1988-1993 Mitsubishi Colt/Lancer Workshop Repair Service Manual in

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🏷️ Basic Information Identification Make: Mitsubishi Model: Colt/Lancer Model Generation: Evo I (CJ4A), Evo II (CJ4A), Evo III (CJ4A), Lancer (CB/CC), Colt (CJ) Model Years Covered: 1988-1993 Codes Chassis Codes: CB, CC Engine Codes Common: 4G13, 4G15, 4G61, 4G63 👋 Introduction Market Position Vehicle Segment: Compact/Subcompact car. The Lancer and Colt occupied a significant segment of the affordable and sporty car market in the late 80s and early 90s. The Lancer Evolutions were performance icons. Competitive Analysis Key Competitors Late 80S Early 90S: Honda Civic/Accord, Toyota Corolla/Camry, Nissan Sentra/Altima, Ford Escort, Chevrolet Cavalier, Mazda 323/626. Key Features Vehicle Strengths: Reliability (especially with the 4G15/4G13), sporty handling, fuel efficiency (for base models), affordable performance (for 4G63T models). Manual Utility: Essential for owners and independent mechanics seeking to perform maintenance, diagnose issues, or undertake complex repairs on these reliable yet mechanically intricate vehicles. Provides access to factory-level technical information. 📋 Manual Details Coverage Areas Main Markets: North America, Europe, Asia (specific regional variations may exist) Page Count Estimated Page Count: 1500-2000+ (This is a comprehensive workshop manual, often compiled from multiple source documents). Manual Type Manual Classification: Workshop Repair Service Manual Language Language: English Format Digital Format: PDF (Likely, given typical online manual sales. Original might be printed.) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (incl. specific variants like 4G63T), fuel system, ignition system, exhaust system, cooling system, lubrication system. Transmission: Manual transmission (5-speed F5M21, W5M33 AWD), automatic transmission (V4A51, KM175). Drivetrain: Front-wheel drive (FWD), All-wheel drive (AWD - specific to Lancer/Evo models). Suspension: Front suspension (MacPherson strut), Rear suspension (Multi-link independent for AWD models, Torsion beam for FWD models). Steering: Power steering system (hydraulic rack and pinion), steering column. Brakes: Front disc brakes, Rear drum/disc brakes (depending on model/trim), ABS (Anti-lock Braking System) where equipped, parking brake. Electrical: 12V electrical system, battery, alternator, starter motor, lighting system, ignition system, instrumentation, fuses and relays. Body And Chassis: Body structure, exterior panels, doors, windows, interior trim, chassis components, underbody protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system. Diagnostics: On-board diagnostics (OBD-I), troubleshooting guides, diagnostic trouble codes (DTCs). Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), fluid checks and top-ups, spark plug replacement, belt inspections and replacement. Component Repair Rebuild: Engine internal repair (pistons, rings, bearings), cylinder head overhaul, transmission overhaul, brake caliper rebuild, steering rack repair. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts. Inspections: Pre-delivery inspections, routine inspections, detailed component inspection guidelines. Adjustments: Valve adjustments, ignition timing adjustments, parking brake adjustments. Disassembly Reassembly: Detailed instructions for removing, inspecting, repairing, and reassembling all major vehicle components. Technical Depth Depth Of Information: Comprehensive. Covers everything from basic maintenance and fluid changes to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Diagnostic Capabilities: Detailed procedures for using OBD-I scan tools, interpreting sensor readings, and performing voltage/resistance tests on various circuits. Wiring Diagrams: Includes detailed electrical wiring diagrams for all major systems (engine, chassis, body, HVAC). 📊 Manual Specifications File Format Digital Format Quality: Typically high-resolution scans, allowing for clear viewing of diagrams and text. Searchable text functionality is a desirable feature if the PDF is OCR'd. Print Quality Original Print Quality: Professional factory print quality, designed for durability in a workshop environment. Binding Type Original Binding: Likely a sturdy perfect bound or spiral bound format to lay flat on a workbench. Paper Type Original Paper Type: Durable, often slightly coated paper to resist grease and workshop grime. ⚙️ Engine Specifications Primary Engine Engine Variant Base: 1.5L (1468cc) SOHC 4-cylinder (4G15). Engine Variant Common Asia Europe: 1.3L (1298cc) SOHC 4-cylinder (4G13). Engine Variant Performance Oriented: 1.6L (1597cc) DOHC 4-cylinder (4G61), 2.0L (1997cc) DOHC Turbocharged 4-cylinder (4G63T) for Lancer GSR/Evo models. Performance Horsepower 4G15 Approx: 70-85 hp Torque 4G15 Approx: 110-125 Nm Horsepower 4G63T Approx: 200-250 hp (depending on generation/tune) Torque 4G63T Approx: 250-300 Nm (depending on generation/tune) Fuel System Fuel Delivery: Fuel injection (Multi-point fuel injection - MPFI) for most variants. Carbureted versions may exist in some markets. Fuel Type: Unleaded Gasoline (Octane rating may vary by engine tune). Engine Construction Block Material: Cast Iron (4G6x series), Aluminum Alloy (4G1x series). Head Material: Aluminum Alloy. 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual (e.g., F5M21 for FWD). Optional Optional Transmission Type: 4-Speed Automatic (e.g., KM175 or V4A51). Features AWD Transmission Variant: Viscous coupling center differential and limited-slip rear differential for AWD Lancer/Evo models (e.g., W5M33-2A transmission). Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 80W-90 (Check manual for specific fill). Automatic Transmission Fluid: Mitsubishi DiaQueen ATF SP-II or equivalent (Check manual for specific fill). 📐 Dimensions Exterior Wheelbase Approx: 2450 - 2500 mm (Varies slightly by body style and generation). Overall Length Approx: 4100 - 4300 mm Overall Width Approx: 1650 - 1700 mm Overall Height Approx: 1350 - 1400...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Colt/Lancer

Model Generation:

Evo I (CJ4A), Evo II (CJ4A), Evo III (CJ4A), Lancer (CB/CC), Colt (CJ)

Model Years Covered:

1988-1993

Codes

Chassis Codes:

CB, CC

Engine Codes Common:

4G13, 4G15, 4G61, 4G63

👋 Introduction

Market Position

Vehicle Segment:

Compact/Subcompact car. The Lancer and Colt occupied a significant segment of the affordable and sporty car market in the late 80s and early 90s. The Lancer Evolutions were performance icons.

Competitive Analysis

Key Competitors Late 80S Early 90S:

Honda Civic/Accord, Toyota Corolla/Camry, Nissan Sentra/Altima, Ford Escort, Chevrolet Cavalier, Mazda 323/626.

Key Features

Vehicle Strengths:

Reliability (especially with the 4G15/4G13), sporty handling, fuel efficiency (for base models), affordable performance (for 4G63T models).

Manual Utility:

Essential for owners and independent mechanics seeking to perform maintenance, diagnose issues, or undertake complex repairs on these reliable yet mechanically intricate vehicles. Provides access to factory-level technical information.

📋 Manual Details

Coverage Areas

Main Markets:

North America, Europe, Asia (specific regional variations may exist)

Page Count

Estimated Page Count:

1500-2000+ (This is a comprehensive workshop manual, often compiled from multiple source documents).

Manual Type

Manual Classification:

Workshop Repair Service Manual

Language

Language:

English

Format

Digital Format:

PDF (Likely, given typical online manual sales. Original might be printed.)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (incl. specific variants like 4G63T), fuel system, ignition system, exhaust system, cooling system, lubrication system.

Transmission:

Manual transmission (5-speed F5M21, W5M33 AWD), automatic transmission (V4A51, KM175).

Drivetrain:

Front-wheel drive (FWD), All-wheel drive (AWD - specific to Lancer/Evo models).

Suspension:

Front suspension (MacPherson strut), Rear suspension (Multi-link independent for AWD models, Torsion beam for FWD models).

Steering:

Power steering system (hydraulic rack and pinion), steering column.

Brakes:

Front disc brakes, Rear drum/disc brakes (depending on model/trim), ABS (Anti-lock Braking System) where equipped, parking brake.

Electrical:

12V electrical system, battery, alternator, starter motor, lighting system, ignition system, instrumentation, fuses and relays.

Body And Chassis:

Body structure, exterior panels, doors, windows, interior trim, chassis components, underbody protection.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system.

Diagnostics:

On-board diagnostics (OBD-I), troubleshooting guides, diagnostic trouble codes (DTCs).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), fluid checks and top-ups, spark plug replacement, belt inspections and replacement.

Component Repair Rebuild:

Engine internal repair (pistons, rings, bearings), cylinder head overhaul, transmission overhaul, brake caliper rebuild, steering rack repair.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts.

Inspections:

Pre-delivery inspections, routine inspections, detailed component inspection guidelines.

Adjustments:

Valve adjustments, ignition timing adjustments, parking brake adjustments.

Disassembly Reassembly:

Detailed instructions for removing, inspecting, repairing, and reassembling all major vehicle components.

Technical Depth

Depth Of Information:

Comprehensive. Covers everything from basic maintenance and fluid changes to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs.

Diagnostic Capabilities:

Detailed procedures for using OBD-I scan tools, interpreting sensor readings, and performing voltage/resistance tests on various circuits.

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all major systems (engine, chassis, body, HVAC).

📊 Manual Specifications

File Format

Digital Format Quality:

Typically high-resolution scans, allowing for clear viewing of diagrams and text. Searchable text functionality is a desirable feature if the PDF is OCR'd.

Print Quality

Original Print Quality:

Professional factory print quality, designed for durability in a workshop environment.

Binding Type

Original Binding:

Likely a sturdy perfect bound or spiral bound format to lay flat on a workbench.

Paper Type

Original Paper Type:

Durable, often slightly coated paper to resist grease and workshop grime.

⚙️ Engine Specifications

Primary Engine

Engine Variant Base:

1.5L (1468cc) SOHC 4-cylinder (4G15).

Engine Variant Common Asia Europe:

1.3L (1298cc) SOHC 4-cylinder (4G13).

Engine Variant Performance Oriented:

1.6L (1597cc) DOHC 4-cylinder (4G61), 2.0L (1997cc) DOHC Turbocharged 4-cylinder (4G63T) for Lancer GSR/Evo models.

Performance

Horsepower 4G15 Approx:

70-85 hp

Torque 4G15 Approx:

110-125 Nm

Horsepower 4G63T Approx:

200-250 hp (depending on generation/tune)

Torque 4G63T Approx:

250-300 Nm (depending on generation/tune)

Fuel System

Fuel Delivery:

Fuel injection (Multi-point fuel injection - MPFI) for most variants. Carbureted versions may exist in some markets.

Fuel Type:

Unleaded Gasoline (Octane rating may vary by engine tune).

Engine Construction

Block Material:

Cast Iron (4G6x series), Aluminum Alloy (4G1x series).

Head Material:

Aluminum Alloy.

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual (e.g., F5M21 for FWD).

Optional

Optional Transmission Type:

4-Speed Automatic (e.g., KM175 or V4A51).

Features

AWD Transmission Variant:

Viscous coupling center differential and limited-slip rear differential for AWD Lancer/Evo models (e.g., W5M33-2A transmission).

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 (Check manual for specific fill).

Automatic Transmission Fluid:

Mitsubishi DiaQueen ATF SP-II or equivalent (Check manual for specific fill).

📐 Dimensions

Exterior

Wheelbase Approx:

2450 - 2500 mm (Varies slightly by body style and generation).

Overall Length Approx:

4100 - 4300 mm

Overall Width Approx:

1650 - 1700 mm

Overall Height Approx:

1350 - 1400 mm

Weights

Curb Weight Approx:

950 - 1300 kg (depending on engine, drivetrain, and trim)

Gross Vehicle Weight Rating:

Varies by model, typically around 1400-1600 kg.

Wheel Tire

Wheel Bolt Pattern:

4x114.3 mm (4x4.5 inches)

Tire Sizes Common:

175/70R13, 185/65R14, 195/60R15 (Evo models may use larger sizes).

🛡️ Safety Features

Ratings

Crash Test Data Availability:

Limited standardized crash test data readily available for this era of vehicle from official bodies like NHTSA or Euro NCAP. However, design principles of the era focused on crumple zones and safety cages.

Active Features

Active Safety Features Common:

Front ventilated disc brakes, rear drum/disc brakes, power-assisted braking system, optional ABS on higher trims/models.

Passive Features

Passive Safety Features Common:

Seat belts (3-point front, 2-point/3-point rear), reinforced body structure, energy-absorbing steering column, side-impact door beams.

💡 Technology Features

Infotainment

Infotainment System Era:

Basic for its time. Likely features include an AM/FM radio, cassette player, and possibly a CD player on later or higher trims.

Driver Assistance

Driver Assistance Features:

Limited. ABS was an option, no advanced driver-assistance systems (ADAS) were available. Focus was on mechanical and active safety features.

Connectivity

Connectivity Features:

None in the modern sense. No Bluetooth, USB, or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first. Consult manual for specific engine oil type and interval.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plug Replacement:

Typically every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on spark plug type (copper vs. platinum).

Timing Belt Replacement:

Crucial for 4G63 engines. Typically every 60,000 miles (96,000 km) or 5 years. Failure can cause severe engine damage.

Fluid Specifications

Engine Oil Capacity 4G15 Approx:

3.7 Liters (4.0 US Quarts) with filter change.

Engine Oil Spec Common:

API SG or SH, SAE 10W-30 or 10W-40. Consult manual for exact specification and viscosity range based on climate.

Coolant Capacity Approx:

5.5 - 6.5 Liters (depending on engine and radiator size). Use a 50/50 mix of ethylene glycol antifreeze and distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 (Check manual for specific requirement).

Known Issues

Engine Issues:

Timing belt failure on 4G63, potential oil leaks from valve cover gasket and crankshaft seals, carburetor issues on older/base models, head gasket leaks (less common but possible).

Transmission Issues:

Synchro wear on manual transmissions, potential leaks from output shaft seals, torque converter issues on automatics. AWD components (transfer case, rear diff) require regular fluid changes.

Suspension Chassis Issues:

Worn ball joints and tie rod ends, front strut mounts, rear trailing arm bushings (especially on AWD models), rust/corrosion on body panels and undercarriage, particularly in areas exposed to salt.

Electrical Issues:

Failing alternators, starter motor issues, corroded grounds, faulty window regulators, HVAC blower motor failures.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Origins:

Founded in 1870, Mitsubishi Group is one of Japan's largest conglomerates. Mitsubishi Motors Corporation was established in 1970.

Model Evolution

Colt Lancer Lineage:

The Colt name was used for Mitsubishi's subcompact cars in some markets, often rebadged as Dodge Colt or Plymouth Colt in North America via an alliance with Chrysler. The Lancer is Mitsubishi's compact car line, with the performance-oriented Evolution (Evo) variants becoming legendary in rally racing.

Production

Production Period:

1988-1993 (This generation of Colt/Lancer).

Manufacturing Locations:

Japan (primarily), with potential assembly in other countries via partnerships.

Notable Variants

Performance Variants:

Lancer GSR, Lancer Evolution I, II, and III (chassis codes CM5A, CD9A, CE9A) - these models significantly boosted Mitsubishi's performance image.

🏆 Awards & Recognition

Recognitions

Rally Racing Heritage:

The Lancer Evolution models were highly successful in the World Rally Championship (WRC), with drivers like Tommi Mäkinen winning multiple championships in the late 1990s. This manual covers the early generation Evi models which laid the groundwork for this success.

Ratings

Consumer Reputation:

Generally positive for reliability and performance (especially Evo variants). Known for being mechanically robust if maintained. Base models offer good value and efficiency.