Mitsubishi Colt/Lancer Chassis Service Manual 1996 – PDF DOWNLOAD
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Mitsubishi Colt/Lancer Chassis Service Manual 1996 – PDF DOWNLOAD
Language : English
Pages : 896
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Mitsubishi Colt/Lancer Chassis Service Manual 1996 – PDF DOWNLOAD
1996 COLT/LANCER WORKSHOP MANUAL................................................ 1 FOREWORD.................................................................... 2 GENERAL..................................................................... 3 HOW TO USE THIS MANUAL.................................................. 4 TROUBLESHOOTING/INSPECTION SERVICE POINTS............................... 8 VEHICLE IDENTIFICATION.................................................. 15 MAJOR SPECIFICATIONS.................................................... 19 PRECAUTIONS BEFORE SERVICE.............................................. 21 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER.... 25 SUPPORT LOCATIONS FOR LIFTING AND JACKING............................... 29 STANDARD PART/TIGHTENING-TORQUE TABLE................................... 33 ENGINE...................................................................... 35 11A - ENGINE<4G1>....................................................... 36 GENERAL INFORMATION................................................. 37 SERVICE SPECIFICATIONS.............................................. 37 SEALANT............................................................. 38 SPECIAL TOOLS....................................................... 38 ON-VEHICLE SERVICE.................................................. 40 CRANKSHAFT PULLEY................................................... 47 CAMSHAFT AND CAMSHAFT OIL SEAL...................................... 48 OIL PAN............................................................. 50 CRANKSHAFT OIL SEAL................................................. 51 CYLINDER HEAD GASKET................................................ 53 TIMING BELT......................................................... 57 ENGINE ASSEMBLY..................................................... 60 11B - ENGINE<4G9>....................................................... 65 GENERAL INFORMATION................................................. 66 SERVICE SPECIFICATIONS.............................................. 66 SEALANT............................................................. 67 SPECIAL TOOLS....................................................... 67 ON-VEHICLE SERVICE.................................................. 69 CRANKSHAFT PULLEY................................................... 76 CAMSHAFT AND CAMSHAFT OIL SEAL...................................... 77 OIL PAN............................................................. 79 CRANKSHAFT OIL SEAL................................................. 80 CYLINDER HEAD GASKET................................................ 82 TIMING BELT......................................................... 86 ENGINE ASSEMBLY..................................................... 89 ENGINE LUBRICATION.......................................................... 93 GENERAL INFORMATION..................................................... 94 LUBRICANTS.............................................................. 95 SPECIAL TOOL............................................................ 95 ON-VEHICLE SERVICE...................................................... 95 FUEL........................................................................ 97 MULTIPOINT FUEL INJECTION (MPI)......................................... 98 MULTIPOINT FUEL INJECTION <4G1>.....................................100 GENERAL INFORMATION.............................................100 SERVICE SPECIFICATIONS..........................................103 SEALANT.........................................................103 SPECIAL TOOLS...................................................104 TROUBLESHOOTING.................................................105 ON-VEHICLE SERVICE..............................................171 INJECTOR........................................................186 THROTTLE BODY...................................................188 MULTIPOINT FUEL INJECTION <4G9>.....................................191 GENERAL INFORMATION.............................................191 SERVICE SPECIFICATIONS..........................................196 SEALANT.........................................................196 SPECIAL TOOLS...................................................197 TROUBLESHOOTING.................................................198 ON-VEHICLE SERVICE..............................................267 INJECTOR........................................................274 THROTTLE BODY...................................................276 FUEL SUPPLY.............................................................279 GENERAL INFORMATION.................................................280 SEALANT.............................................................280 FUEL TANK...........................................................281 ENGINE COOLING..............................................................285 GENERAL INFORMATION.....................................................286 SERVICE SPECIFICATIONS..................................................286 LUBRICANT...............................................................286 SEALANTS................................................................286 ON-VEHICLE SERVICE......................................................287 THERMOSTAT..............................................................289 WATER PUMP .............................................................291 <4G1>...............................................................291 <4G9>...............................................................292 WATER HOSE AND WATER PIPE ..............................................293 <4G1>...............................................................293 <4G9>...............................................................295 RADIATOR ...............................................................297 INTAKE & EXHAUST............................................................299 GENERAL INFORMATION.....................................................300 SERVICE SPECIFICATIONS..................................................300 SPECIAL TOOL............................................................300 ON-VEHICLE SERVICE......................................................300 INTAKE MANIFOLD ........................................................301 EXHAUST MANIFOLD .......................................................306 EXHAUST PIPE AND MAIN MUFFLER ..........................................308 ENGINE ELECTRICAL...........................................................311 CHARGING SYSTEM.........................................................312 GENERAL INFORMATION.................................................312 SERVICE SPECIFICATIONS..............................................313 SPECIAL TOOL........................................................313 ON-VEHICLE SERVICE..................................................314 ALTERNATOR .........................................................321 STARTING SYSTEM.........................................................326 GENERAL INFORMATION.................................................326 SERVICE SPECIFICATIONS..............................................326 STARTER MOTOR.......................................................327 IGNITION SYSTEM.........................................................339 GENERAL INFORMATION.................................................339 SERVICE SPECIFICATIONS..............................................341 SPECIAL TOOL........................................................341 ON-VEHICLE SERVICE..................................................342 DISTRIBUTOR <4G1> ..................................................354 CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR <4G9>...............356 DETONATION SENSOR <4G9>.............................................357 ENGINE & EMISSION CONTROL...................................................359 ENGINE CONTROL SYSYTEM..................................................361 GENERAL INFORMATION.................................................361 SERVICE SPECIFICATIONS..............................................361 ON-VEHICLE SERVICE..................................................361 ACCELERATOR CABLE AND PEDAL.........................................362 EMISSION CONTROL SYSTEM.................................................363 GENERAL INFORMATION.................................................363 SERVICE SPECIFICATIONS..............................................364 VACUUM HOSE.........................................................364 CRANKCASE EMISSION CONTROL SYSTEM...................................368 EVAPORATIVE EMISSION CONTROL SYSTEM.................................370 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................373 CATALYTIC CONVERTER.................................................378 CANISTER AND TWO-WAY VALVE..........................................379 CLUTCH......................................................................381 GENERAL INFORMATION.....................................................382 SERVICE SPECIFICATIONS..................................................382 LUBRICANTS..............................................................382 ON-VEHICLE SERVICE......................................................382 CLUTCH PEDAL............................................................384 CLUTCH CONTROL..........................................................385 MANUAL TRANSMISSION.........................................................387 SERVICE SPECIFICATION...................................................388 LUBRICANTS..............................................................388 SPECIAL TOOLS...........................................................388 ON-VEHICLE SERVICE......................................................389 TRANSMISSION CONTROL*...................................................390 TRANSMISSION ASSEMBLY ..................................................393 AUTOMATIC TRANSMISSION......................................................397 SERVICE SPECIFICATIONS..................................................398 LUBRICANTS..............................................................398 SPECIAL TOOLS...........................................................398 TROUBLESHOOTING.........................................................400 ON-VEHICLE SERVICE......................................................438 TRANSMISSION CONTROL*...................................................454 TRANSMISSION ASSEMBLY ..................................................457 FRONT AXLE..................................................................461 GENERAL INFORMATION.....................................................462 SERVICE SPECIFICATIONS..................................................462 LUBRICANTS..............................................................462 SPECIAL TOOLS...........................................................463 ON-VEHICLE SERVICE......................................................465 AXLE HUB................................................................466 DRIVE SHAFT ............................................................471 REAR AXLE...................................................................481 GENERAL INFORMATION.....................................................482 SERVICE SPECIFICATIONS..................................................482 SPECIAL TOOLS...........................................................482 ON-VEHICLE SERVICE......................................................483 REAR AXLE HUB ..........................................................484 WHEELS & TYRES..............................................................487 GENERAL INFORMATION.....................................................488 SERVICE SPECIFICATIONS..................................................488 TROUBLESHOOTING.........................................................489 ON-VEHICLE SERVICE......................................................490 WHEELS & TYRES..........................................................490 POWER PLANT MOUNT...........................................................491 GENERAL INFORMATION.....................................................492 SERVICE SPECIFICATION...................................................492 SPECIAL TOOLS...........................................................493 ENGINE MOUNTING.........................................................493 TRANSMISSION MOUNTING...................................................495 ENGINE ROLL STOPPER, CENTERMEMBER.......................................497 CROSSMEMBER.............................................................498 FRONT SUSPENSION............................................................501 GENERAL INFORMATION.....................................................502 SERVICE SPECIFICATIONS..................................................503 SPECIAL TOOLS...........................................................504 ON-VEHICLE SERVICE......................................................505 STRUT ASSEMBLY..........................................................507 LOWER ARM ..............................................................510 STABILIZER BAR..........................................................513 REAR SUSPENSION.............................................................515 GENERAL INFORMATION.....................................................516 SERVICE SPECIFICATIONS..................................................517 SPECIAL TOOLS...........................................................517 ON-VEHICLE SERVICE......................................................518 CONTROL LINK,UPPER LINK AND LOWER ARM...................................520 TRAILING ARM ...........................................................522 STRUT ASSEMBLYSTRUT ASSEMBLYSTRUT ASSEMBLY..............................525 SERVICE BRAKES..............................................................529 BASIC BRAKE SYSTEM......................................................530 GENERAL INFORMATION.................................................531 SERVICE SPECIFICATIONS..............................................532 LUBRICANTS..........................................................533 SEALANT.............................................................533 SPECIAL TOOLS.......................................................533 ON-VEHICLE SERVICE..................................................534 BRAKE PEDAL ........................................................543 MASTER CYLINDER AND BRAKE BOOSTER ..................................545 FRONT DISC BRAKE....................................................548 REAR DRUM BRAKE ....................................................553 PROPORTIONING VALVE.................................................556 ANTI-SKID BRAKING SYSTEM (ABS) <2WD>....................................557 GENERAL INFORMATION.................................................559 SERVICE SPECIFICATIONS..............................................560 LUBRICANTS..........................................................561 SPECIAL TOOLS.......................................................561 TROUBLESHOOTING ....................................................562 ON-VEHICLE SERVICE..................................................579 MASTER CYLINDER AND BRAKE BOOSTER ..................................586 REAR DRUM BRAKE ....................................................588 PROPORTIONING VALVE.................................................591 HYDRAULIC UNIT .....................................................592 WHEEL SPEED SENSOR .................................................594 ABS-ECU.............................................................597 PARKING BRAKES..............................................................599 GENERAL INFORMATION.....................................................600 SERVICE SPECIFICATIONS..................................................600 LUBRICANTS..............................................................600 ON-VEHICLE SERVICE......................................................601 PARKING BRAKE LEVER.....................................................602 PARKING BRAKE CABLE.....................................................603 STEERING....................................................................605 GENERAL INFORMATION.....................................................606 SERVICE SPECIFICATIONS..................................................607 LUBRICANTS..............................................................607 SEALANT.................................................................607 SPECIAL TOOLS...........................................................608 ON-VEHICLE SERVICE......................................................610 STEERING WHEEL AND SHAFT*...............................................617 POWER STEERING GEAR BOX*................................................620 POWER STEERING OIL PUMP.................................................632 POWER STEERING HOSES....................................................637 BODY........................................................................639 HOOD....................................................................641 TRUNK LID <Sedan>.......................................................642 SPECIAL TOOL........................................................642 TRUNK LID ..........................................................642 FENDER..................................................................644 SEALANT.............................................................644 FENDER..............................................................645 FUEL FILLER DOOR........................................................646 WINDOW GLASS............................................................647 ADHESIVES...........................................................647 SPECIALTOOLS........................................................647 WINDOW REPAIR.......................................................647 WINDSHIELD..........................................................650 QUARTER WINDOW GLASS <Hatchback>....................................654 TAILGATE WINDOW GLASS <Hatchback>...................................656 REAR WINDOW GLASS <Sedan>...........................................658 DOOR....................................................................660 SERVICE SPECIFICATIONS..............................................660 SEALANT.............................................................660 SPECIAL TOOLS.......................................................660 TROUBLESHOOTING ....................................................661 ON-VEHICLE SERVICE..................................................670 DOOR ASSEMBLY.......................................................673 DOOR TRIM AND WATERPROOF FILM.......................................675 DOOR GLASS AND REGULATOR............................................677 DOOR HANDLE AND LATCH...............................................679 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP...............682 TAILGATE <Hatchback>....................................................683 SPECIAL TOOL........................................................683 TROUBLESHOOTING ....................................................683 TAILGATE ASSEMBLY...................................................684 TAILGATE LATCH......................................................686 SUNROOF.................................................................687 SERVICE SPECIFICATIONS..............................................687 SEALANT.............................................................687 SPECIAL TOOLS.......................................................687 TROUBLESHOOTING ....................................................688 ON-VEHICLE SERVICE..................................................691 SUNROOF.............................................................692 EXTERIOR....................................................................697 SERVICE SPECIFICATIONS..................................................698 SEALANT AND ADHESIVE....................................................698 SPECIAL TOOLS...........................................................698 FRONT BUMPER............................................................699 REAR BUMPER ............................................................701 RADIATOR GRILLE ........................................................703 MOULDINGS...............................................................703 AERO PARTS..............................................................705 WINDSHIELD WIPER AND WASHER.............................................709 REAR WIPER AND WASHER...................................................712 HEADLAMP WASHER.........................................................715 MARKS...................................................................717 DOOR MIRROR.............................................................719 INTERIOR & SRS..............................................................721 INTERIOR................................................................722 SERVICE SPECIFICATIONS..............................................723 ADHESIVES...........................................................723 SPECIAL TOOL........................................................723 INSTRUMENT PANEL*...................................................724 FLOOR CONSOLE*......................................................727 TRIMS...............................................................728 HEADLINING..........................................................730 INSIDE REAR VIEW MIRROR.............................................730 FRONT SEAT..........................................................731 REAR SEAT...........................................................734 FRONT SEAT BELT.....................................................736 REAR SEAT BELT......................................................737 SUPPLEMENTAL RESTRAINT SYSTEM...........................................739 GENERAL INFORMATION.................................................740 SRS SERVICE PRECAUTIONS.............................................742 SPECIAL TOOLS.......................................................744 TEST EQUIPMENT......................................................744 TROUBLESHOOTING ....................................................744 SRS MAINTENANCE.....................................................753 POST-COLLISION DIAGNOSIS............................................757 INDIVIDUAL COMPONENT SERVICE........................................760 WARNING/CAUTION LABELS..............................................761 SRS AIR BAG CONTROL UNIT (SRS-ECU)..................................762 AIR BAG MODULES AND CLOCK SPRING....................................763 SEAT BELT WITH PRE-TENSIONER........................................769 AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES......772 CHASSIS ELECTRICAL..........................................................781 BATTERY.................................................................784 SERVICE SPECIFICATION...............................................784 ON-VEHICLE SERVICE..................................................784 IGNITION SWITCH AND IMMOBILIZER SYSTEM..................................787 SPECIAL TOOL........................................................787 TROUBLESHOOTING ....................................................787 IGNITION SWITCH AND IMMOBILIZER SYSTEM..............................794 COMBINATION METERS......................................................797 SERVICE SPECIFICATIONS..............................................797 SEALANT.............................................................797 SPECIAL TOOLS.......................................................798 TROUBLESHOOTING ....................................................799 ON-VEHICLE SERVICE..................................................802 COMBINATION METERS..................................................805 HEADLAMP AND FRONT TURN-SIGNAL LAMP.....................................807 SERVICE SPECIFICATIONS..............................................807 SPECIAL TOOLS.......................................................807 TROUBLESHOOTING ....................................................808 ON-VEHICLE SERVICE..................................................815 HEADLAMP AND FRONT TURN-SIGNAL LAMP.................................818 SIDE TURN-SIGNAL LAMP...................................................821 SPECIAL TOOL........................................................821 SIDE TURN-SIGNAL LAMP...............................................821 FRONT FOG LAMP..........................................................822 SERVICE SPECIFICATIONS..............................................822 SPECIAL TOOL........................................................822 ON-VEHICLE SERVICE..................................................822 FRONT FOG LAMP......................................................825 REAR COMBINATION LAMP...................................................826 REAR FOG LAMP...........................................................827 SPECIAL TOOL........................................................827 REAR FOG LAMP.......................................................827 HIGH-MOUNTED STOP LAMP..................................................829 RHEOSTAT................................................................830 SPECIAL TOOL........................................................830 RHEOSTAT............................................................830 HAZARD WARNING LAMP SWITCH..............................................831 SPECIAL TOOL........................................................831 HAZARD WARNING LAMP SWITCH..........................................831 CIGARETTE LIGHTER.......................................................832 CLOCK...................................................................833 SPECIAL TOOL........................................................833 CLOCK...............................................................833 RADIO AND TAPE PLAYER...................................................834 SPECIAL TOOL........................................................834 TROUBLESHOOTING ....................................................834 RADIO AND TAPE PLAYER WITH ANTI-THEFT SYSTEM........................850 RADIO AND TAPE PLAYER...............................................853 SPEAKER.................................................................854 ANTENNA.................................................................855 REAR WINDOW DEFOGGER....................................................856 ON-VEHICLE SERVICE..................................................856 REAR WINDOW DEFOGGER SWITCH.........................................857 HEATER, AIR CONDITIONER & VENTILATION.......................................859 GENERAL INFORMATION.....................................................861 SERVICE SPECIFICATIONS..................................................862 LUBRICANTS..............................................................862 SPECIAL TOOLS...........................................................862 TROUBLESHOOTING ........................................................863 ON-VEHICLE SERVICE......................................................865 HEATER CONTROL ASSEMBLY AND A/C SWITCH..................................876 HEATER UNIT AND HEATER CORE*............................................879 BLOWER ASSEMBLY AND RESISTOR <EXCEPT R.H. DRIVE VEHICLES WITH A/C>*.....880 EVAPORATOR <L.H. DRIVE VEHICLES WITH A/C>...............................882 EVAPORATOR,BLOWER UNIT AND RESISTOR <R.H. DRIVE VEHICLES WITH A/C>......884 COMPRESSOR AND TENSION PULLEY ..........................................886 REFRIGERANT LINE .......................................................890 CONDENSER AND CONDENSER FAN MOTOR.......................................893 VENTILATORS ............................................................895
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