Mitsubishi Colt-All models 2WD & 4WD Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Colt Generations Covered: Specific generations aligning with 4G19, 4A90, 4G15, 4A91 engine availability (primarily 2002-2012 models, depending on market and specific generation designation). Codes Engine Codes Covered: 4G19, 4A90, 4G15, 4A91 Drivetrain Codes Covered: 2WD (Front-Wheel Drive), 4WD (Four-Wheel Drive) 👋 Introduction Market Position Market Segment: Subcompact hatchback/sedan, known for affordability, fuel efficiency, and practicality. Competitive Analysis Key Competitors: Toyota Yaris, Honda Fit/Jazz, Ford Fiesta, Volkswagen Polo, Hyundai i20, Suzuki Swift. Key Features Vehicle Common Strengths: Compact dimensions for urban maneuverability, reliable powertrains, cost-effective to own and operate, surprisingly spacious interior for its class. Key Features Manual Manual Value Proposition: Provides comprehensive, factory-authorized repair and maintenance procedures, enabling owners and technicians to perform accurate diagnostics and repairs, thereby saving on dealership service costs and ensuring proper vehicle upkeep. 📋 Manual Details Coverage Areas Systems Covered Overview: Engine mechanical and electrical, transmission, drivetrain, suspension, steering, brakes, body, climate control, fuel system, exhaust system, cooling system, lubrication system, chassis, electrical system, diagnostics, and troubleshooting. Page Count Page Count: Precise page count not specified, but described as 'complete factory service repair manual,' indicating extensive documentation. Manual Type Manual Type: Factory Service Repair Manual Language Language: English (based on typical factory service manual content and sales descriptions) Format Format: Digital (likely PDF, given the product description mentioning 'easy-to-read text sect...') 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block assembly, pistons, connecting rods, crankshaft, camshafts, timing system, valve train, lubrication system (oil pump, oil filter, oil passages). Engine Electrical: Ignition system, fuel injection system (EFI), ECU (Engine Control Unit) diagnostics, sensors (crankshaft position, camshaft position, MAP, TPS, O2, coolant temperature), actuators, starter motor, alternator, wiring diagrams. Transmission Manual: Gearbox disassembly and assembly, clutch system, gear shifting mechanisms, transmission fluid specifications and replacement. Transmission Automatic: If applicable to specific models covered, automatic transmission operation, component identification, fluid checks, and basic troubleshooting. Drivetrain: Front axle, rear axle (for 4WD models), differentials, driveshafts, CV joints, transfer case (for 4WD models), hub bearings. Suspension Front: MacPherson strut assembly, control arms, ball joints, bushings, springs, shock absorbers, wheel alignment specifications. Steering: Power steering system (hydraulic or electric), steering rack, tie rods, steering column, alignment specifications. Brakes: Front and rear brake systems (disc/drum configurations), brake calipers, brake pads, brake rotors, master cylinder, brake booster, ABS (Anti-lock Braking System) components and diagnostics, parking brake. Electrical Chassis: Lighting system (headlights, taillights, interior lights), power windows, power locks, central locking, wipers and washers, horn, battery, charging system, starter. Body: Body panel removal and installation, doors, hood, trunk lid, bumpers, interior trim, glass replacement, weatherstripping, anti-corrosion treatment. Climate Control: Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, HVAC controls, cabin air filter replacement. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulator, evaporative emission control system (EVAP). Cooling System: Radiator, coolant, thermostat, water pump, cooling fans, hoses, expansion tank. Exhaust System: Exhaust manifolds, catalytic converter, muffler, exhaust pipes, oxygen sensors. Suspension Rear Suspension Rear: Multi-link or trailing arm suspension (depending on generation), control arms, bushings, springs, shock absorbers, wheel alignment specifications. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush and replacement, transmission fluid service, differential fluid service (4WD). Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code (DTC) interpretation. Engine Repair: Detailed procedures for internal engine repairs including gasket replacement, timing belt/chain replacement, piston ring replacement, bearing replacement, head gasket repair, valve seat grinding, and complete engine rebuilds. Transmission Repair: Clutch replacement, transmission overhaul, seal replacements, bearing replacements, synchro ring replacement (manual), gear set replacement. Brake System Repair: Brake pad and rotor replacement, caliper rebuilding or replacement, master cylinder replacement, brake line repair/replacement, ABS bleeding procedures. Electrical Diagnosis: Wiring harness repair, component testing, circuit diagnosis using multimeters and oscilloscopes, ECU testing, sensor calibration. Suspension And Steering Repair: Replacement of ball joints, control arm bushings, tie rod ends, wheel bearings, shock absorbers, struts, steering rack replacement. Body And Trim Repair: Interior and exterior trim panel removal/installation, door mechanism adjustments, window regulator repair, glass replacement. Component Replacement: Detailed instructions for replacing all major components including starters, alternators, fuel pumps, radiators, water pumps, AC compressors, power steering pumps. Technical Depth Depth Of Information: Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Includes torque specifications, clearances, diagnostic procedures, and wiring diagrams. 📊 Manual Specifications File Format File Format: Likely PDF, optimized for digital viewing and printing. Print Quality Print Quality: High-resolution text and diagrams, ensuring clarity for detailed repair instructions. Binding Type Binding Type: Not applicable for digital format. Paper Type Paper Type: Not applicable for digital format. ⚙️ Engine Specifications Primary Engine 4G19 Engine Code: 4G19 Engine Type: Inline 4-cylinder, SOHC (Single Overhead Cam) or DOHC (Double Overhead...

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Stichworte: Car Cars Colt Misc Mitsubishi

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🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Generations Covered:

Specific generations aligning with 4G19, 4A90, 4G15, 4A91 engine availability (primarily 2002-2012 models, depending on market and specific generation designation).

Codes

Engine Codes Covered:

4G19, 4A90, 4G15, 4A91

Drivetrain Codes Covered:

2WD (Front-Wheel Drive), 4WD (Four-Wheel Drive)

👋 Introduction

Market Position

Market Segment:

Subcompact hatchback/sedan, known for affordability, fuel efficiency, and practicality.

Competitive Analysis

Key Competitors:

Toyota Yaris, Honda Fit/Jazz, Ford Fiesta, Volkswagen Polo, Hyundai i20, Suzuki Swift.

Key Features Vehicle

Common Strengths:

Compact dimensions for urban maneuverability, reliable powertrains, cost-effective to own and operate, surprisingly spacious interior for its class.

Key Features Manual

Manual Value Proposition:

Provides comprehensive, factory-authorized repair and maintenance procedures, enabling owners and technicians to perform accurate diagnostics and repairs, thereby saving on dealership service costs and ensuring proper vehicle upkeep.

📋 Manual Details

Coverage Areas

Systems Covered Overview:

Engine mechanical and electrical, transmission, drivetrain, suspension, steering, brakes, body, climate control, fuel system, exhaust system, cooling system, lubrication system, chassis, electrical system, diagnostics, and troubleshooting.

Page Count

Page Count:

Precise page count not specified, but described as 'complete factory service repair manual,' indicating extensive documentation.

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English (based on typical factory service manual content and sales descriptions)

Format

Format:

Digital (likely PDF, given the product description mentioning 'easy-to-read text sect...')

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block assembly, pistons, connecting rods, crankshaft, camshafts, timing system, valve train, lubrication system (oil pump, oil filter, oil passages).

Engine Electrical:

Ignition system, fuel injection system (EFI), ECU (Engine Control Unit) diagnostics, sensors (crankshaft position, camshaft position, MAP, TPS, O2, coolant temperature), actuators, starter motor, alternator, wiring diagrams.

Transmission Manual:

Gearbox disassembly and assembly, clutch system, gear shifting mechanisms, transmission fluid specifications and replacement.

Transmission Automatic:

If applicable to specific models covered, automatic transmission operation, component identification, fluid checks, and basic troubleshooting.

Drivetrain:

Front axle, rear axle (for 4WD models), differentials, driveshafts, CV joints, transfer case (for 4WD models), hub bearings.

Suspension Front:

MacPherson strut assembly, control arms, ball joints, bushings, springs, shock absorbers, wheel alignment specifications.

Steering:

Power steering system (hydraulic or electric), steering rack, tie rods, steering column, alignment specifications.

Brakes:

Front and rear brake systems (disc/drum configurations), brake calipers, brake pads, brake rotors, master cylinder, brake booster, ABS (Anti-lock Braking System) components and diagnostics, parking brake.

Electrical Chassis:

Lighting system (headlights, taillights, interior lights), power windows, power locks, central locking, wipers and washers, horn, battery, charging system, starter.

Body:

Body panel removal and installation, doors, hood, trunk lid, bumpers, interior trim, glass replacement, weatherstripping, anti-corrosion treatment.

Climate Control:

Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, HVAC controls, cabin air filter replacement.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulator, evaporative emission control system (EVAP).

Cooling System:

Radiator, coolant, thermostat, water pump, cooling fans, hoses, expansion tank.

Exhaust System:

Exhaust manifolds, catalytic converter, muffler, exhaust pipes, oxygen sensors.

Suspension Rear

Suspension Rear:

Multi-link or trailing arm suspension (depending on generation), control arms, bushings, springs, shock absorbers, wheel alignment specifications.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush and replacement, transmission fluid service, differential fluid service (4WD).

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code (DTC) interpretation.

Engine Repair:

Detailed procedures for internal engine repairs including gasket replacement, timing belt/chain replacement, piston ring replacement, bearing replacement, head gasket repair, valve seat grinding, and complete engine rebuilds.

Transmission Repair:

Clutch replacement, transmission overhaul, seal replacements, bearing replacements, synchro ring replacement (manual), gear set replacement.

Brake System Repair:

Brake pad and rotor replacement, caliper rebuilding or replacement, master cylinder replacement, brake line repair/replacement, ABS bleeding procedures.

Electrical Diagnosis:

Wiring harness repair, component testing, circuit diagnosis using multimeters and oscilloscopes, ECU testing, sensor calibration.

Suspension And Steering Repair:

Replacement of ball joints, control arm bushings, tie rod ends, wheel bearings, shock absorbers, struts, steering rack replacement.

Body And Trim Repair:

Interior and exterior trim panel removal/installation, door mechanism adjustments, window regulator repair, glass replacement.

Component Replacement:

Detailed instructions for replacing all major components including starters, alternators, fuel pumps, radiators, water pumps, AC compressors, power steering pumps.

Technical Depth

Depth Of Information:

Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Includes torque specifications, clearances, diagnostic procedures, and wiring diagrams.

📊 Manual Specifications

File Format

File Format:

Likely PDF, optimized for digital viewing and printing.

Print Quality

Print Quality:

High-resolution text and diagrams, ensuring clarity for detailed repair instructions.

Binding Type

Binding Type:

Not applicable for digital format.

Paper Type

Paper Type:

Not applicable for digital format.

⚙️ Engine Specifications

Primary Engine 4G19

Engine Code:

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Cam) or DOHC (Double Overhead Cam) depending on variant.

Displacement Cc:

1.3L (1343 cc)

Bore X Stroke Mm:

71.0 x 85.4

Compression Ratio:

Approx. 9.5:1 to 10.0:1 (varies by specific application)

Horsepower Ps Kw:

Approx. 82-95 PS (60-70 kW) at 5500-6000 rpm (varies by market and specific tune)

Torque Nm:

Approx. 115-125 Nm at 3500-4000 rpm (varies by market and specific tune)

Primary Engine 4A90

Engine Code:

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Cam), MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Displacement Cc:

1.3L (1332 cc)

Bore X Stroke Mm:

73.4 x 77.4

Compression Ratio:

Approx. 10.0:1

Horsepower Ps Kw:

Approx. 95 PS (70 kW) at 6000 rpm

Torque Nm:

Approx. 125 Nm at 4000 rpm

Primary Engine 4G15

Engine Code:

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Cam) or DOHC (Double Overhead Cam), MIVEC on some variants.

Displacement Cc:

1.5L (1468 cc)

Bore X Stroke Mm:

75.5 x 82.0

Compression Ratio:

Approx. 9.5:1 to 10.0:1 (varies by specific application)

Horsepower Ps Kw:

Approx. 90-110 PS (66-81 kW) at 5500-6000 rpm (varies by market and specific tune)

Torque Nm:

Approx. 130-140 Nm at 3500-4500 rpm (varies by market and specific tune)

Primary Engine 4A91

Engine Code:

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Cam), MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Displacement Cc:

1.5L (1499 cc)

Bore X Stroke Mm:

75.0 x 84.7

Compression Ratio:

Approx. 10.0:1

Horsepower Ps Kw:

Approx. 109 PS (80 kW) at 6000 rpm

Torque Nm:

Approx. 145 Nm at 4000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (Octane rating varies by market, typically 91 RON or higher recommended).

Engine Management

ECU Type:

Mitsubishi proprietary ECU, often referred to by specific model numbers (e.g., MFI, ECFI) which will be detailed in the manual.

Lubrication System

Oil Capacity Liters:

Approx. 3.5 - 4.0 Liters (with filter change), specific value for each engine variant will be in the manual.

Recommended Oil Viscosity:

API SN/SP or ILSAC GF-5/GF-6, SAE 0W-20, 5W-30 (depending on climate and engine model, confirmed in manual).

Cooling System

Coolant Capacity Liters:

Approx. 5.0 - 5.5 Liters (refer to manual for specific engine).

Coolant Type:

Ethylene Glycol based coolant, typically Mitsubishi DiaQueen Super Long Life Coolant (LLC) or equivalent. (Specific color and type detailed in manual).

🔧 Transmission

Standard Transmission

Manual Gearbox Codes:

Various manual transmission codes depending on engine and drive configuration (e.g., F5M43 series, W5MG1 series for 4WD models). Detailed in manual.

Manual Gearbox Gears:

Typically 5-speed manual.

Optional Transmission

Automatic Gearbox Codes:

Various automatic transmission codes depending on engine and drive configuration (e.g., F4A series). Detailed in manual.

Automatic Gearbox Gears:

Typically 4-speed automatic.

Features

Clutch Type:

Hydraulically operated, single dry plate clutch.

Transmission Fluid Capacity Liters Manual:

Approx. 2.0 - 2.5 Liters (manual transmission).

Transmission Fluid Capacity Liters Auto:

Approx. 5.5 - 6.0 Liters (automatic transmission, including torque converter drain and refill).

Transmission Fluid Type Manual:

API GL-4 SAE 75W-85 or SAE 75W-90 manual transmission fluid (specific part numbers and types in manual).

Transmission Fluid Type Auto:

Mitsubishi DiaQueen ATF SP-III or equivalent Dexron III/Mercon compatible fluid. (Specific part numbers and types in manual).

4Wd System Type:

Typically an electronically controlled or viscous coupling type 4WD system, with front and rear differentials and a transfer case. Specific details and service procedures for the 4WD system are included.

📐 Dimensions

Exterior

Length Mm:

Approx. 3,800 - 4,000 mm (varies by generation and body style - hatchback/sedan).

Width Mm:

Approx. 1,680 - 1,700 mm

Height Mm:

Approx. 1,400 - 1,550 mm (varies by body style)

Wheelbase Mm:

Approx. 2,450 - 2,500 mm

Track Width Front Rear Mm:

Refer to manual for specific generation and trim.

Interior

Passenger Capacity:

5 seats.

Cargo

Cargo Volume Liters Hatchback:

Approx. 250-300 liters (rear seats up), expandable with seats folded.

Weights

Curb Weight Kg:

Approx. 1,000 - 1,200 kg (varies by engine, drivetrain, and trim).

Gross Vehicle Weight Rating Kg:

Refer to vehicle's compliance plate or manual.

Wheels Tires

Wheel Bolt Pattern:

Typically 4x100 or 4x114.3 mm (specific to generation).

Typical Tire Sizes:

175/70 R14, 185/65 R14, 195/55 R15 (refer to manual for specific model and trim).

🛡️ Safety Features

Ratings

Euroncap Rating:

Varies by generation and testing year. Later generations likely achieved 4 or 5 stars, while earlier models may have lower ratings. Consult specific test results for the relevant year.

Ancap Rating:

Varies by generation and testing year. Consult specific test results for the relevant year.

Active Features

Standard on most models, with EBD (Electronic Brakeforce Distribution) and Brake Assist on many.

Traction Control TCS:

Optional or standard on higher trims/later models.

Electronic Stability Control Esc:

Optional or standard on higher trims/later models (often referred to as ASC - Active Stability Control by Mitsubishi).

Passive Features

Airbags Front:

Driver and front passenger airbags standard.

Airbags Side:

Optional or standard on higher trims (front side airbags, curtain airbags).

Seatbelts:

3-point ELR seatbelts with pretensioners and load limiters for front seats, 3-point or 2-point for rear seats depending on configuration.

Child Seat Anchors:

ISOFIX/LATCH child seat anchor points.

💡 Technology Features

Infotainment

Head Unit Features:

Basic AM/FM radio with CD player, optional MP3 playback and auxiliary input. Higher trims may have touchscreen infotainment systems with navigation and Bluetooth connectivity in later iterations.

Speaker System:

Typically 4-6 speaker system, depending on trim level.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Parking Sensors:

Optional on some models.

Connectivity

Usb Aux Ports:

Auxiliary audio input jack typically standard. USB ports became more common in later model years or optional.

Engine Tech

Mivec Variable Valve Timing:

Engines 4A90 and 4A91 feature MIVEC for improved performance and fuel efficiency. Manual details its operation and diagnostics.

🔧 Maintenance

Service Intervals General

Oil Change Interval:

Every 10,000 - 15,000 km or 12 months, whichever comes first (depending on driving conditions and oil used, consult manual).

Air Filter Replacement:

Every 20,000 - 40,000 km or 24 months.

Spark Plug Replacement:

Every 40,000 - 100,000 km depending on plug type (standard copper vs. iridium/platinum). Consult manual for specific recommendation.

Coolant Replacement:

Every 40,000 - 80,000 km or 4-5 years, whichever comes first. Longer life coolants may extend this interval.

Brake Fluid Replacement:

Every 2 years or 40,000 km.

Transmission Fluid Replacement Manual:

Every 60,000 - 80,000 km or as per manual recommendations. Check for leaks.

Transmission Fluid Replacement Auto:

Every 40,000 - 60,000 km or 24-48 months, depending on driving conditions (severe duty may require more frequent changes). Flush and fill with new fluid and filter replacement often recommended.

Timing Belt Replacement:

For engines with timing belts (check specific engine), typically every 90,000 - 120,000 km or 7-10 years. Engines with timing chains generally do not require scheduled replacement, but chain tensioners and guides may need inspection.

Fluid Specifications

Power Steering Fluid:

ATF Dexron II/III or specific power steering fluid as specified in the manual. Check for leaks and maintain level.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific requirement and brand).

Differential Fluid 4Wd:

GL-5 SAE 75W-90 hypoid gear oil (for front/rear differentials and transfer case, specific capacities in manual).

Known Issues

Engine Idling Instability:

Can be caused by dirty throttle body, faulty IAC valve, or vacuum leaks. Manual details cleaning and diagnosis procedures.

Oxygen Sensor Failure:

Leads to poor fuel economy and check engine light. Manual provides diagnostic steps and replacement procedures.

Suspension Bushings Wear:

Can cause clunking noises and poor handling. Manual details inspection and replacement of control arm and sway bar bushings.

Window Regulator Failure:

Power windows may stop working or move erratically. Manual covers disassembly and repair of door panels and window mechanisms.

ABS Sensor Issues:

Can trigger ABS warning light and disable ABS function. Manual covers cleaning and testing of wheel speed sensors.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Corporation:

A long-standing Japanese automaker with a history of producing robust and innovative vehicles across various segments, from passenger cars to SUVs and commercial vehicles. Known for their 'J-factor' engineering and motorsports heritage.

Model Evolution

Colt Lineage:

The Mitsubishi Colt nameplate has been used since the 1960s, with various generations and model types (hatchback, sedan, coupe). The models covered by this manual are primarily from the fifth generation (produced from 2002 onwards), often known as the Mitsubishi Colt Z20 series, which was developed in collaboration with DaimlerChrysler. This generation was distinct from earlier Colt models and often shared platforms with other small cars of the era.

Production

Manufacturing Locations:

Primarily manufactured in Japan by Mitsubishi Motors Corporation, with potential for assembly in other global locations depending on the specific market and generation.

Production Years:

The specific models covered by this manual, featuring the 4G19, 4A90, 4G15, and 4A91 engines, were predominantly produced from the early 2000s (around 2002) through the early 2010s (up to approximately 2012), with some regional variations in model year availability.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Specific awards vary by year and market. Later models generally performed well in safety tests for their class.

Fuel Efficiency Awards:

Often recognized for competitive fuel economy in the subcompact segment.

Certifications

Emission Standards:

Meets relevant emission standards for the markets in which it was sold (e.g., Euro 4, Euro 5, EPA standards).