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Mitsubishi Colt Lancer 1996-2001 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Colt Lancer Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001 Codes Chassis Codes: CJ (JDM/Global variations), CK (South Africa), CS (North America) Engine Codes Common: 4G13, 4G15, 4G91, 4G92, 4G93 (DOHC/SOHC) 👋 Introduction Market Position Market Segment: Compact Car / Subcompact Car Target Audience: DIY mechanics, professional technicians, enthusiast owners Competitive Analysis Key Competitors Era: Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cavalier Key Features Key Selling Points: Reliability, fuel efficiency, sporty handling (in certain trims), affordability Manual Value Proposition: Empowers owners to perform maintenance and repairs accurately, reducing labor costs and extending vehicle lifespan. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Primary Coverage: Complete Repair and Service Procedures Diagnostic Coverage: Extensive Diagnostic Procedures and Troubleshooting Guides Page Count Estimated Page Count: 1500+ Language Language: English Format File Format: Digital (PDF) Format Description: Searchable, printable PDF document 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, pistons, crankshaft, camshafts, timing components Engine Management: Fuel injection system, ignition system, emission control systems, sensors, actuators Transmission Manual: Clutch, gearbox overhaul, shift mechanism, gears, bearings Transmission Automatic: Torque converter, valve body, planetary gears, hydraulic control, ATF specifications Drivetrain: Front-wheel drive, constant velocity (CV) joints, driveshafts, differential Suspension: Front struts, rear shock absorbers, control arms, springs, bushings, alignment specifications Steering: Power steering system, rack and pinion, steering column, tie rods Brakes: Front disc brakes, rear drum/disc brakes, ABS system, brake fluid specifications, bleeding procedures Electrical System: Battery, charging system, starter, lighting system, fuses, relays, wiring diagrams Body Exterior: Body panels, doors, hood, trunk, bumpers, glass replacement, trim Body Interior: Dashboard, seats, upholstery, door panels, HVAC system, sound insulation HVAC: Air conditioning system, heater core, blower motor, refrigerant, operation and service Safety Systems: Airbag system (SRS), seat belt mechanisms, related diagnostics Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, coolant flushes, belt replacements Repair Procedures: Step-by-step repair instructions for all major systems Troubleshooting: Diagnostic flowcharts, common fault identification, solutions Specifications Data: Torque values, clearances, fluid capacities, electrical resistance Wiring Diagrams: Comprehensive electrical schematics for all vehicle circuits Special Tools: Identification and usage of specialized tools required for certain repairs Technical Depth Depth Level: Factory Level Diagnostics and Repair Rebuild Instructions: Detailed procedures for engine and transmission rebuilds Component Disassembly: Complete disassembly and reassembly of all major components Diagnostic Codes: OBD-I and OBD-II diagnostic trouble codes (DTCs) and their meanings/causes 📊 Manual Specifications File Format Searchability: Fully searchable text Print Quality: High-resolution diagrams and clear text Digital Access: Instant download upon purchase Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options Common: 1.3L SOHC I4 (4G13), 1.5L SOHC I4 (4G15), 1.6L DOHC I4 (4G92 MIVEC), 1.8L SOHC I4 (4G93), 1.8L DOHC I4 (4G93 DOHC) Engine Description: Inline 4-cylinder, multi-point fuel injection (MPI) or carburetor (early models), SOHC or DOHC configurations. Performance Horsepower Range: Approx. 70-125 hp (depending on engine variant) Torque Range: Approx. 80-110 lb-ft (depending on engine variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Recommended Octane: 87 Octane (AKI) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission Optional Optional Transmission: 4-Speed Automatic Transmission Features Transmission Fluid Type: Dexron III (Automatic), Manual Transmission Fluid API GL-4 75W-90 Transmission Fluid Capacity Auto: Approx. 6.7 Liters (14.2 Pints) Transmission Fluid Capacity Manual: Approx. 2.0 Liters (2.1 Quarts) 📐 Dimensions Exterior Length Approx: 4345-4410 mm (171.1-173.6 inches) Width Approx: 1690-1700 mm (66.5-66.9 inches) Height Approx: 1390-1450 mm (54.7-57.1 inches) Wheelbase Approx: 2500 mm (98.4 inches) Weights Curb Weight Range: Approx. 1050-1150 kg (2315-2535 lbs) Gross Vehicle Weight Rating Gvwr: Varies by model and configuration 🛡️ Safety Features Ratings NHTSA Ratings: Not consistently rated across all model years and configurations; generally considered a safe vehicle for its class during its time. Active Features ABS Availability: Optional on many models, standard on higher trims/later years Passive Features Airbags: Driver and passenger front airbags (standard on most models) Seatbelts: 3-point front and rear seat belts, pretensioners on front belts 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio with cassette player, optional CD player on higher trims. Speaker Configuration: Typically 4 or 6 speakers Driver Assistance Cruise Control: Optional on many models Traction Control: Rarely available on standard Colt Lancer models of this era; more common on performance variants. Connectivity Auxiliary Inputs: N/A (No factory aux or USB ports) 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) or annually. Spark Plug Replacement: Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type. Timing Belt Replacement: Crucial for interference engines; typically every 60,000-90,000 miles (96,000-144,000 km). Consult manual for specific engine. Fluid Specifications...
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Mitsubishi Colt Lancer 1996-2001 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Colt Lancer
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001
Codes
Chassis Codes:
CJ (JDM/Global variations), CK (South Africa), CS (North America)
Engine Codes Common:
4G13, 4G15, 4G91, 4G92, 4G93 (DOHC/SOHC)
👋 Introduction
Market Position
Market Segment:
Compact Car / Subcompact Car
Target Audience:
DIY mechanics, professional technicians, enthusiast owners
Competitive Analysis
Key Competitors Era:
Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cavalier
Key Features
Key Selling Points:
Reliability, fuel efficiency, sporty handling (in certain trims), affordability
Manual Value Proposition:
Empowers owners to perform maintenance and repairs accurately, reducing labor costs and extending vehicle lifespan.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Primary Coverage:
Complete Repair and Service Procedures
Diagnostic Coverage:
Extensive Diagnostic Procedures and Troubleshooting Guides
Page Count
Estimated Page Count:
1500+
Language
Language:
English
Format
File Format:
Digital (PDF)
Format Description:
Searchable, printable PDF document
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, pistons, crankshaft, camshafts, timing components
Engine Management:
Fuel injection system, ignition system, emission control systems, sensors, actuators
Transmission Manual:
Clutch, gearbox overhaul, shift mechanism, gears, bearings
Transmission Automatic:
Torque converter, valve body, planetary gears, hydraulic control, ATF specifications
Drivetrain:
Front-wheel drive, constant velocity (CV) joints, driveshafts, differential
Suspension:
Front struts, rear shock absorbers, control arms, springs, bushings, alignment specifications
Steering:
Power steering system, rack and pinion, steering column, tie rods
Brakes:
Front disc brakes, rear drum/disc brakes, ABS system, brake fluid specifications, bleeding procedures
Electrical System:
Battery, charging system, starter, lighting system, fuses, relays, wiring diagrams
Body Exterior:
Body panels, doors, hood, trunk, bumpers, glass replacement, trim
Body Interior:
Dashboard, seats, upholstery, door panels, HVAC system, sound insulation
HVAC:
Air conditioning system, heater core, blower motor, refrigerant, operation and service
Safety Systems:
Airbag system (SRS), seat belt mechanisms, related diagnostics
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, coolant flushes, belt replacements
Repair Procedures:
Step-by-step repair instructions for all major systems
Troubleshooting:
Diagnostic flowcharts, common fault identification, solutions
Specifications Data:
Torque values, clearances, fluid capacities, electrical resistance
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle circuits
Special Tools:
Identification and usage of specialized tools required for certain repairs
Technical Depth
Depth Level:
Factory Level Diagnostics and Repair
Rebuild Instructions:
Detailed procedures for engine and transmission rebuilds
Component Disassembly:
Complete disassembly and reassembly of all major components
Diagnostic Codes:
OBD-I and OBD-II diagnostic trouble codes (DTCs) and their meanings/causes
📊 Manual Specifications
File Format
Searchability:
Fully searchable text
Print Quality:
High-resolution diagrams and clear text
Digital Access:
Instant download upon purchase
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Options Common:
1.3L SOHC I4 (4G13), 1.5L SOHC I4 (4G15), 1.6L DOHC I4 (4G92 MIVEC), 1.8L SOHC I4 (4G93), 1.8L DOHC I4 (4G93 DOHC)
Engine Description:
Inline 4-cylinder, multi-point fuel injection (MPI) or carburetor (early models), SOHC or DOHC configurations.
Performance
Horsepower Range:
Approx. 70-125 hp (depending on engine variant)
Torque Range:
Approx. 80-110 lb-ft (depending on engine variant)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 Octane (AKI)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission
Optional
Optional Transmission:
4-Speed Automatic Transmission
Features
Transmission Fluid Type:
Dexron III (Automatic), Manual Transmission Fluid API GL-4 75W-90
Transmission Fluid Capacity Auto:
Approx. 6.7 Liters (14.2 Pints)
Transmission Fluid Capacity Manual:
Approx. 2.0 Liters (2.1 Quarts)
📐 Dimensions
Exterior
Length Approx:
4345-4410 mm (171.1-173.6 inches)
Width Approx:
1690-1700 mm (66.5-66.9 inches)
Height Approx:
1390-1450 mm (54.7-57.1 inches)
Wheelbase Approx:
2500 mm (98.4 inches)
Weights
Curb Weight Range:
Approx. 1050-1150 kg (2315-2535 lbs)
Gross Vehicle Weight Rating Gvwr:
Varies by model and configuration
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not consistently rated across all model years and configurations; generally considered a safe vehicle for its class during its time.
Active Features
ABS Availability:
Optional on many models, standard on higher trims/later years
Passive Features
Airbags:
Driver and passenger front airbags (standard on most models)
Seatbelts:
3-point front and rear seat belts, pretensioners on front belts
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with cassette player, optional CD player on higher trims.
Speaker Configuration:
Typically 4 or 6 speakers
Driver Assistance
Cruise Control:
Optional on many models
Traction Control:
Rarely available on standard Colt Lancer models of this era; more common on performance variants.
Connectivity
Auxiliary Inputs:
N/A (No factory aux or USB ports)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or annually.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type.
Timing Belt Replacement:
Crucial for interference engines; typically every 60,000-90,000 miles (96,000-144,000 km). Consult manual for specific engine.
Fluid Specifications
Engine Oil Type:
API SJ/SL, SAE 5W-30 or 10W-30 (check owner's manual for climate variations)
Engine Oil Capacity:
Approx. 3.5-4.5 Liters (3.7-4.8 Quarts) depending on engine
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Front struts, rear shock absorbers, control arm bushings, engine mounts, CV boots, exhaust components.
Engine Problems:
Timing belt failure (if not replaced), oil leaks, occasional head gasket issues on higher mileage engines.
Transmission Problems:
Automatic transmission harsh shifting or slipping (older units), manual clutch wear.
Electrical Problems:
Alternator failures, power window motor issues, corrosion in electrical connectors.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors has a long history of producing reliable and affordable vehicles, known for its engineering prowess and innovation.
Model Evolution
Colt Lancer Lineage:
The Lancer nameplate has been used by Mitsubishi for decades, evolving through multiple generations. The 1996-2001 models represent the sixth generation (CK/CM Lancer).
Key Design Elements:
Aerodynamic styling, available hatchback (Colt) and sedan (Lancer) variants, sporty GSR and Evolution variants (not typically covered in standard Colt Lancer manuals but relevant to the platform).
Production
Production Locations:
Japan, Australia, South Africa, and other global assembly plants.
Market Introduction Period:
Sixth generation introduced globally starting in the mid-1990s.
🏆 Awards & Recognition
Recognitions
Common Accolades:
The Mitsubishi Lancer line has historically been recognized for its value, reliability, and affordability in the compact car segment.
Ratings
Consumer Reports History:
Generally received average to above-average ratings for reliability in its class during this period.
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