Mitsubishi Colt/Lancer chassis Bulletin Supplement Service Manual – PDF DOWNLOAD
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Mitsubishi Colt/Lancer chassis Bulletin Supplement Service Manual – PDF DOWNLOAD
Language : English
Pages : 895
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Mitsubishi Colt/Lancer chassis Bulletin Supplement Service Manual – PDF DOWNLOAD
FOREWORD.................................................................... 1 GENERAL [00]................................................................ 2 HOW TO USE THIS MANUAL.................................................. 3 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS.................... 7 VEHICLE IDENTIFICATION.................................................. 14 MAJOR SPECIFICATIONS.................................................... 18 PRECAUTIONS BEFORE SERVICE.............................................. 20 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER.... 24 SUPPORT LOCATIONS FOR LIFTING AND JACKING............................... 28 STANDARD PART/TIGHTENING-TORQUE TABLE................................... 32 ENGINE [11]................................................................. 34 ENGINE<4G1> [11A]....................................................... 35 GENERAL INFORMATION................................................. 36 SERVICE SPECIFICATIONS.............................................. 36 SEALANT............................................................. 37 SPECIAL TOOLS....................................................... 37 ON-VEHICLE SERVICE.................................................. 39 CRANKSHAFT PULLEY................................................... 46 CAMSHAFT AND CAMSHAFT OIL SEAL...................................... 47 OIL PAN............................................................. 49 CRANKSHAFT OIL SEAL................................................. 50 CYLINDER HEAD GASKET................................................ 52 TIMING BELT......................................................... 56 ENGINE ASSEMBLY..................................................... 59 ENGINE<4G9> [11B]....................................................... 64 GENERAL INFORMATION................................................. 65 SERVICE SPECIFICATIONS.............................................. 65 SEALANT............................................................. 66 SPECIAL TOOLS....................................................... 66 ON-VEHICLE SERVICE.................................................. 68 CRANKSHAFT PULLEY................................................... 75 CAMSHAFT AND CAMSHAFT OIL SEAL...................................... 76 OIL PAN............................................................. 78 CRANKSHAFT OIL SEAL................................................. 79 CYLINDER HEAD GASKET................................................ 81 TIMING BELT......................................................... 85 ENGINE ASSEMBLY..................................................... 88 ENGINE LUBRICATION [12]..................................................... 92 GENERAL INFORMATION..................................................... 93 LUBRICANTS.............................................................. 94 SPECIAL TOOL............................................................ 94 ON-VEHICLE SERVICE...................................................... 94 FUEL [13]................................................................... 96 MULTIPOINT FUEL INJECTION (MPI) [13A]................................... 97 MULTIPOINT FUEL INJECTION <4G1>..................................... 99 GENERAL INFORMATION............................................. 99 SERVICE SPECIFICATIONS..........................................102 SEALANT.........................................................102 SPECIAL TOOLS...................................................103 TROUBLESHOOTING.................................................104 ON-VEHICLE SERVICE..............................................170 INJECTOR........................................................185 THROTTLE BODY...................................................187 MULTIPOINT FUEL INJECTION <4G9>.....................................190 GENERAL INFORMATION.............................................190 SERVICE SPECIFICATIONS..........................................195 SEALANT.........................................................195 SPECIAL TOOLS...................................................196 TROUBLESHOOTING.................................................197 ON-VEHICLE SERVICE..............................................266 INJECTOR........................................................273 THROTTLE BODY...................................................275 FUEL SUPPLY [13F].......................................................278 GENERAL INFORMATION.................................................279 SEALANT.............................................................279 FUEL TANK...........................................................280 ENGINE COOLING [14].........................................................284 GENERAL INFORMATION.....................................................285 SERVICE SPECIFICATIONS..................................................285 LUBRICANT...............................................................285 SEALANTS................................................................285 ON-VEHICLE SERVICE......................................................286 THERMOSTAT..............................................................288 WATER PUMP .............................................................290 <4G1>...............................................................290 <4G9>...............................................................291 WATER HOSE AND WATER PIPE ..............................................292 <4G1>...............................................................292 <4G9>...............................................................294 RADIATOR ...............................................................296 INTAKE AND EXHAUST [15].....................................................298 GENERAL INFORMATION.....................................................299 SERVICE SPECIFICATIONS..................................................299 SPECIAL TOOL............................................................299 ON-VEHICLE SERVICE......................................................299 INTAKE MANIFOLD ........................................................300 EXHAUST MANIFOLD .......................................................305 EXHAUST PIPE AND MAIN MUFFLER ..........................................307 ENGINE ELECTRICAL [16]......................................................310 CHARGING SYSTEM.........................................................311 GENERAL INFORMATION.................................................311 SERVICE SPECIFICATIONS..............................................312 SPECIAL TOOL........................................................312 ON-VEHICLE SERVICE..................................................313 ALTERNATOR .........................................................320 STARTING SYSTEM.........................................................325 GENERAL INFORMATION.................................................325 SERVICE SPECIFICATIONS..............................................325 STARTER MOTOR.......................................................326 IGNITION SYSTEM.........................................................338 GENERAL INFORMATION.................................................338 SERVICE SPECIFICATIONS..............................................340 SPECIAL TOOL........................................................340 ON-VEHICLE SERVICE..................................................341 DISTRIBUTOR <4G1> ..................................................353 CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR <4G9>...............355 DETONATION SENSOR <4G9>.............................................356 ENGINE AND EMISSION CONTROL [17]............................................358 ENGINE CONTROL SYSYTEM..................................................360 GENERAL INFORMATION.................................................360 SERVICE SPECIFICATIONS..............................................360 ON-VEHICLE SERVICE..................................................360 ACCELERATOR CABLE AND PEDAL.........................................361 EMISSION CONTROL SYSTEM.................................................362 GENERAL INFORMATION.................................................362 SERVICE SPECIFICATIONS..............................................363 VACUUM HOSE.........................................................363 CRANKCASE EMISSION CONTROL SYSTEM...................................367 EVAPORATIVE EMISSION CONTROL SYSTEM.................................369 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................372 CATALYTIC CONVERTER.................................................377 CANISTER AND TWO-WAY VALVE..........................................378 CLUTCH [21].................................................................380 GENERAL INFORMATION.....................................................381 SERVICE SPECIFICATIONS..................................................381 LUBRICANTS..............................................................381 ON-VEHICLE SERVICE......................................................381 CLUTCH PEDAL............................................................383 CLUTCH CONTROL..........................................................384 MANUAL TRANSMISSION [22]....................................................386 SERVICE SPECIFICATION...................................................387 LUBRICANTS..............................................................387 SPECIAL TOOLS...........................................................387 ON-VEHICLE SERVICE......................................................388 TRANSMISSION CONTROL*...................................................389 TRANSMISSION ASSEMBLY ..................................................392 AUTOMATIC TRANSMISSION [23].................................................396 SERVICE SPECIFICATIONS..................................................397 LUBRICANTS..............................................................397 SPECIAL TOOLS...........................................................397 TROUBLESHOOTING.........................................................399 ON-VEHICLE SERVICE......................................................437 TRANSMISSION CONTROL*...................................................453 TRANSMISSION ASSEMBLY ..................................................456 FRONT AXLE [26].............................................................460 GENERAL INFORMATION.....................................................461 SERVICE SPECIFICATIONS..................................................461 LUBRICANTS..............................................................461 SPECIAL TOOLS...........................................................462 ON-VEHICLE SERVICE......................................................464 AXLE HUB................................................................465 DRIVE SHAFT ............................................................470 REAR AXLE [27]..............................................................480 GENERAL INFORMATION.....................................................481 SERVICE SPECIFICATIONS..................................................481 SPECIAL TOOLS...........................................................481 ON-VEHICLE SERVICE......................................................482 REAR AXLE HUB ..........................................................483 WHEEL AND TYRE [31].........................................................486 GENERAL INFORMATION.....................................................487 SERVICE SPECIFICATIONS..................................................487 TROUBLESHOOTING.........................................................488 ON-VEHICLE SERVICE......................................................489 WHEEL AND TYRE..........................................................489 POWER PLANT MOUNT [32]......................................................490 GENERAL INFORMATION.....................................................491 SERVICE SPECIFICATION...................................................491 SPECIAL TOOLS...........................................................492 ENGINE MOUNTING.........................................................492 TRANSMISSION MOUNTING...................................................494 ENGINE ROLL STOPPER,CENTERMEMBER........................................496 CROSSMEMBER.............................................................497 FRONT SUSPENSION [33A]......................................................500 GENERAL INFORMATION.....................................................501 SERVICE SPECIFICATIONS..................................................502 SPECIAL TOOLS...........................................................503 ON-VEHICLE SERVICE......................................................504 STRUT ASSEMBLY..........................................................506 LOWER ARM ..............................................................509 STABILIZER BAR..........................................................512 REAR SUSPENSION [34]........................................................514 GENERAL INFORMATION.....................................................515 SERVICE SPECIFICATIONS..................................................516 SPECIAL TOOLS...........................................................516 ON-VEHICLE SERVICE......................................................517 CONTROL LINK,UPPER LINK AND LOWER ARM...................................519 TRAILING ARM ...........................................................521 STRUT ASSEMBLYSTRUT ASSEMBLYSTRUT ASSEMBLY..............................524 SERVICE BRAKES [35].........................................................528 BASIC BRAKE SYSTEM [35A]................................................529 GENERAL INFORMATION.................................................530 SERVICE SPECIFICATIONS..............................................531 LUBRICANTS..........................................................532 SEALANT.............................................................532 SPECIAL TOOLS.......................................................532 ON-VEHICLE SERVICE..................................................533 BRAKE PEDAL ........................................................542 MASTER CYLINDER AND BRAKE BOOSTER ..................................544 FRONT DISC BRAKE....................................................547 REAR DRUM BRAKE ....................................................552 PROPORTIONING VALVE.................................................555 ANTI-SKID BRAKING SYSTEM (ABS) <2WD> [35B]..............................556 GENERAL INFORMATION.................................................558 SERVICE SPECIFICATIONS..............................................559 LUBRICANTS..........................................................560 SPECIAL TOOLS.......................................................560 TROUBLESHOOTING ....................................................561 ON-VEHICLE SERVICE..................................................578 MASTER CYLINDER AND BRAKE BOOSTER ..................................585 REAR DRUM BRAKE ....................................................587 PROPORTIONING VALVE.................................................590 HYDRAULIC UNIT .....................................................591 WHEEL SPEED SENSOR .................................................593 ABS-ECU*............................................................596 PARKING BRAKES [36].........................................................598 GENERAL INFORMATION.....................................................599 SERVICE SPECIFICATIONS..................................................599 LUBRICANTS..............................................................599 ON-VEHICLE SERVICE......................................................600 PARKING BRAKE LEVER.....................................................601 PARKING BRAKE CABLE.....................................................602 STEERING [37A]..............................................................604 GENERAL INFORMATION.....................................................605 SERVICE SPECIFICATIONS..................................................606 LUBRICANTS..............................................................606 SEALANT.................................................................606 SPECIAL TOOLS...........................................................607 ON-VEHICLE SERVICE......................................................609 STEERING WHEEL AND SHAFT*...............................................616 POWER STEERING GEAR BOX*................................................619 POWER STEERING OIL PUMP.................................................631 POWER STEERING HOSES....................................................636 BODY [42]...................................................................638 HOOD....................................................................640 TRUNK LID <Sedan>.......................................................641 SPECIAL TOOL........................................................641 TRUNK LID ..........................................................641 FENDER..................................................................643 SEALANT.............................................................643 FENDER..............................................................644 FUEL FILLER DOOR........................................................645 WINDOW GLASS............................................................646 ADHESIVES...........................................................646 SPECIALTOOLS........................................................646 WINDOW REPAIR.......................................................646 WINDSHIELD..........................................................649 QUARTER WINDOW GLASS <Hatchback>....................................653 TAILGATE WINDOW GLASS <Hatchback>...................................655 REAR WINDOW GLASS <Sedan>...........................................657 DOOR....................................................................659 SERVICE SPECIFICATIONS..............................................659 SEALANT.............................................................659 SPECIAL TOOLS.......................................................659 TROUBLESHOOTING ....................................................660 ON-VEHICLE SERVICE..................................................669 DOOR ASSEMBLY.......................................................672 DOOR TRIM AND WATERPROOF FILM.......................................674 DOOR GLASS AND REGULATOR............................................676 DOOR HANDLE AND LATCH...............................................678 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP...............681 TAILGATE <Hatchback>....................................................682 SPECIAL TOOL........................................................682 TROUBLESHOOTING ....................................................682 TAILGATE ASSEMBLY...................................................683 TAILGATE LATCH......................................................685 SUNROOF.................................................................686 SERVICE SPECIFICATIONS..............................................686 SEALANT.............................................................686 SPECIAL TOOLS.......................................................686 TROUBLESHOOTING ....................................................687 ON-VEHICLE SERVICE..................................................690 SUNROOF.............................................................691 EXTERIOR [51]...............................................................696 SERVICE SPECIFICATIONS..................................................697 SEALANT AND ADHESIVE....................................................697 SPECIAL TOOLS...........................................................697 FRONT BUMPER............................................................698 REAR BUMPER ............................................................700 RADIATOR GRILLE ........................................................702 MOULDINGS...............................................................702 AERO PARTS..............................................................704 WINDSHIELD WIPER AND WASHER.............................................708 REAR WIPER AND WASHER...................................................711 HEADLAMP WASHER.........................................................714 MARKS...................................................................716 DOOR MIRROR.............................................................718 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) [52].......................720 INTERIOR [52A]..........................................................721 SERVICE SPECIFICATIONS..............................................722 ADHESIVES...........................................................722 SPECIAL TOOL........................................................722 INSTRUMENT PANEL*...................................................723 FLOOR CONSOLE*......................................................726 TRIMS...............................................................727 HEADLINING..........................................................729 INSIDE REAR VIEW MIRROR.............................................729 FRONT SEAT..........................................................730 REAR SEAT...........................................................733 FRONT SEAT BELT.....................................................735 REAR SEAT BELT......................................................736 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) [52B]...............................738 GENERAL INFORMATION.................................................739 SRS SERVICE PRECAUTIONS.............................................741 SPECIAL TOOLS.......................................................743 TEST EQUIPMENT......................................................743 TROUBLESHOOTING ....................................................743 SRS MAINTENANCE.....................................................752 POST-COLLISION DIAGNOSIS............................................756 INDIVIDUAL COMPONENT SERVICE........................................759 WARNING/CAUTION LABELS..............................................760 SRS AIR BAG CONTROL UNIT (SRS-ECU)..................................761 AIR BAG MODULES AND CLOCK SPRING....................................762 SEAT BELT WITH PRE-TENSIONER........................................768 AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES......771 CHASSIS ELECTRICAL [54].....................................................780 BATTERY.................................................................783 SERVICE SPECIFICATION...............................................783 ON-VEHICLE SERVICE..................................................783 IGNITION SWITCH AND IMMOBILIZER SYSTEM*.................................786 SPECIAL TOOL........................................................786 TROUBLESHOOTING ....................................................786 IGNITION SWITCH AND IMMOBILIZER SYSTEM..............................793 COMBINATION METERS......................................................796 SERVICE SPECIFICATIONS..............................................796 SEALANT.............................................................796 SPECIAL TOOLS.......................................................797 TROUBLESHOOTING ....................................................798 ON-VEHICLE SERVICE..................................................801 COMBINATION METERS..................................................804 HEADLAMP AND FRONT TURN-SIGNAL LAMP*....................................806 SERVICE SPECIFICATIONS..............................................806 SPECIAL TOOLS.......................................................806 TROUBLESHOOTING ....................................................807 ON-VEHICLE SERVICE..................................................814 HEADLAMP AND FRONT TURN-SIGNAL LAMP.................................817 SIDE TURN-SIGNAL LAMP...................................................820 SPECIAL TOOL........................................................820 SIDE TURN-SIGNAL LAMP...............................................820 FRONT FOG LAMP..........................................................821 SERVICE SPECIFICATIONS..............................................821 SPECIAL TOOL........................................................821 ON-VEHICLE SERVICE..................................................821 FRONT FOG LAMP......................................................824 REAR COMBINATION LAMP*..................................................825 REAR FOG LAMP...........................................................826 SPECIAL TOOL........................................................826 REAR FOG LAMP.......................................................826 HIGH-MOUNTED STOP LAMP..................................................828 RHEOSTAT................................................................829 SPECIAL TOOL........................................................829 RHEOSTAT............................................................829 HAZARD WARNING LAMP SWITCH..............................................830 SPECIAL TOOL........................................................830 HAZARD WARNING LAMP SWITCH..........................................830 CIGARETTE LIGHTER.......................................................831 CLOCK...................................................................832 SPECIAL TOOL........................................................832 CLOCK...............................................................832 RADIO AND TAPE PLAYER...................................................833 SPECIAL TOOL........................................................833 TROUBLESHOOTING ....................................................833 RADIO AND TAPE PLAYER WITH ANTI-THEFT SYSTEM........................849 RADIO AND TAPE PLAYER...............................................852 SPEAKER.................................................................853 ANTENNA.................................................................854 REAR WINDOW DEFOGGER....................................................855 ON-VEHICLE SERVICE..................................................855 REAR WINDOW DEFOGGER SWITCH.........................................856 HEATER, AIR CONDITIONER AND VENTILATION [55]................................858 GENERAL INFORMATION.....................................................860 SERVICE SPECIFICATIONS..................................................861 LUBRICANTS..............................................................861 SPECIAL TOOLS...........................................................861 TROUBLESHOOTING ........................................................862 ON-VEHICLE SERVICE......................................................864 HEATER CONTROL ASSEMBLY AND A/C SWITCH..................................875 HEATER UNIT AND HEATER CORE*............................................878 BLOWER ASSEMBLY AND RESISTOR <EXCEPT R.H. DRIVE VEHICLES WITH A/C>*.....879 EVAPORATOR <L.H. DRIVE VEHICLES WITH A/C>...............................881 EVAPORATOR,BLOWER UNIT AND RESISTOR <R.H. DRIVE VEHICLES WITH A/C>......883 COMPRESSOR AND TENSION PULLEY ..........................................885 REFRIGERANT LINE .......................................................889 CONDENSER AND CONDENSER FAN MOTOR.......................................892 VENTILATORS ............................................................894
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