Mitsubishi Colt Lancer 1996-2003 Repair Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer (Colt Lancer) Model Variant: This manual covers the Lancer, often referred to as the Colt Lancer in various markets during this period. Generation Generation Code: CJ (often referred to as 6th Generation Lancer) Codes Chassis Codes: CK1A, CK2A, CK4A, CK5A, CK6A, CK8A, CK9A, CM5A, CM6A, CN9A, CP9A (specific codes vary by market and engine) 👋 Introduction Market Position Market Segment: Compact to mid-size sedan and hatchback segment, often competing with models like the Honda Civic, Toyota Corolla, and Nissan Sentra. Competitive Analysis Key Strengths: Known for its sporty handling (especially performance variants like the GSR and Evo derivatives, though this manual covers standard models), reliable engines, and practical design. The AWD variants offered excellent traction. Key Features Manual Value Proposition: Provides comprehensive, step-by-step repair and maintenance procedures, equipping owners and technicians with factory-level knowledge to service the vehicle efficiently and safely. Manual Type Clarification Manual Equivalence: Equivalent to factory service manuals, offering detailed technical information typically not found in owner's manuals or basic repair guides. 📋 Manual Details Coverage Areas Coverage Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Page Count Estimated Page Count: Approximately 2000-3000+ pages (typical for comprehensive factory-level repair manuals covering multiple variants). Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed coverage of engine assembly, disassembly, internal components, timing, lubrication, cooling, and exhaust systems for various engine variants. Engine Electrical: Ignition system, fuel injection system (ECI Multi), starting and charging systems, engine control unit (ECU) diagnostics, sensor operations, and wiring diagrams. Transmission: Manual transmission (F5M series) and automatic transmission (V4A51, F4AXX series) overhaul, adjustments, service procedures, and hydraulic/electronic control systems. Drivetrain: Front-wheel drive (FWD) and all-wheel drive (AWD - Super Select 4WD) systems, including driveshafts, CV joints, differentials, and transfer case (for AWD). Suspension: Front MacPherson strut and rear multi-link suspension systems, including component replacement, alignment procedures, and shock absorber/spring service. Steering: Power steering system, steering rack and pinion, column, and related components, including fluid types and bleeding procedures. Brakes: Front disc and rear drum/disc brake systems, anti-lock braking system (ABS) components and diagnostics, brake fluid specifications, and caliper/rotor service. Electrical Body: Lighting systems (headlights, taillights, interior), power windows, door locks, mirrors, wipers, horn, instrument cluster, and body control modules. Climate Control: Air conditioning system (refrigerant types, compressor, evaporator, condenser), heating system, and ventilation components. Body And Chassis: Body construction, panel replacement, door and latch mechanisms, interior trim removal, and corrosion protection. Safety Systems: Airbag system (SRS) components and service precautions, seat belt mechanisms. Procedures Included Scheduled Maintenance: Detailed service intervals for oil changes, filter replacements, fluid checks and changes, spark plug replacement, and timing belt inspection/replacement. Diagnostic Troubleshooting: Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues. Component Replacement: Step-by-step instructions for replacing major components such as engines, transmissions, alternators, starters, radiators, and suspension parts. Disassembly Assembly: Detailed procedures for taking apart and reassembling various vehicle systems and components. Cleaning And Reinstalling: Instructions for cleaning components during overhaul and proper reinstallation techniques. Wiring Diagrams: Color-coded and comprehensive wiring diagrams for all electrical systems, aiding in diagnosis and repair. Torque Specifications: Essential torque values for all critical fasteners, ensuring proper assembly and preventing damage. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth Level: Factory-level comprehensive coverage suitable for professional technicians, with enough detail for advanced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF Print Quality Printable: Full Printable Zoom Functionality: Zoom IN/OUT functionality for detailed viewing of diagrams and text. Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: Not applicable (digital format) Requirements Software Requirements: Adobe PDF Reader, WinZip (or equivalent decompression software) Compatibility Operating Systems: Compatible with All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Family: 4G9x family (e.g., 4G92, 4G93, 4G94) and 4G6x family (e.g., 4G63 for some higher performance variants not explicitly detailed here, but covered in broader manuals). Common Displacements Liters: 1.3L (4G13), 1.5L (4G91/4G92), 1.6L (4G92), 1.8L (4G93), 2.0L (4G94, 4G63 for performance models) Performance Horsepower Range Hp: Typically ranges from 75 hp to 135 hp for standard naturally aspirated engines. Performance variants (e.g., GSR, RS) could exceed 200 hp. Torque Range Nm: Varies significantly by engine, generally from 110 Nm to 180 Nm for standard models. Fuel System Fuel Delivery: Electronic Fuel Injection (ECI Multi), sequential multi-point fuel injection (MPI). Fuel Type: Unleaded Gasoline Engine Codes Engine Code Examples: 4G92 (1.6L SOHC/DOHC), 4G93 (1.8L SOHC/DOHC), 4G94 (2.0L SOHC) 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission (e.g., F5M33 for AWD variants, F5M22/F5M21 for FWD) Optional Optional Transmission Type: 4-speed Automatic Transmission (e.g., V4A51, F4AXX series) Features AWD System: Available with Mitsubishi's 'Super Select...
This manual covers the Lancer, often referred to as the Colt Lancer in various markets during this period.
Generation
Generation Code:
CJ (often referred to as 6th Generation Lancer)
Codes
Chassis Codes:
CK1A, CK2A, CK4A, CK5A, CK6A, CK8A, CK9A, CM5A, CM6A, CN9A, CP9A (specific codes vary by market and engine)
👋 Introduction
Market Position
Market Segment:
Compact to mid-size sedan and hatchback segment, often competing with models like the Honda Civic, Toyota Corolla, and Nissan Sentra.
Competitive Analysis
Key Strengths:
Known for its sporty handling (especially performance variants like the GSR and Evo derivatives, though this manual covers standard models), reliable engines, and practical design. The AWD variants offered excellent traction.
Key Features
Manual Value Proposition:
Provides comprehensive, step-by-step repair and maintenance procedures, equipping owners and technicians with factory-level knowledge to service the vehicle efficiently and safely.
Manual Type Clarification
Manual Equivalence:
Equivalent to factory service manuals, offering detailed technical information typically not found in owner's manuals or basic repair guides.
📋 Manual Details
Coverage Areas
Coverage Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Page Count
Estimated Page Count:
Approximately 2000-3000+ pages (typical for comprehensive factory-level repair manuals covering multiple variants).
Manual Type
Manual Type:
Repair Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed coverage of engine assembly, disassembly, internal components, timing, lubrication, cooling, and exhaust systems for various engine variants.
Engine Electrical:
Ignition system, fuel injection system (ECI Multi), starting and charging systems, engine control unit (ECU) diagnostics, sensor operations, and wiring diagrams.
Transmission:
Manual transmission (F5M series) and automatic transmission (V4A51, F4AXX series) overhaul, adjustments, service procedures, and hydraulic/electronic control systems.
Drivetrain:
Front-wheel drive (FWD) and all-wheel drive (AWD - Super Select 4WD) systems, including driveshafts, CV joints, differentials, and transfer case (for AWD).
Suspension:
Front MacPherson strut and rear multi-link suspension systems, including component replacement, alignment procedures, and shock absorber/spring service.
Steering:
Power steering system, steering rack and pinion, column, and related components, including fluid types and bleeding procedures.
Brakes:
Front disc and rear drum/disc brake systems, anti-lock braking system (ABS) components and diagnostics, brake fluid specifications, and caliper/rotor service.
Electrical Body:
Lighting systems (headlights, taillights, interior), power windows, door locks, mirrors, wipers, horn, instrument cluster, and body control modules.
Climate Control:
Air conditioning system (refrigerant types, compressor, evaporator, condenser), heating system, and ventilation components.
Body And Chassis:
Body construction, panel replacement, door and latch mechanisms, interior trim removal, and corrosion protection.
Safety Systems:
Airbag system (SRS) components and service precautions, seat belt mechanisms.
Procedures Included
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, fluid checks and changes, spark plug replacement, and timing belt inspection/replacement.
Diagnostic Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.
Component Replacement:
Step-by-step instructions for replacing major components such as engines, transmissions, alternators, starters, radiators, and suspension parts.
Disassembly Assembly:
Detailed procedures for taking apart and reassembling various vehicle systems and components.
Cleaning And Reinstalling:
Instructions for cleaning components during overhaul and proper reinstallation techniques.
Wiring Diagrams:
Color-coded and comprehensive wiring diagrams for all electrical systems, aiding in diagnosis and repair.
Torque Specifications:
Essential torque values for all critical fasteners, ensuring proper assembly and preventing damage.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Technical Depth
Depth Level:
Factory-level comprehensive coverage suitable for professional technicians, with enough detail for advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printable:
Full Printable
Zoom Functionality:
Zoom IN/OUT functionality for detailed viewing of diagrams and text.
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Paper Type:
Not applicable (digital format)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (or equivalent decompression software)
Compatibility
Operating Systems:
Compatible with All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Family:
4G9x family (e.g., 4G92, 4G93, 4G94) and 4G6x family (e.g., 4G63 for some higher performance variants not explicitly detailed here, but covered in broader manuals).
Available with Mitsubishi's 'Super Select 4WD' system on certain performance and higher-trim models, offering various driving modes.
📐 Dimensions
Exterior
Length Mm:
Approximately 4350-4420 mm (varies slightly by body style - sedan/hatchback/wagon)
Width Mm:
Approximately 1690-1700 mm
Height Mm:
Approximately 1400-1450 mm
Weights
Curb Weight Kg:
Approximately 1050-1250 kg (depending on engine, transmission, and drivetrain)
🛡️ Safety Features
Ratings
Crash Test Data:
Refer to specific regional safety authority reports (e.g., NHTSA for US market, Euro NCAP for European market) for detailed crash test results. Models from this era often had average to good safety ratings for their time.
Active Features
Active Safety Features Available:
Anti-lock Braking System (ABS) was often an option or standard on higher trims.
Passive Features
Passive Safety Features Available:
Driver and passenger front airbags, seat belt pretensioners, reinforced body structure.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player or CD player with AM/FM tuner, basic speaker systems.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. ABS was the primary electronic driver assistance feature available.
Connectivity
Connectivity Options:
No integrated smartphone connectivity or Bluetooth found in factory systems of this era.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 7,500-10,000 miles (12,000-16,000 km) or 6-12 months, depending on driving conditions.
Timing Belt Replacement:
Critical interval, usually around 60,000-100,000 miles (96,000-160,000 km) or 5-7 years. Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, viscosity typically 5W-30 or 10W-30 (refer to manual for specific engine variant).
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4 gear oil, viscosity typically 75W-90 or 80W-90.
Transmission Fluid Automatic:
Diamond SP-III ATF (or equivalent) for most 4-speed automatics.
Known Issues
Common Wear Items:
Front suspension components (bushings, ball joints), exhaust system corrosion, radiator leaks, automatic transmission shift solenoid issues (on higher mileage units).
Engine Specific Issues:
Timing belt maintenance is crucial. Oil leaks from valve cover gaskets or oil pan gaskets can occur with age.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Mitsubishi Motors has a history of producing reliable and often performance-oriented vehicles, with the Lancer evolving from a compact car to a motorsport icon (Evolution series).
Model Evolution
Lancer Generations:
The 1996-2003 models represent the sixth generation (CJ chassis), a significant update over its predecessor, introducing more aerodynamic styling and advanced features. This generation also laid the groundwork for the legendary Lancer Evolution IV through VI.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with assembly plants also located in various countries for different markets.
🏆 Awards & Recognition
Recognitions
Motorsport Heritage:
While this manual covers standard models, the Lancer platform's reputation was significantly boosted by the success of the Lancer Evolution in World Rally Championship (WRC), lending performance credibility to the entire model line.
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