Mitsubishi Colt 2004 Workshop Manual – PDF DOWNLOAD

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Mitsubishi Colt 2004 Workshop Manual – PDF DOWNLOAD

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Mitsubishi Colt 2004 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 361
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Mitsubishi Colt 2004 Workshop Manual – PDF DOWNLOAD

00_General 1
GENERAL 1
HOW TO USE THIS MANUAL 2
MODEL INDICATIONS 2
TARGETS OF DEVELOPMENT 2
PRODUCT FEATURES 2
ADVANCED AND FASHIONABLE STYLING 2
NEWLY DEVELOPED ENGINE WITH GOOD FUEL EFFICIENCY AND EXCELLENT POWER-DRIVEN PERFORMANCE 2
HIGH LEVEL OF SAFETY 2
EXCELLENT PRACTICABILITY AND SPACE UTILITY 2
TECHNICAL FEATURES 3
EXTERIOR 3
DESIGN FEATURES 3
INTERIOR 4
DESIGN FEATURES 4
SPACIOUS CABIN 4
ENGINE 5
TRANSMISSION 5
MANUAL TRANSMISSION 6
SECTIONAL VIEW 6
AUTOMATED MANUAL TRANSMISSION 7
SUSPENSION 8
FRONT SUSPENSION 8
REAR SUSPENSION 9
BRAKE 10
STEERING 11
LOCAL INTERCONNECT NETWORK (LIN) 12
ACTIVE SAFETY 13
BRAKING SYSTEM 13
PASSENGER’S AIR BAG CUT OFF SWITCH 17
PASSIVE SAFETY 17
IMPACT SAFETY BODY 17
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND FRONT SEAT BELTS WITH PRE-TENSIONER 19
EQUIPMENTS 20
MULTI-CENTRE DISPLAY 20
IMMOBILIZER SYSTEM 21
ENVIRONMENTAL PROTECTION 21
SERVICEABILITY AND RELIABILITY 21
MUT-III (MULTI USE TESTER-III) 21
IMPROVED SERVICEABILITY 22
VEHICLE IDENTIFICATION 22
MODEL CODE 22
MAJOR SPECIFICATIONS 23
11_Engine 25
ENGINE 25
11A_Engine_Mechanical_(134) 26
ENGINE MECHANICAL <134> 26
GENERAL INFORMATION 27
BASE ENGINE 28
CYLINDER HEAD 28
VALVE SEAT 28
VALVE GUIDE 29
CYLINDER HEAD GASKET 29
CYLINDER HEAD COVER 30
CYLINDER BLOCK 31
REAR OIL SEAL CASE 32
PISTON 32
PISTON PIN 32
PISTON RING 33
CONNECTING ROD 34
CONNECTING ROD BEARING 34
CRANKSHAFT 35
CRANKSHAFT BEARING, THRUST BEARING 35
CRANKSHAFT PULLEY 36
FLYWHEEL 37
TIMING CHAIN TRAIN 38
TIMING CHAIN TENSIONER 38
VALVE MECHANISM 39
VALVE 40
VALVE STEM SEAL 40
VALVE SPRING 40
VALVE TAPPET 41
MIVEC (MITSUBISHI INNOVATIVE VALVE TIMING ELECTRONIC CONTROL SYSTEM) 41
V V T SPROCKET (VARIABLE VALVE TIMING SPROCKET) 41
CAMSHAFT 42
OIL CONTROL VALVE (OCV) 42
TIMING CHAIN CASE 43
BALANCER 44
BALANCE SHAFT 45
11B_Engine_Mechanical_(135) 46
ENGINE MECHANICAL <135> 46
GENERAL INFORMATION 47
BASE ENGINE 47
CYLINDER HEAD 47
VALVE SEAT 48
VALVE GUIDE 48
CYLINDER HEAD GASKET 49
CYLINDER HEAD COVER 49
CYLINDER BLOCK 50
REAR OIL SEAL CASE 51
PISTON 51
PISTON PIN 52
PISTON RING 52
CONNECTING ROD 53
CONNECTING ROD BEARING 53
CRANKSHAFT 54
CRANKSHAFT BEARING, THRUST BEARING 55
CRANKSHAFT PULLEY 55
FLYWHEEL 56
TIMING CHAIN TRAIN 57
TIMING CHAIN TENSIONER 57
VALVE MECHANISM 58
VALVE 58
VALVE STEM SEAL 59
VALVE SPRING 59
VALVE TAPPET 59
MIVEC (MITSUBISHI INNOVATIVE VALVE TIMING ELECTRONIC CONTROL SYSTEM) 60
V V T SPROCKET (VARIABLE VALVE TIMING SPROCKET) 60
CAMSHAFT 61
OIL CONTROL VALVE (OCV) 61
TIMING CHAIN CASE 62
12_Engine_Lubrication 63
ENGINE LUBRICATION 63
GENERAL INFORMATION 64
LUBRICATION SYSTEM SCHEMATIC 64
OIL PUMP 65
RELIEF VALVE 65
OIL SCREEN 66
OIL FILTER 66
OIL PAN 67
OIL LEVEL GAUGE, OIL FILLER CAP, OIL DRAIN PLUG 68
13_Fuel 69
FUEL 69
13A_Multipoint_Fuel_Injection 70
MULTIPOINT FUEL INJECTION (MPI) 70
GENERAL INFORMATION 71
System Block Diagram 72
Control System Diagram 73
CONTROL SYSTEM 76
Engine-ECU or Engine-A-M/T-ECU 76
ECU Connector Input / Output Pin Arrangement 76
SENSOR 77
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 77
INTAKE AIR TEMPERATURE SENSOR 78
ENGINE COOLANT TEMPERATURE SENSOR 78
THROTTLE POSITION SENSOR (TPS) 79
ACCELERATOR POSITION SENSOR (APS) 80
OXYGEN SENSOR 80
CRANK ANGLE SENSOR 81
CAMSHAFT POSITION SENSOR 82
DETONATION SENSOR 82
IGNITION SWITCH-IG 82
IGNITION SWITCH-ST (STARTING SIGNAL) 82
ACTUATOR 83
INJECTOR 83
IGNITION COIL 83
THROTTLE VALVE CONTROL SERVO 83
OIL CONTROL VALVE 84
FUEL INJECTION CONTROL 84
System Configuration Diagram 85
Control Block Diagram 85
INJECTOR ACTUATION (FUEL INJECTION) TIMING 85
<134 engine> 86
<135 engine> 86
<134 engine> 87
<135 engine> 87
<134 engine> 88
<135 engine> 88
FUEL INJECTION VOLUME (INJECTOR ACTUATION DURATION) CONTROL 88
Fuel Injection Volume Control Block Diagram 89
THROTTLE VALVE OPENING ANGLE CONTROL 92
System Configuration Diagram 93
ENGINE CONTROL SYSTEM 93
IGNITION TIMING AND DISTRIBUTION CONTROL 94
System Configuration Diagram 95
Control Block Diagram 95
IGNITION DISTRIBUTION CONTROL 95
<134 engine> 96
<135 engine> 97
IGNITION TIMING CONTROL 97
IGNITION TIMING ADVANCE ANGLE CONTROL 98
Ignition Timing Advance Angle Control Block Diagram 98
Knock Control Block Diagram (Overview) 99
CURRENT DURATION CONTROL 100
Current Duration Control Block Diagram 100
MIVEC (Mitsubishi Innovative Valve timing Electronic Control system) 100
BASIC OPERATION 101
Timing Advance 101
Timing Retard 102
Holding 103
OPERATION UNDER VARIOUS DRIVING CONDITIONS 103
Conceptual Diagram of Operation 104
OIL CONTROL VALVE CONTROL 105
System Configuration Diagram 106
PHASE ANGLE CONTROL 106
<134 engine> 107
<135 engine> 107
POWER SUPPLY CONTROL 108
FUEL PUMP RELAY CONTROL 109
OXYGEN SENSOR HEATER CONTROL 110
A/C COMPRESSOR CONTROL 111
ALTERNATOR CONTROL 112
STARTER RELAY CONTROL 113
CONTROLLER AREA NETWORK (CAN) 113
DIAGNOSIS SYSTEM 114
FREEZE-FRAME DATA 114
DIAGNOSIS CODE 114
DATA LIST FUNCTION 118
13B_Fuel_Supply 121
FUEL SUPPLY 121
GENERAL INFORMATION 122
FUEL TANK 123
CONSTRUCTION DIAGRAM 123
13C_Fuel_Supply 124
FUEL SUPPLY 124
GENERAL INFORMATION 125
<134, 135> 125
<639> 126
FUEL TANK 127
CONSTRUCTION DIAGRAM 127
14_Engine_Cooling 128
ENGINE COOLING 128
GENERAL INFORMATION 129
CONSTRUCTION DIAGRAM 130
<134, 135> 130
<639> 130
15_Intake_and_Exhaust 131
INTAKE AND EXHAUST 131
AIR INTAKE SYSTEM 132
AIR DUCT AND AIR CLEANER <134, 135> 132
CONSTRUCTION DIAGRAM 132
AIR DUCT AND AIR CLEANER <639> 132
CONSTRUCTION DIAGRAM 132
INTERCOOLER <639> 132
CONSTRUCTION DIAGRAM 133
EXHAUST SYSTEM 133
EXHAUST PIPE AND MUFFLER <134, 135> 133
CONSTRUCTION DIAGRAM 134
EXHAUST PIPE AND MUFFLER <639> 134
CONSTRUCTION DIAGRAM 134
16_Engine_Electrical 135
ENGINE ELECTRICAL 135
STARTER MOTOR 136
ALTERNATOR 136
IGNITION COIL 136
SPARK PLUG 137
17_Engine_and_Enmission_Control 138
ENGINE AND EMISSION CONTROL 138
ACCELERATOR SYSTEM 139
GENERAL INFORMATION 139
CONSTRUCTION DIAGRAM 139
21_Clutch 140
CLUTCH 140
GENERAL INFORMATION 141
CONSTRUCTION DIAGRAM 141
22_Manual_Transmission 143
MANUAL TRANSMISSION 143
22A_Manual_Transmission 144
MANUAL TRANSMISSION 144
MANUAL TRANSMISSION 145
GENERAL INFORMATION 145
SECTIONAL VIEW 146
TRANSMISSION CONTROL 146
GENERAL INFORMATION 146
22B_Automated_Manual_Transmission 148
AUTOMATED MANUAL TRANSMISSION 148
AUTOMATED MANUAL TRANSMISSION 149
GENERAL INFORMATION 149
OUTSIDE VIEW 149
DESCRIPTION OF STRUCTURE AND OPERATION 150
STRUCTURE 150
Automated Manual Transmission System 150
Automated Manual Transmission 150
TWIN-DRUM SHIFT SYSTEM (HART OF QUICKER SHIFT) 150
OPERATIONS 152
CLUTCH ACTUATION 153
DRIVING MODE 154
ELECTRONIC CONTROL SYSTEM 155
ENGINE-A-M/T-ECU 155
SOFTWARE AND MANAGEMENT 155
AUTOMATIC MODE 156
OTHER FUNCTIONS 157
26_Front_Axle 158
FRONT AXLE 158
GENERAL INFORMATION 159
CONSTRUCTION DIAGRAM 160
27_Rear_Axle 161
REAR AXLE 161
GENERAL INFORMATION 162
CONSTRUCTION DIAGRAM 162
31_Wheel_and_Tyre 163
WHEEL AND TYRE 163
GENERAL INFORMATION 164
ROAD WHEEL AND TYRE 164
SPARE WHEEL AND TYRE OR TYRE REPAIR KIT 164
32_Power_Plant_Mount 165
POWER PLANT MOUNT 165
GENERAL INFORMATION 166
CONSTRUCTION DIAGRAM 166
33_Front_Suspension 167
FRONT SUSPENSION 167
GENERAL INFORMATION 168
CONSTRUCTION DIAGRAM 168
SPECIFICATIONS 168
33A_Front_Suspension 170
FRONT SUSPENSION 170
GENERAL INFORMATION 171
CONSTRUCTION DIAGRAM 171
SPECIFICATIONS 171
34_Rear_Suspension 173
REAR SUSPENSION 173
GENERAL INFORMATION 174
CONSTRUCTION DIAGRAM 175
SPECIFICATIONS 175
35_Service_Brakes 176
SERVICE BRAKES 176
35A_Servise_Brakes 177
SERVICE BRAKES 177
GENERAL INFORMATION 178
FEATURES 178
CONSTRUCTION DIAGRAM 179
CONSTRUCTION DESCRIPTION 181
MASTER CYLINDER 181
BRAKE BOOSTER 181
BRAKE PEDAL 182
FRONT BRAKE 183
DISC BRAKE DESIGNATION 183
REAR BRAKE 183
Disc brake designation 184
35B_Four-Wheel_Anti-Skid_Brake_System_(4ABS) 185
FOUR-WHEEL ANTI-SKID BRAKE SYSTEM (4ABS) 185
GENERAL INFORMATION 186
FEATURES 186
EBD CONTROL 186
CONSTRUCTION DIAGRAM 187
SYSTEM CONFIGURATION DIAGRAM 188
ABS ELECTRICAL CIRCUIT DIAGRAM 189
CONSTRUCTION DESCRIPTION 190
SENSORS 190
WHEEL SPEED SENSORS AND MAGNETIC ENCODER FOR WHEEL SPEED DETECTION 190
ABS-ECU 190
ABS FLUID PRESSURE CONTROL 190
EBD FLUID PRESSURE CONTROL 191
INITIAL CHECK 191
STARTUP CHECK 191
CONSTANT CHECK 191
CAN COMMUNICATION 192
FAIL – SAFE FUNCTION 192
DIAGNOSTIC FUNCTION 194
35C_Traction_Control,_Active_Stability_Control_System 196
TRACTION CONTROL/ACTIVE STABILITY CONTROL SYSTEM 196
FEATURES 197
CONSTRUCTION DIAGRAM 197
SCHEMATIC DIAGRAM 199
CONSTRUCTION DESCRIPTION 200
SENSOR 200
ACTUATOR 200
ABS/active stability control system-ECU 201
EXAMPLE OF OPERATION OF ANTI-SKID CONTROL 202
SYSTEM OPERATION 211
ACTIVE STABILITY CONTROL SYSTEM OPERATION 211
ANTI-SKID CONTROL SYSTEM OPERATION 218
36_Parking_Brake 219
PARKING BRAKE 219
GENERAL INFORMATION 220
CONSTRUCTION DIAGRAM 220
37_Power_Steering 221
POWER STEERING 221
GENERAL INFORMATION 222
FEATURES 222
CONSTRUCTION DIAGRAM 223
STEERING WHEEL 223
STEERING SHAFT AND COLUMN 224
Impact-absorbing mechanism 224
ELECTRICAL POWER STEERING 225
GENERAL INFORMATION 225
SYSTEM CONFIGURATION 225
GENERAL DESCRIPTION ON SYSTEM 226
STEERING GEAR 227
MOTOR 227
ELECTRIC POWER STEERING-ECU 227
CAN COMMUNICATION 227
FAIL – SAFE FUNCTION 228
DIAGNOSTIC FUNCTION 228
OPERATION 228
IGNITION SWITCH ON 228
IGNITION SWITCH ON 228
STEERING WHEEL OPERATION 229
FAIL-SAFE FUNCTION OPERATION 229
37A_Power_Steering 230
POWER STEERING 230
GENERAL INFORMATION 231
FEATURES 231
CONSTRUCTION DIAGRAM 232
STEERING WHEEL 232
STEERING SHAFT AND COLUMN 233
Impact-absorbing mechanism 233
ELECTRICAL POWER STEERING 234
GENERAL INFORMATION 234
SYSTEM CONFIGURATION 235
GENERAL DESCRIPTION ON SYSTEM 236
STEERING GEAR 236
MOTOR 237
ELECTRIC POWER STEERING-ECU 237
CAN COMMUNICATION 237
FAIL – SAFE FUNCTION 237
DIAGNOSTIC FUNCTION 237
OPERATION 239
IGNITION SWITCH ON 239
IGNITION SWITCH ON 240
STEERING WHEEL OPERATION 240
FAIL-SAFE FUNCTION OPERATION 241
42_Body 242
BODY 242
GENERAL INFORMATION 243
FEATURES 243
MAIN BODY 244
BODY PANELING 244
BODY SHELL 245
IMPACT SAFETY BODY 245
UNEVEN THICKNESS STEEL SHEET 246
DRIVING STABILITY 247
QUIETNESS 247
BODY COLOUR CHARTS 248
HOOD 248
HOOD LATCH COVER 248
DOOR 248
DOOR LOCK 248
CONSTRUCTION DIAGRAM 249
DESCRIPTION OF STRUCTURE AND OPERATION 249
KEYLESS ENTRY SYSTEM 250
CONSTRUCTION DIAGRAM 251
DESCRIPTION OF STRUCTURE AND OPERATION 252
WINDOW GLASS REGULATOR 254
CONSTRUCTION DIAGRAM 254
DESCRIPTION OF STRUCTURE AND OPERATION 255
WEATHERSTRIP 256
CONSTRUCTION DIAGRAM 257
PROTECTOR FILM 257
CONSTRUCTION DIAGRAM 258
WINDOW GLASS 258
SUNROOF 260
DESCRIPTION OF STRUCTURE AND OPERATION 261
51_Exterior 262
EXTERIOR 262
GENERAL INFORMATION 263
FEATURES 263
BUMPER 264
CONSTRUCTION DIAGRAM 264
AERO PARTS 265
CONSTRUCTION DIAGRAM 265
WIPER AND WASHER 265
WINDSHIELD WIPER AND WASHER 265
CONSTRUCTION DIAGRAM 266
DESCRIPTION OF CONSTRUCTION AND OPERATION 267
REAR WIPER AND WASHER 268
CONSTRUCTION DIAGRAM 269
HEADLAMP WASHER 269
CONSTRUCTION DIAGRAM 270
OUTSIDE MIRROR 270
CONSTRUCTION DIAGRAM 271
52_Interior_and_Suplemental_System 272
INTERIOR AND SUPPLEMENTAL SYSTEM (SRS) 272
52A_Interior 273
INTERIOR 273
GENERAL INFORMATION 274
FEATURES 274
INSTRUMENT PANEL AND FLOOR CONSOLE 275
SEAT 276
FRONT SEAT 276
HEATED SEAT SYSTEM CIRCUIT DIAGRAM 278
REAR SEAT 279
MULTI SEAT ARRANGE 279
SEAT BELT 281
TRIMS 282
INTERIOR TRIMS 282
DOOR TRIM 283
LUGGAGE ROOM 284
FLOOR CARPET 285
52B_Suplemental_Restraint_System_(SRS) 286
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 286
GENERAL INFORMATION 287
CONSTRUCTION DIAGRAM 288
SRS SYSTEM CIRCUIT DIAGRAM 289
CAUTION LABELS 290
SYSTEM OPERATION 293
FRONT AIR BAG AND SEAT BELT WITH PRE-TENSIONER 293
SIDE AND CURTAIN AIR BAGS 294
SYSTEM CONSTRUCTION 294
DRIVER’S SIDE AIR BAG MODULE 294
FRONT PASSENGER’S SIDE AIR BAG MODULE 294
SIDE AIR BAG MODULE 294
CURTAIN AIR BAG MODULE 294
FRONT IMPACT SENSOR 295
SIDE IMPACT SENSOR 295
SEAT BELT WITH PRE-TENSIONER 296
PASSENGER’S AIR BAG CUT OFF SWITCH 296
SRS-ECU 297
DIAGNOSIS FUNCTION 297
DIAGNOSIS CODE SET 297
DATA LIST OUTPUT 299
ACTUATOR TEST 299
SRS AIR BAG SPECIAL CONNECTOR 300
54_Chassis_Electrical 301
CHASSIS ELECTRICAL 301
54A_Chassis_Electrical 302
CHASSIS ELECTRICAL 302
GENERAL INFORMATION 303
FEATURES 303
DIAGNOSTIC SYSTEM 303
DIAGNOSIS CONNECTORS 304
BATTERY 304
IMMOBILIZER SYSTEM 305
CONSTRUCTION DIAGRAM 306
Encrypted code registration criteria table 306
LIGHTING 307
EXTERIOR LAMPS 307
INTERIOR LAMPS 310
COMBINATION METER 311
CONSTRUCTION DIAGRAM 311
STEPPING MOTOR 312
MULTI CENTRE DISPLAY 313
CONSTRUCTION DIAGRAM 314
RADIO AND CD PLAYER, ANTENNA 316
RADIO AND CD PLAYER 316
SPEAKER 316
ANTENNA 317
ACCESSORY SOCKET 318
54B_Local_Interconect_Network_(LIN) 319
LOCAL INTERCONNECT NETWORK (LIN) 319
GENERAL DESCRIPTION 320
STRUCTURE 320
SYSTEM OPERATION 321
LIN COMMUNICATION SIGNAL TABLE 324
DIAGNOSIS CODE TABLE 324
MULTI-DISTRIBUTION INPUT/OUTPUT BY CIRCUIT 325
INPUT SIGNAL TABLE 328
ACTUATOR TEST TABLE 329
FUNCTION AND CONTROL BY ECUS OF LIN 330
BUZZER 330
WINDSHIELD WIPER/WASHER 331
REAR WIPER/WASHER 333
HEADLAMP WASHER 334
HEADLAMP 334
FLASHER TIMER FUNCTION 335
FRONT FOG LAMP 336
REAR FOG LAMP 336
CUSTOMIZATION FUNCTION 337
54C_Controller_Area_Network_(CAN) 339
CONTROLLER AREA NETWORK (CAN) 339
GENERAL INFORMATION 340
STRUCTURE 340
OPERATION 341
SELF-DIAGNOSIS 343
CAN BUS DIAGNOSTICS 343
CAN COMMUNICATION SIGNAL TABLE 344
CAN COMMUNICATION-RELATED DIAGNOSIS CODE (U CODE) TABLE 346
55_Heater,_Air_Conditioner_and_Ventilation 350
HEATER, AIR CONDITIONER AND VENTILATION 350
GENERAL 351
FEATURES 351
CONSTRUCTION DIAGRAM 352
HEATER UNIT 353
HEATER UNIT 353
OPERATION 354
COMPRESSOR 354
EXTERNALLY-CONTROLLED, 5-CYLINDER, CONTINUOUSLY VARIABLE DISPLACEMENT COMPRESSOR 354
OPERATION 355
HEATER CONTROL 355
HEATER CONTROLLER 355
IN CAR SENSOR FAN 356
A/C-ECU 356
CONTROL 356
DUCTS 359
index 360

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S.V 08/24