🏷️ Basic Information

Make:

Mitsubishi

Model:

Colt

Model Generation:

Z20 Series (2002-2012)

👋 Introduction

Segment:

Subcompact hatchback, known for its compact size, fuel efficiency, and affordability.

Competitors:

Competed with vehicles like the Ford Fiesta, Vauxhall Corsa, Peugeot 207, Volkswagen Polo, Toyota Yaris, and Honda Jazz during its production run.

Design Philosophy:

Focus on practicality, urban maneuverability, and economical operation. Often praised for its spacious interior relative to its exterior dimensions.

📋 Manual Details

Covered Years:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012

Estimated Pages:

Extensive (specific number not provided, typical for comprehensive workshop manuals)

Type:

Workshop Service Repair Manual

Manual Purpose:

For repair, maintenance, and troubleshooting of the Mitsubishi Colt.

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel injection system, ignition system, emission control systems, turbocharger (if applicable).

Engine Electrical:

ECU, sensors, actuators, starting system, charging system, ignition system, fuel pump, injectors, diagnostic trouble codes (DTCs).

Transmission:

Manual and Automatic Transmission (if applicable). Clutch, gearbox overhaul, torque converter, transmission control module (TCM), fluid specifications, shifting mechanisms.

Drivetrain:

Front-wheel drive (FWD) system, drive shafts, CV joints, differential.

Suspension:

Front and rear suspension components, shock absorbers, struts, springs, control arms, anti-roll bars, wheel alignment specifications.

Steering:

Power steering system, steering column, steering rack, tie rods, fluid specifications.

Brakes:

Front and rear brake systems, disc brakes, drum brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, bleeding procedures, caliper and master cylinder overhaul.

Body Exterior:

Body panel removal and installation, doors, hood, trunk lid, bumpers, glass, mirrors, exterior trim, rust repair, chassis structure.

Body Interior:

Dashboard removal, seats, carpeting, door panels, headliner, interior trim, HVAC controls, airbags.

Electrical Body:

Lighting systems (headlights, taillights, interior lights), power windows, power locks, wipers, horn, audio system, alarm system, instrument cluster, fuses and relays.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, blower motor, controls, troubleshooting.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure specifications.

Maintenance Tasks:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation.

Repair Procedures:

Detailed step-by-step instructions for component removal, overhaul, and reinstallation for all major vehicle systems.

Troubleshooting:

Diagnostic flowcharts, common fault diagnosis, symptom-based troubleshooting guides, DTC interpretation.

Electrical Diagnostics:

Wiring diagrams, circuit testing, component testing procedures, connector pinouts.

Engine Rebuild:

Complete procedures for engine disassembly, inspection, repair, and reassembly, including torque specifications and clearances for all internal engine components.

Transmission Overhaul:

Detailed steps for manual and automatic transmission overhaul, including clutch assembly, gear set inspection, valve body servicing (for automatic), and replacement of seals and bearings.

Body And Chassis:

Procedures for body panel alignment, dent repair, rust treatment, window replacement, and chassis component inspection and replacement.

Electrical Schematics:

Comprehensive wiring diagrams for all electrical systems, including engine control, lighting, accessories, and comfort systems.

Diagnostic Tools:

Information on diagnostic scan tools, OBD-II code definitions, and how to use them for troubleshooting.

Depth:

Comprehensive: Covers everything from routine maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics and body repair.

Torque Specifications:

Provides critical torque specifications for all fasteners, ensuring correct assembly and preventing component damage.

Diagnostic Charts:

Includes diagnostic flowcharts and decision trees to systematically identify and resolve faults.

📊 Manual Specifications

Compatibility:

Compatible with all PDF readers (Adobe Acrobat, etc.).

Searchability:

Searchable text within the PDF document allows for quick access to specific topics or components.

Quality:

High-resolution images and clear text, suitable for printing.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

Scope:

Full workshop manual scope, designed for professional technicians and advanced DIY mechanics.

⚙️ Engine Specifications

Engine Options:

Primarily equipped with 1.1L (3A91), 1.3L (4A90), and 1.5L (4A91) MIVEC 4-cylinder gasoline engines. Some markets may have offered diesel variants (e.g., 1.5L DI-D).

1.3L Mivec (4A90) Estimated:

Horsepower: ~90-95 PS (66-70 kW), Torque: ~120-125 Nm (89-92 lb-ft)

1.5L Mivec (4A91) Estimated:

Horsepower: ~107-110 PS (79-81 kW), Torque: ~140-145 Nm (103-107 lb-ft)

Injection Type:

Electronic Multi-point Fuel Injection (MPI) or Direct Injection (DI-D for diesel).

Engine Codes:

Commonly includes 4A9 series engines (e.g., 4A90, 4A91) for gasoline, and 4D56 or similar for diesel if applicable.

🔧 Transmission

Transmission Options:

Typically offered with a 5-speed manual transmission as standard.

Transmission Options:

Optional Continuously Variable Transmission (CVT) or 4-speed automatic transmission available on select models and markets.

Clutch Type:

Dry single-plate clutch (for manual transmission).

📐 Dimensions

Length:

Approx. 3,810 mm (149.9 in) (Varies slightly by specific model year/trim)

Width:

Approx. 1,680 mm (66.1 in)

Height:

Approx. 1,550 mm (61.0 in)

Wheelbase:

Approx. 2,500 mm (98.4 in)

Curb Weight:

Approx. 950 - 1100 kg (2094 - 2425 lbs) (Depending on engine and transmission)

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (for models tested, e.g., 2005 model tested with standard safety equipment).

Active Safety:

ABS with EBD (Electronic Brakeforce Distribution) often standard or available. Some models may feature traction control (TCL) or stability control (ASC).

Passive Safety:

Front airbags for driver and passenger, side airbags (optional on some trims), seatbelt pretensioners, reinforced body structure.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants, and three-point or lap belts for rear occupants.

💡 Technology Features

Infotainment Systems:

Basic AM/FM radio with CD player, optional auxiliary input or MP3 playback capabilities on later models. Limited infotainment features compared to modern vehicles.

Assistance Features:

Primarily focused on basic safety features like ABS. Advanced driver-assistance systems (ADAS) were not common for this model's era.

Connectivity Options:

Basic connectivity through audio system, potentially with Bluetooth on later facelifted models. No advanced smartphone integration like Apple CarPlay or Android Auto.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using synthetic oil. Refer to specific manual for exact intervals.

Air Filter Replacement:

Recommended every 30,000 km (18,600 miles) or as needed based on operating conditions.

Spark Plug Replacement:

Platinum or Iridium spark plugs typically require replacement around 60,000 - 100,000 km (37,000 - 62,000 miles).

Engine Oil Type:

API SN/SP, ILSAC GF-5 or newer. Viscosity grade typically 0W-20 or 5W-30 depending on engine and climate. (Always verify with manual).

Coolant Type:

Ethylene glycol based coolant, typically pink or red long-life coolant. (e.g., Diaqueen Super Long Life Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Manual:

API GL-4, SAE 75W-85 or 75W-90 gear oil.

Transmission Fluid Automatic Cvt:

Specific CVT fluid (e.g., Diaqueen CVTF-J1 or equivalent). Crucial to use the correct fluid type for CVT longevity.

Common Problems:

Potential for minor electrical gremlins, occasional issues with suspension components (e.g., worn bushings), and clutch wear in manual transmissions under heavy use. CVT reliability can depend heavily on adherence to fluid change intervals.

Common Wear Items:

CV joints, brake components (rotors, pads), suspension bushings, and exhaust system components are typical wear items.

Engine Oil Capacity:

Approximately 3.5 - 4.0 liters (3.7 - 4.2 US quarts) with filter change for 1.1L/1.3L/1.5L engines. (Verify with manual).

📚 Vehicle History

Mitsubishi History:

Mitsubishi Motors has a long history of producing reliable and innovative vehicles across various segments.

Colt Z20 Evolution:

The Z20 series Colt, launched in 2002 (as the Colt Plus in some markets), represented a significant redesign from previous generations. It was developed on a new platform and focused on modern styling and enhanced practicality. It served as a key model in Mitsubishi's European lineup during this period.

Facelifts:

The Z20 Colt received at least one significant facelift during its production run, typically involving updated front and rear styling, and potentially interior trim enhancements.

Manufacturing Locations:

Primarily manufactured in Japan and also in the Netherlands (NedCar) for the European market.

🏆 Awards & Recognition

Awards And Ratings:

While not a recipient of major specific awards, the Colt was generally well-regarded in its segment for its balance of practicality, efficiency, and value for money, contributing to its consistent sales figures.