Mitsubushi COLT & COLT RALLIART 2003-2010 Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Colt Model Variant: Colt & Colt Ralliart Production Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Chassis Code: Z20 Series (Commonly referred to as the Z20 generation) 👋 Introduction Market Position Segment: Subcompact hatchback Target Audience: Young drivers, small families, urban commuters seeking economical and reliable transportation. Competitive Analysis Competitors: Ford Fiesta, Vauxhall Corsa, Volkswagen Polo, Peugeot 207, Renault Clio, Honda Jazz. Key Features Manual Value Proposition: This comprehensive factory service manual provides an unparalleled resource for maintaining and repairing the Mitsubishi Colt (Z20 series) and its performance-oriented Ralliart variant. Its detailed coverage and high-quality digital format ensure accurate and efficient servicing. 📋 Manual Details Coverage Areas Systems Covered: General Maintenance, Engine Mechanical (4A91, 4G15 MIVEC), Engine Lubrication, Fuel System, Engine Cooling System, Intake and Exhaust Systems, Engine Electrical System, Engine and Emission Control, Clutch System, Manual Transmission, Automatic Transmission, Front Axle, Rear Axle, Wheels and Tires, Power Plant Mounts, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering System, Body Structure, Exterior Components, Interior Components, Supplemental Restraint Systems (SRS), Chassis Electrical System, HVAC (Heater, Air Conditioner, Ventilation) Page Count Total Pages: 1500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed specifications, disassembly, assembly, inspection, and repair of 4A91 1.5L MIVEC and 4G15 1.5L MIVEC (Ralliart) engines. Includes cylinder head, block, pistons, crankshaft, camshafts, timing system, valve train. Engine Control: Engine and Emission Control systems, including ECU diagnosis, sensors (O2, MAP, MAF, TPS, Crank/Cam position), actuators (injectors, ignition coils), MIVEC system control, emissions components (EVAP, EGR if applicable). Transmission: Coverage for both Manual Transmissions (MT) and Automatic Transmissions (AT), including internal components, hydraulic systems (for AT), shift mechanisms, lubrication, and diagnosis. Suspension Steering: Front and Rear suspension components (struts, springs, control arms, bushings, stabilizer bars), steering system (rack and pinion, power steering pump/motor, tie rods), alignment specifications. Brakes: Service Brakes (front and rear disc brake systems, hydraulic lines, calipers, master cylinder, ABS components) and Parking Brakes (mechanical actuation, parking brake shoes/calipers). Electrical Chassis: Comprehensive chassis electrical system coverage including lighting, power windows, door locks, wipers, horn, instrument cluster, audio system, security system, fuses, relays, and wiring diagrams. HVAC: Heater, Air Conditioning, and Ventilation systems, including A/C compressor, condenser, evaporator, refrigerant circuits, blower motor, climate controls, and cabin air filter replacement. Body Interior Exterior: Body construction, exterior panels (doors, hood, trunk, fenders), interior trim, seating, airbags (SRS components and deployment warnings), door mechanisms, glass replacement, and weather stripping. Procedures Included Maintenance: Scheduled maintenance intervals, fluid checks and changes (oil, coolant, brake fluid, transmission fluid, power steering fluid), filter replacements (oil, air, cabin), spark plug replacement, belt inspection and replacement. Diagnosis Troubleshooting: Systematic troubleshooting guides for common issues, diagnostic trouble codes (DTCs) and their interpretation, electrical system diagnostics using multimeter and scan tools. Repair Rebuild: Detailed step-by-step instructions for component removal, installation, repair, and rebuilding of engine, transmission, suspension, brake, steering, and electrical components. Torque Specifications: Essential torque values for critical fasteners across all major mechanical systems (engine, transmission, chassis, suspension). Wiring Diagrams: Comprehensive electrical wiring diagrams for various circuits, facilitating diagnosis and repair of electrical faults. Technical Depth Depth: Factory-level technical depth, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission overhauls. 📊 Manual Specifications File Format File Format: PDF Print Quality Quality: High-quality, non-scanned digital reproduction. Text is searchable, images and diagrams are clear and legible. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine 1 Engine Code: 4A91 Engine Type: Inline-4, DOHC, 16-valve, MIVEC (Mitsubishi Innovative Valve timing Electronic Control) Displacement: 1.5 Liters (1499 cc) Bore X Stroke: 75.0 mm x 84.3 mm Compression Ratio: Approximately 10.5:1 (Varies slightly by market/tune) Fuel Delivery: Electronic Fuel Injection (MPI) Performance Est Hp: Approx. 107-112 HP (80-84 kW) @ 6000 rpm (Varies by market and specific tune) Performance Est Torque: Approx. 145-150 Nm (107-111 lb-ft) @ 4000 rpm (Varies by market and specific tune) Primary Engine 2 Engine Code: 4G15 Engine Type: Inline-4, DOHC, 16-valve, MIVEC (Mitsubishi Innovative Valve timing Electronic Control) Displacement: 1.5 Liters (1499 cc) Fuel Delivery: Electronic Fuel Injection (MPI) Performance Est Hp: Approx. 150-160 HP (112-119 kW) @ 6000 rpm (Ralliart specific tune) Performance Est Torque: Approx. 210-220 Nm (155-162 lb-ft) @ 3500 rpm (Ralliart specific tune) Turbocharger: Yes (Intercooled Turbocharger for Ralliart) Fluid Specifications Engine Oil Type: API SJ or higher, SAE 5W-30 or 10W-30 (Check manual for specific climate/usage recommendations) Coolant Type: Mitsubishi Genuine Super Long Life Coolant (or equivalent OAT type coolant) Spark Plugs: NGK ILFR6A or similar (refer to manual for specific gap and type) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission (Commonly fitted) Optional Transmission Type: 6-Speed Automatic Transmission with...

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Type: Car

Vendor:

Sku: 283830

Collections: ALL Mitsubishi

Availability: In stock

Tags: 2003 2004 2005 2006 2007 2008 2009 2010 Car Cars COLT COLT RALLIART Mitsubishi Mitsubushi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Model Variant:

Colt & Colt Ralliart

Production Years Covered:

2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Chassis Code:

Z20 Series (Commonly referred to as the Z20 generation)

👋 Introduction

Market Position

Segment:

Subcompact hatchback

Target Audience:

Young drivers, small families, urban commuters seeking economical and reliable transportation.

Competitive Analysis

Competitors:

Ford Fiesta, Vauxhall Corsa, Volkswagen Polo, Peugeot 207, Renault Clio, Honda Jazz.

Key Features Manual

Value Proposition:

This comprehensive factory service manual provides an unparalleled resource for maintaining and repairing the Mitsubishi Colt (Z20 series) and its performance-oriented Ralliart variant. Its detailed coverage and high-quality digital format ensure accurate and efficient servicing.

📋 Manual Details

Coverage Areas

Systems Covered:

General Maintenance, Engine Mechanical (4A91, 4G15 MIVEC), Engine Lubrication, Fuel System, Engine Cooling System, Intake and Exhaust Systems, Engine Electrical System, Engine and Emission Control, Clutch System, Manual Transmission, Automatic Transmission, Front Axle, Rear Axle, Wheels and Tires, Power Plant Mounts, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering System, Body Structure, Exterior Components, Interior Components, Supplemental Restraint Systems (SRS), Chassis Electrical System, HVAC (Heater, Air Conditioner, Ventilation)

Page Count

Total Pages:

1500+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed specifications, disassembly, assembly, inspection, and repair of 4A91 1.5L MIVEC and 4G15 1.5L MIVEC (Ralliart) engines. Includes cylinder head, block, pistons, crankshaft, camshafts, timing system, valve train.

Engine Control:

Engine and Emission Control systems, including ECU diagnosis, sensors (O2, MAP, MAF, TPS, Crank/Cam position), actuators (injectors, ignition coils), MIVEC system control, emissions components (EVAP, EGR if applicable).

Transmission:

Coverage for both Manual Transmissions (MT) and Automatic Transmissions (AT), including internal components, hydraulic systems (for AT), shift mechanisms, lubrication, and diagnosis.

Suspension Steering:

Front and Rear suspension components (struts, springs, control arms, bushings, stabilizer bars), steering system (rack and pinion, power steering pump/motor, tie rods), alignment specifications.

Brakes:

Service Brakes (front and rear disc brake systems, hydraulic lines, calipers, master cylinder, ABS components) and Parking Brakes (mechanical actuation, parking brake shoes/calipers).

Electrical Chassis:

Comprehensive chassis electrical system coverage including lighting, power windows, door locks, wipers, horn, instrument cluster, audio system, security system, fuses, relays, and wiring diagrams.

HVAC:

Heater, Air Conditioning, and Ventilation systems, including A/C compressor, condenser, evaporator, refrigerant circuits, blower motor, climate controls, and cabin air filter replacement.

Body Interior Exterior:

Body construction, exterior panels (doors, hood, trunk, fenders), interior trim, seating, airbags (SRS components and deployment warnings), door mechanisms, glass replacement, and weather stripping.

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid checks and changes (oil, coolant, brake fluid, transmission fluid, power steering fluid), filter replacements (oil, air, cabin), spark plug replacement, belt inspection and replacement.

Diagnosis Troubleshooting:

Systematic troubleshooting guides for common issues, diagnostic trouble codes (DTCs) and their interpretation, electrical system diagnostics using multimeter and scan tools.

Repair Rebuild:

Detailed step-by-step instructions for component removal, installation, repair, and rebuilding of engine, transmission, suspension, brake, steering, and electrical components.

Torque Specifications:

Essential torque values for critical fasteners across all major mechanical systems (engine, transmission, chassis, suspension).

Wiring Diagrams:

Comprehensive electrical wiring diagrams for various circuits, facilitating diagnosis and repair of electrical faults.

Technical Depth

Depth:

Factory-level technical depth, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission overhauls.

📊 Manual Specifications

File Format

File Format:

Print Quality

Quality:

High-quality, non-scanned digital reproduction. Text is searchable, images and diagrams are clear and legible.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine 1

Engine Code:

Engine Type:

Inline-4, DOHC, 16-valve, MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Displacement:

1.5 Liters (1499 cc)

Bore X Stroke:

75.0 mm x 84.3 mm

Compression Ratio:

Approximately 10.5:1 (Varies slightly by market/tune)

Fuel Delivery:

Electronic Fuel Injection (MPI)

Performance Est Hp:

Approx. 107-112 HP (80-84 kW) @ 6000 rpm (Varies by market and specific tune)

Performance Est Torque:

Approx. 145-150 Nm (107-111 lb-ft) @ 4000 rpm (Varies by market and specific tune)

Primary Engine 2

Engine Code:

Engine Type:

Inline-4, DOHC, 16-valve, MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Displacement:

1.5 Liters (1499 cc)

Fuel Delivery:

Electronic Fuel Injection (MPI)

Performance Est Hp:

Approx. 150-160 HP (112-119 kW) @ 6000 rpm (Ralliart specific tune)

Performance Est Torque:

Approx. 210-220 Nm (155-162 lb-ft) @ 3500 rpm (Ralliart specific tune)

Turbocharger:

Yes (Intercooled Turbocharger for Ralliart)

Fluid Specifications

Engine Oil Type:

API SJ or higher, SAE 5W-30 or 10W-30 (Check manual for specific climate/usage recommendations)

Coolant Type:

Mitsubishi Genuine Super Long Life Coolant (or equivalent OAT type coolant)

Spark Plugs:

NGK ILFR6A or similar (refer to manual for specific gap and type)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission (Commonly fitted)

Optional

Transmission Type:

6-Speed Automatic Transmission with Tiptronic (Sportronic) shifting (Optional on some models)

Manual Transmission Fluid

Fluid Type:

API GL-4, SAE 75W-85 (Refer to manual for precise specification)

Automatic Transmission Fluid

Fluid Type:

DIA QUEEN ATF-J2 (or equivalent Dexron III/Mercon compatible fluid)

📐 Dimensions

Exterior

Length:

Approx. 3,810 - 3,865 mm (Varies slightly by trim and body style)

Width:

Approx. 1,680 - 1,720 mm (Varies slightly by trim)

Height:

Approx. 1,500 - 1,550 mm (Varies slightly by trim)

Weights

Curb Weight:

Approx. 1050 - 1250 kg (Varies significantly by engine and transmission)

Gross Vehicle Weight Rating:

Refer to vehicle's VIN plate or owner's manual for specific GVWR.

🛡️ Safety Features

Passive Features

Airbags:

Front airbags (driver and passenger), side airbags (optional), curtain airbags (optional).

Seatbelts:

Three-point seatbelts with pretensioners and load limiters (front seats).

Body Structure:

RISE (Reinforced Impact Safety Evolution) body structure for enhanced crash energy absorption.

Active Features

Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) (Standard on most variants).

Traction Control:

Traction Control System (TCL) and Active Stability Control (ASC) often available, particularly on Ralliart models.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player, often with basic speaker setup. Higher trims might include steering wheel audio controls or upgraded sound systems.

Driver Assistance

Features:

ABS, EBD, optional Traction Control and Stability Control. Cruise control available on higher trims or as an option.

Connectivity

Auxiliary Input:

May be present on later models or as an aftermarket addition.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 miles (12,000 km) or 6-12 months, whichever comes first (check manual for specific recommendations).

Air Filter Replacement:

Every 15,000 miles (24,000 km) or as needed based on driving conditions.

Cabin Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Coolant Flush:

Initial flush at 60,000 miles (96,000 km) or 4 years, then every 30,000 miles (48,000 km) or 2 years thereafter.

Transmission Fluid Change:

Manual: Inspect periodically, change if signs of contamination or wear. Automatic: Typically every 30,000-60,000 miles (48,000-96,000 km), depending on driving severity. Consult manual for specific intervals.

Known Issues

Common Issues:

Early models may experience some minor electrical gremlins (e.g., window regulators, central locking). Clutch wear on manual transmissions under hard use. Some reports of premature catalytic converter failure or oil consumption in high-mileage examples. Ralliart models may require more frequent servicing of turbocharger and related components.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mitsubishi Motors Corporation (Japan)

Model Evolution

Generation:

The Z20 series Colt represented the fifth generation of the Colt nameplate. This generation saw a significant redesign, moving to a more modern platform and offering more refined engines and features, including the introduction of the performance-oriented Ralliart variant.

Production

Manufacturing Location:

Primarily manufactured in Japan. Some markets may have received units produced in other Mitsubishi assembly plants globally.

🏆 Awards & Recognition

Recognitions

Awards Received:

Specific awards for the Z20 Colt are not widely documented as major industry accolades. However, it was generally recognized as a competent and popular subcompact in its segment, praised for its practicality, fuel efficiency, and the sporty character of the Ralliart version.