrical Quirks:
Intermittent issues with power windows, central locking, or dashboard warning lights can occur due to age and component wear.
Engine Performance:
Minor power loss or rough idle might indicate need for spark plug, air filter, or fuel injector cleaning/replacement.
📚 Vehicle History
Brand Heritage
Mitsubishi Legacy:
Mitsubishi Motors Corporation has a long history of producing reliable and innovative vehicles, with the Colt nameplate being one of its longest-standing models, tracing its roots back to the 1960s.
Model Evolution
Z20 Generation Context:
The Z20 generation Colt, introduced in 2002, represented a significant redesign for the model, focusing on modern styling, improved practicality, and enhanced technology for the subcompact segment.
Production
Production Plants:
Primarily produced at Mitsubishi's Okazaki Plant in Japan, with some models potentially assembled in other international facilities.
🏆 Awards & Recognition
Recognitions
General Reputation:
The Colt has historically been recognized for its value proposition and efficiency, making it a popular choice for budget-conscious buyers and first-time car owners.
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