Mitsubishi Colt 2006 User Manual

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GROUP 13

FUEL

CONTENTS

MULTIPOINT FUEL INJECTION (MPI). . . . . . . . . . . . . . . . . . . . 13A

MULTIPOINT FUEL INJECTION (MPI) <4G1>. . . . . . . . . . . . . . 13B

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

AIR INTAKE SYSTEM . . . . . . . . . . . . 15-2

AIR DUCT AND AIR CLEANER . . . . . . . . . 15-2

INTERCOOLER <4G1> . . . . . . . . . . . . . . . 15-3

INLET MANIFOLD <4A9>. . . . . . . . . . . . . . 15-4

INLET MANIFOLD <4G1> . . . . . . . . . . . . . 15-4

EXHAUST SYSTEM . . . . . . . . . . . . . . 15-5

EXHAUST MANIFOLD <4A9> . . . . . . . . . . 15-5

TURBOCHARGER <4G1> . . . . . . . . . . . . . 15-6

EXHAUST PIPE AND MUFFLER <4A9> . . 15-7

EXHAUST PIPE AND MUFFLER <4G1> . . 15-8

15-2

INTAKE AND EXHAUST

AIR INTAKE SYSTEM

AIR DUCT AND AIR CLEANER

CONSTRUCTION DIAGRAM

<4A9>

Engine air intake hose <M/T>

Air cleaner intake duct

<4G1>

M2150004000504

Engine air intake hose <CVT>

Air cleaner resonator

Air cleaner assembly

AC601193

Engine air intake hose

Air cleaner intake duct

• An air cleaner resonator has been adopted to improve engine performance and reduce air intake noise <4A9>.

• A front air intake system that actively sucks cooling air from the front through the top of the radiator has been adopted in order to improve engine performance and reduce air intake noise.

Air cleaner assembly

AC402138

• For the air cleaner intake duct, a venturi duct with a diaphragm on its path has been adopted to sup press rise in air resistance and reduce air intake noise.

• In consideration of industrial waste reduction and global environment, recycled materials made from eating utensils and the scraps have been adopted for the air cleaner body and cover of the air cleaner assembly.

INTAKE AND EXHAUST

AIR INTAKE SYSTEM

INTERCOOLER <4G1>

M2150007000246

An air cooled intercooler has been adopted to lower the intake air temperature drastically and improve engine performance.

CONSTRUCTION DIAGRAM

Air by-pass valve

15-3

Intercooler inlet air duct

Intercooler assembly

AC600080

15-4

INLET MANIFOLD <4A9>

INTAKE AND EXHAUST

AIR INTAKE SYSTEM

M2150010000105

Inlet port

The inlet manifold is made of resin. The inlet ports are curled for size and weight reduction.

INLET MANIFOLD <4G1>

AK305379

M2150010000116

The port shape is changed to be optimum for the vehicle with the turbocharger.

AK403235

INTAKE AND EXHAUST

EXHAUST SYSTEM

15-5

EXHAUST MANIFOLD <4A9>

Pipes

M2150006000317

The exhaust manifold consists of stainless steel pipes, with all the ports being equal in length, to achieve robust mid-range torque and weight reduc tion.

AK402037

15-6

INTAKE AND EXHAUST

EXHAUST SYSTEM

TURBOCHARGER <4G1>

Considering the balance among the engine output, the response and the amount of the exhaust gases, the optimized size is used .

M2150009000123

AK402141

INTAKE AND EXHAUST

EXHAUST SYSTEM

EXHAUST PIPE AND MUFFLER <4A9>

M2150003000642

CONSTRUCTION DIAGRAM

15-7

<M/T>

Annular joint

Front exhaust pipe

<CVT>

Annular joint

Under floor catalytic converter

Centre exhaust pipe

Exhaust pre-muffler

Centre exhaust pipe

Exhaust main muffler

Insertion joint

Exhaust main muffler

Insertion joint

AC601362

Front exhaust pipe

Exhaust pre-muffler

Exhaust pipe consisting of three separation system: front exhaust pipe, centre exhaust pipe, and exhaust main muffler, has the following features:

• An exhaust pre-muffler has been installed to the centre exhaust pipe in order to reduce exhaust noise.

• An insertion joint has been adopted for the connection between the centre exhaust pipe and the exhaust main muffler to save the weight of the exhaust system.

AC601363

• The under floor catalytic converter has been moved closer to the engine side to improve exhaust gas performance.

• An annular joint has been adopted for the connection between the exhaust manifold and the front exhaust pipe to reduce the exhaust pipe's vibration from the engine side.

15-8

INTAKE AND EXHAUST

EXHAUST PIPE AND MUFFLER <4G1>

M2150003000653

CONSTRUCTION DIAGRAM

Under floor

Front catalytic converter

Front exhaust pipe

catalytic converter

EXHAUST SYSTEM

Exhaust main muffler

Centre exhaust pipe

Insertion joint

Annular joint

Exhaust pipe consisting of three separation system: front exhaust pipe, centre exhaust pipe, and exhaust main muffler, has the following features:

• An exhaust pre-muffler has been installed to the centre exhaust pipe in order to reduce exhaust noise.

• An insertion joint has been adopted for the connection between the centre exhaust pipe and the exhaust main muffler to save the weight of the exhaust system.

Exhaust pre-muffler

AC601366

• An annular joint has been adopted for the connection between the front exhaust pipe and the front catalytic converter has been adopted to reduce vibration from the engine side.

• A front catalytic converter and an under floor catalytic converter have been adopted to improve exhaust gas performance.

GROUP 17

ENGINE AND

EMISSION

CONTROL

CONTENTS

ENGINE CONTROL . . . . . . . . . . . . . . 17-2

ACCELERATOR SYSTEM . . . . . . . . . . . . . 17-2

EMISSION CONTROL . . . . . . . . . . . . 17-3

GENERAL INFORMATION <4A9> . . . . . . . 17-3

GENERAL INFORMATION <4G1> . . . . . . . 17-4

17-2

ENGINE AND EMISSION CONTROL

ENGINE CONTROL

ACCELERATOR SYSTEM

M2170003000310

For the accelerator system, an electronic throttle valve control system has been adopted, eliminating of an accelerator cable. This system detects the amount of the accelerator pedal movement by using a accelerator pedal-position sensor in the accelerator pedal assembly for electronic control of the throttle valve angle.

CONSTRUCTION DIAGRAM

Accelerator pedal assembly (Built-in accelerator pedal position sensor)

Accelerator pedal arm stopper

AC206106

ENGINE AND EMISSION CONTROL

EMISSION CONTROL

17-3

GENERAL INFORMATION <4A9>

Although the emission control systems are basically the same as those of the 4G1-Non-Turbo engine used in the COLT, the following improvements have been added.

System Remarks

Crank case ventilaton system Closed type

Evaporative emission control system Electronic control type with duty signal

Exhaust gas recirculation (EGR) system <CVT> Electronic control (stepper motor) type

Air/fuel ratio closed loop control Oxygen sensor signal used

Catalytic converter Three-way catalytic converter

• The adoption of the catalytic converter just beneath exhaust manifold realizes the earlier activation.

• The adoption of the dual oxygen sensor has increased reliability air/fuel ratio control.

•

The abolition of the EGR system <M/T>.

EMISSION CONTROL SYSTEM DIAGRAM

Oxygen sensor (rear)

Oxygen sensor (front)

M2171000100838

Air inlet

PCV valve

Catalytic converter

Injector

From fuel pump

EGR valve (stepper motor) <CVT>

Purge control solenoid valve

Canister

AK402829

17-4

ENGINE AND EMISSION CONTROL

EMISSION CONTROL

GENERAL INFORMATION <4G1>

Although the emission control systems are basically the same as those of the 4G1-Non-Turbo engine used in the COLT, the following improvements have been added.

• The adoption of the catalytic converter just beneath turbo charger and under the floor increased the performance of the emission con

trols.

System Remarks

Crank case ventilaton system Closed type

Evaporative emission control system Electronic control type with duty signal

Air/fuel ratio closed loop control Oxygen sensor signal used

Catalytic converter Three-way catalytic converter

• The adoption of the check valve between the purge control solenoid valve and the canister pro tects the regurgitation as turbocharging.

•

The abolition of the EGR system

EMISSION CONTROL SYSTEM DIAGRAM

M2171000100849

Air inlet

Check valve

Purge control solenoid valve

Canister

Waste gate solenoid valve

Waste gate actuator

Fuel pressure control solenoid valve

To fuel tank

Oxygen sensor (front)

Catalytic converter

Fuel pressure regulator

From fuel pump

Injector

Oxygen sensor (rear)

Catalytic converter

AK600530AB

GROUP 23

CONTINUOUSLY

VARIABLE

TRANSMISSION

(CVT)

CONTENTS

CVT. . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2

GENERAL INFORMATION. . . . . . . . . . . . . 23-2

ELECTRONIC CONTROL SYSTEM. . . . . . 23-3

EEPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3

CONTROLLER AREA NETWORK (CAN)

COMMUNICATION . . . . . . . . . . . . . . . . . . . 23-3

RATIO PATTERN . . . . . . . . . . . . . . . . . . . . 23-3

DIAGNOSIS CLASSIFICATION TABLE . . . 23-4

ATF WARMER (ATF COOLER) . . . . . . . . . 23-5

TRANSMISSION CONTROL . . . . . . . 23-6

GENERAL INFORMATION . . . . . . . . . . . . . 23-6

SELECTOR LEVER ASSEMBLY . . . . . . . . 23-7

CVT ERRONEOUS OPERATION

PREVENTION MECHANISMS . . . . . . . . . . 23-8

23-2

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

CVT

GENERAL INFORMATION

M2231000100165

The F1C1A transmission is adopted for the CVT. This transmission is basically the same as conven tional transmission. The ATF warmer (ATF cooler) is adopted.

SPECIFICATIONS

Item Specification

Transmission model F1C1A

Engine model 4A91

Tor qu e co nv er te r Type 3-element, 1-stage, 2-phase type

Lock-up Provided

Stall torque ratio 2.0

Transmission type Forward automatic continuously variable (steel belt type),

1st in reverse

Gear ratio Forward 2.319 − 0.445

Reverse 2.588

Clutch A pair of multi-plate system

Brake A pair of multi-plate system

Manual control system P-R-N-D-Ds-L (smart shift)

Function Variable speed control Yes

Line pressure control Yes

Direct engagement control Yes

N-D/N-R control Ye s

Shift pattern control Yes

Self-diagnosis Yes

Failsafe Ye s

Oil pump Type External gear pump

Configuration Built-in (chain drive)

Control method Electronic control (INVECS-III)

Transmission oil Specified lubricants DIA QUEEN ATF SP III

Quantity L 8.1

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

ELECTRONIC CONTROL SYSTEM

CVT

23-3

EEPROM

M2231012000024

Because EEPROM has been used, even if the battery terminals or control unit connectors are disconnected, the necessary learned values are stored in the engine-CVT-ECU to prevent a loss of shift qual ity. (Initialisation is available by M.U.T.-III).

CONTROLLER AREA NETWORK (CAN) COMMUNICATION

CAN* communication has been adopted for communication with other ECUs in order to decrease the

number of wires and ensure information transmis

sion. For CVT control, the engine-CVT-ECU receives the following signals.

CAN COMMUNICATION INPUT SIGNAL TABLE

Input signal Transmitter ECU

Average vehicle speed signal from drive wheels ABS-ECU

Motor current signal EPS-ECU

EPS warning lamp illumination request signal

Compressor signal Meter and A/C-ECU

NOTE: *: For more information about CAN (Controller Area Network), refer to GROUP 54C P.54C-2.

RATIO PATTERN

M2231013000061

Engine speed (r/min)

7,000

LOW

M2231017000018

6,000

5,000

4,000

3,000

2,000

1,000

Accelerator fully open

40%

Accelerator fully closed, 20%

Vehicle speed (km/h)

80%

60%

100 15050

AC403740

23-4

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

CVT

DIAGNOSIS CLASSIFICATION TABLE

M2231015000056

Item Diagnosis Data list Actuator

Code No. Trouble symptoms Item No. Display

Crank angle sensor

CVT fluid temperature sensor 15 Open circuit 08

− −

16 Short circuit

01 r/min

°C −

test

−

Line pressure sensor 18 Open circuit 09 MPa

19 Short circuit

Turbine speed sensor 22 Open circuit 02 r/min

Primary speed sensor 23 Open circuit 03 r/min

26 System failure

Secondary speed sensor 24 Open circuit 04 r/min

25 System failure

Accelerator pedal position sensor (APS)

Primary pressure sensor 27 Open circuit 11 MPa

Gear ratio

Line pressure control solenoid valve 31 Open circuit/short

Shift control solenoid valve 32 Open circuit 15 % 02

Damper clutch control solenoid valve 33 Open circuit 14 % 03

Clutch pressure control solenoid valve 34 Open circuit 17 % 04

− −

28 Short circuit

− −

circuit

36 Short circuit

37 Short circuit

06 mV

12 Displays the

gear ratio.

16 % 01

−

38 Short circuit

Shift system 42 System failure

Damper clutch system 44 System failure 10 r/min

Clutch system 46 System failure

Inhibitor switch 51 Open circuit 26 P/R/N/D/Ds/L

52 Short circuit

Stop lamp switch 53 Open circuit 33 ON/OFF

54 Short circuit

Battery voltage

CVT control relay 56 Open circuit 25 V 11

Steel belt system 59 System failure

Line pressure system 57 System failure

− −

− − −

24 V

− − −

−

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

ATF WARMER (ATF C OOL ER)

Thermo valve

ATF Warmer (ATF Cooler)

M2230000600082

CVT

23-5

Sectional view

Engine coolant

ATF

Thermostat

Thermo

Radiator

valve

ATF warmer (ATF cooler)

Engine

CVT CVT CVT

<Engine coolant temperature: 75˚C or less> Engine coolant flows through the heater only.

Heater

Radiator

ATF warmer (ATF cooler)

<Engine coolant temperature: 75 - 85˚C> Engine coolant flows through the heater and the ATF warmer.

Thermostat

Thermo valve

The ATF warmer (ATF cooler) is adopted. (the ATF cooler incorporating the radiator is not adopted) At the start of running, the temperature of the engine coolant rises earlier than that of the ATF. The ATF warmer utilizes this characteristic to raise the ATF temperature as early as possible to an appropriate level (70 - 80

°C). It also controls fluid temperature

Engine

: Valve open

: Valve closed

Heater

: Engine coolant

: ATF

Thermostat

Thermo

Radiator

valve

ATF warmer (ATF cooler)

AC403052

Engine

Heater

<Engine coolant temperature: 85˚C or more> Engine coolant flows through

AC403006

all the sections.

stably and reduces ATF agitation resistance to improve fuel consumption ratio. In addition, a thermo-valve has been adopted to restrict the engine coolant supply to the ATF warmer (ATF cooler) until the engine coolant temperature reaches the appropriate temperature when low tem

perature start in winter, giving the priority to the heating performance.

23-6

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

TRANSMISSION CONTROL

GENERAL INFORMATION

M2232000100447

• A smart shift type selector lever has been adopted in order to facilitate walkthrough between the seats.

• A gun grip type selector lever knob has been adopted for better operation and easier visual recognition of the switches arranged in the centre panel.

• The selector lever assembly has been a single unit made by aluminium die casting for better accuracy and fewer parts, resulting in the light weight and compact structure.

COMPONENT VIEW

• The selector lever has been designed to be compact and appropriately configured not to interfere with the energy absorbing mechanism on the steering column upon impact of the vehicle.

• In order to prevent abrupt start by erroneous operation of selector lever, a CVT erroneous operation prevention mechanism (the shiftlock mechanism and key interlock mechanism) has been adopted.

Inhibitor switch

AC206842

Transmission control cable

Selector lever assembly

AC207638

AC206864

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

SELECTOR LEVER ASSEMBLY

Push button

TRANSMISSION CONTROL

M2232002000190

Detent pin

23-7

Front of vehicles

Selector lever (P position)

Selector lever (except for P position)

AC206896

AC206897

Lock cam

AC206898

Detent pin

Detent block

AC206899

Operation

1. When the selector lever is in the P position, the detent pin is engaged with the lock cam. When the pushbutton on the selector lever is pressed, the detent pin moves in the direction A as illustrated in the figure to rotate the lock cam.

2. When the detent pin rotates the lock cam to disengage, the selector lever can go over the protruding part of the detent block. This enables shifting the selector lever.

AC207644

23-8

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

TRANSMISSION CONTROL

CVT ERRONEOUS OPERATION PREVENTION MECHANISMS

SHIFT LOCK MECHANISM

Only when the following two conditions are satisfied, the selector lever can be shifted from the P position to another position:

• When the brake pedal is depressed

• When the ignition key is in other than the LOCK

(OFF) position

When the brake pedal is not depressed

Detent pin

Lever

Shiftlock cable

Stopper

Brake pedal

M2232003000104

Lock cam

Rod

When the selector lever is in the P position with the brake pedal not depressed, the shiftlock cable stop per keeps the lever locked so that the rod and lock cam do not move.

When the brake pedal is depressed

Shiftlock cable

Brake pedal

When the brake pedal is depressed, the stopper is pulled by the shiftlock cable so that the lever becomes unlocked. Then the lock cam linked to the rod can also rotate so that the selector lever can be shifted from the P position to another position by pressing the pushbut ton.

As a result of this, the pushbutton of the selector

lever linked to the detent pin cannot be pressed and the selector lever cannot be shifted from the P posi tion to another position.

Detent pin

Lever

Lock cam

Rod

Stopper

NOTE: When the brake pedal is depressed with the ignition key in the LOCK (OFF) position, the selector lever cannot be shifted from the P position to another position.

AC206902

AC206903

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

TRANSMISSION CONTROL

23-9

When the ignition key is in the LOCK (OFF) position or pulled out (With the selector lever in the P position)

Slider

Projection of rotor

Key interlock cable

Ignition key Engine starting switch assembly

LOCK (OFF) position

In the engine starting switch assembly, the slider is engaged with the groove of the key interlock cable, and the slider is locked by the projection of the rotor so that the key interlock cable as well as the lever, rod, and lock cam does not move.

Lever

Lock cam

Rod

AC206911

As a result of this, any attempt to shift the selector lever is prevented. The pushbutton on the selector lever cannot be pressed because the lock cam does not rotate, then the selector lever cannot be shifted from the P position to another position.

23-10

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

TRANSMISSION CONTROL

When the ignition key is in other than the LOCK (OFF) position (With the selector lever in the P position)

Slider

Projection of rotor

Key interlock cable

The rotor in the engine starting switch assembly has a notch between ACC and START so that the slider becomes unlocked. Then the slider can move in the direction A as illustrated in the figure to allow the lock cam to rotate so that the selector lever can be shifted from the P posi tion to another position by pressing the pushbutton.

KEY INTERLOCK MECHANISM

When the selector lever is not in the P position, the ignition key cannot be turned to the LOCK (OFF) position and pulled out.

Engine starting switch assembly

Lever

Ignition key ACC to START position

Lock cam

Rod

AC206912

NOTE: When the ignition key is in other than the LOCK (OFF) position with the brake pedal not depressed, the selector lever cannot be shifted from the P position to another position.

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

TRANSMISSION CONTROL

When pulling out the key with the selector lever in other than the P position

Slider

Projection of rotor

Key interlock cable

23-11

The lock cam is kept in a rotated condition, and the key interlock cable is kept pulled in direction A as illustrated in the figure. In this state, the slider in the engine starting switch assembly is moved and locked in direction B as illustrated in the figure.

Engine starting switch assembly

Lever

Ignition key ACC to START position

Rod

Lock cam

AC206912

As a result of this, any attempt to turn the ignition key to the LOCK (OFF) position is prevented because the slider prevents the rotor from rotating, and the ignition key can only turn up to the ACC position and cannot be pulled out.

23-12

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

TRANSMISSION CONTROL

When pulling out the key with the selector lever in the P position

Slider

Projection of rotor

Key interlock cable

When releasing the pushbutton on the selector lever with the selector lever in the P position, the lock cam is rotated by the detent pin. Then the key interlock cable is moved by the lock cam in direction A as illustrated in the figure.

Engine starting switch assembly

Lever

Detent pin

Ignition key ACC to START position

Lock cam

Rod

AC206911

As a result of this, the slider in the engine starting switch assembly is unlocked. The rotor can then turn, and the ignition key can be pulled out by turning it to the LOCK (OFF) position.

GROUP 26

FRONT AXLE

CONTENTS

GENERAL INFORMATION . . . . . . . . 26-2

26-2

FRONT AXLE

GENERAL INFORMATION

The front axle consists of front hub, wheel bearing, knuckles and driveshafts, and has the following fea tures:

• The wheel bearing incorporates magnetic encoder for wheel speed sensing.

• The driveshaft incorporates EBJ-TJ type constant velocity joint <4A9-CVT, 4A9-M/T (LS)>, EBJ-ETJ type constant velocity joint <4A9-M/T (VR)>, BJ-TJ type constant velocity joint <4G1>.

• The dynamic damper is mounted to reduce differential gear noise.

• The bracket assembly is mounted to reduce torque steer. < 4G1>

SPECIFICATIONS

Item 4A9 4G1

• For environmental protection, a lead-free grease

CVT M/T

is used on the joints.

EBJ(Eight Ball Fixed Joint):The use of the

smaller-sized eight balls inside the joint achieves weight saving and compact size compared with a BJ(Birfield Joint).

ETJ(Eco type Tripod Joint):This joint achieves

weight saving and compact size compared with a

TJ(Tripod Joint). BJ:Birfield Joint TJ: Tripod Joint

LS VR

M2260000100701

Wheel bearing Type Double-row angular contact ball bearing

Bearing (OD x ID) mm 76 × 40 76 × 40 76 × 40 76 × 40

Driveshaft Joint type Outer EBJ EBJ EBJ BJ

Inner TJ TJ ETJ TJ

Length (joint to joint) × diameter mm

LH 377 × 21.2 377 × 21.2 379 × 23 352 × 24.9

RH 688 × 21.2 688 × 21.2 664.3 × 23 378.2 × 24.9

CONSTRUCTION DIAGRAM

FRONT AXLE

GENERAL INFORMATION

26-3

<4A9>

Front hub

<4G1>

Strut assembly

Knuckle

Strut assembly

EBJ

Wheel bearing

TJ (LH) <CVT, M/T (LS)> ETJ (LH) <M/T (VR)>

Dynamic damper

Driveshaft (LH)

Driveshaft (RH)

TJ (RH) <CVT, M/T (LS)> ETJ (RH) <M/T (VR)>

Dynamic damper

AC402000

AC403318

Front hub

Knuckle

Wheel bearing

Driveshaft (LH)

Bracket assembly

Driveshaft (RH)

Dynamic damper

AC511705

26-4

FRONT AXLE

GENERAL INFORMATION

Comparison between BJ and EBJ

EBJ

Comparison between TJ and ETJ

ETJ

AC306013AE

GROUP 27

REAR AXLE

CONTENTS

GENERAL INFORMATION . . . . . . . . 27-2

27-2

REAR AXLE

GENERAL INFORMATION

M2270000100382

The rear axle has the following features:

• The wheel bearing is a unit ball bearing (double-row angular contact ball bearing) for reduced friction.

• The wheel bearing incorporates magnetic encoder for wheel speed sensing.

SPECIFICATION

Item Specification

Wheel bearing Type Unit ball bearing (double-row angular

NOTE: The wheel bearing is part of the hub, therefore its size is not listed here.

CONSTRUCTION DIAGRAM

• The rear wheel hub assembly combines the hub, wheel bearing and oil seal in a single unit for fewer parts, better durability, improved assembly precision, and better structural organization.

contact ball bearing)

Rear hub

<4G1> <4A9>

Oil seal

Magnetic encoder

Wheel bearing

Rear hub

Wheel bearing

Oil seal

Magnetic encoder

AC402053AC600026

AC600074

GROUP 31

WHEEL AND TYRE

CONTENTS

GENERAL INFORMATION . . . . . . . . 31-2

31-2

WHEEL AND TYRE

GENERAL INFORMATION

M2310000100800

The wheels and tyres of the following specifications have been established.

SPECIFICATIONS

ROAD WHEEL AND TYRE

Item LS VR, VR-X RALLIART

Wheel Type Steel type Aluminium type Aluminium type

Size 14 × 5.5JJ 15 × 6JJ 16 × 6.5JJ

Amount of wheel offset mm46 46 43

PCD mm 100 100 11 4 . 3

Tyre Size 175/65R14 82S 185/55R15 81V 205/45R16 83W

NOTE: PCD indicates the pitch circle diameter of the wheel installation holes.

SPARE WHEEL AND TYRE

Item LS, VR VR-X RALLIART

Spare wheel

Type Steel type Steel type Steel type

Size 14 × 4T 15 × 4T 15 × 3.5B

Amount of wheel offset mm38 46 40

PCD mm 100 100 11 4 . 3

Spare tyre Size T115/70D14 88M T125/70D15 95M T125/70D15 95M

NOTE: PCD indicates the pitch circle diameter of the wheel installation holes.

GROUP 33

FRONT

SUSPENSION

CONTENTS

GENERAL INFORMATION . . . . . . . . 33-2

33-2

FRONT SUSPENSION

GENERAL INFORMATION

Newly developed MacPherson strut suspension has been adopted.

• The steering gear box is installed in the lower position for better cornering performance.

• The roll centre and the kingpin axle are installed appropriately for better cornering performance.

• The long stroke strut is adopted for sufficient road holding quality.

M2330000100824

• High-rigid and light-weight flat crossmember is adopted for sufficient suspension rigidity.

• The strut coil spring is installed appropriately for friction reduction and comfortable ride.

• The coil spring of high tension material is adopted for weight reduction.

• The open-section lower arm is adopted for weight reduction.

CONSTRUCTION DIAGRAM

<4A9>

Coil spring

FRONT SUSPENSION

GENERAL INFORMATION

Strut assembly

Stabilizer bar

33-3

Lower arm close section

Lower arm

<4G1>

Ball joint

Coil spring

Front axle No.1 crossmember (Flat crossmember)

A-point bushing

Lower arm

Strut assembly

Stabilizer bar

AC402422

Lower arm close section

AC207732

Lower arm

Ball joint

Front axle No.1 crossmember (Flat crossmember)

A-point bushing

Lower arm

AC402422

33-4

FRONT SUSPENSION

GENERAL INFORMATION

SPECIFICATIONS SUSPENSION SYSTEM

Item Specification

Suspension type MacPherson strut with coil spring

WHEEL ALIGNMENT

Item Specification

Camber

Caster 4A9 2°35'

4G1 2°40'

Kingpin inclination 13°20'

Toe -i n At the centre of tyre tread mm 0

To e- an gle ( pe r wh ee l) 0°

− 0 °30'

COIL SPRING

<4A9>

Item Specification

Wire diameter mm 12

Average outside diameter mm 133 − 149 − 154

Free length mm CVT 331

5MT 301

<4G1>

Item Specification

Wire diameter mm 13

Average outside diameter mm 133 − 150 − 154

Free length mm 300

GROUP 34

REAR SUSPENSION

CONTENTS

GENERAL INFORMATION . . . . . . . . 34-2

34-2

REAR SUSPENSION

GENERAL INFORMATION

Newly developed H-shaped torsion beam type suspension has been introduced.

• The coil spring is installed under the rear floor, the torsion beam and arm assembly is installed in front of the spare tyre house, and the shock absorber is installed outside, so that the large cabin space is achieved.

• The arm bushing with the toe control function is adopted to optimise the tyre steering angle using the bushing deflection caused by lateral force and longitudinal force generated at cornering, so that the good cornering performance is secured.

CONSTRUCTION DIAGRAM

M2340000100825

• The layout of shock absorber is optimised for smooth riding.

• Long wheel stroke secures sufficient road holding quality.

• The hub-integrated unit bearing is adopted for the wheel bearing for sufficient suspension rigidity (Refer to GROUP 27, Rear Axle

P.27-2).

• The dumping characteristic of shock absorber has been changed. <4G1>

• The urethane bump stopper has been adopted to improve the linearity. <4G1>

• To rs io n b ea m r ig id it y h as b ee n i mp ro v ed < 4G 1>

Shock absorber

Arm bushing

Section A – A <4G9>

Torsion bar

Torsion beam and arm assembly

Coil spring

Section A – A <4G1>

Torsion beam and arm assembly

AC405533

REAR SUSPENSION

GENERAL INFORMATION

SPECIFICATIONS SUSPENSION SYSTEM

Item Specification

Suspension type To rs ion b ea m sus pe ns io n

WHEEL ALIGNMENT

Item Specification

Camber

Toe -i n At the centre of tyre tread mm 3

To e- an g le ( per w he el ) 0°09'

−1°

COIL SPRING

Item 4A9 4G1

Wire diameter mm 10 11

Average outside diameter mm 75 − 107 − 75 111

34-3

Free length mm 301 283

GROUP 35

SERVICE BRAKE

CONTENTS

BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

ANTI-SKID BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . 35B

ACTIVE STABILITY CONTROL SYSTEM (ASC). . . . . . . . . . . . 35C

GROUP 35A

BASIC BRAKE

SYSTEM

CONTENTS

GENERAL INFORMATION . . . . . . . . 35A-2

CONSTRUCTION DESCRIPTION . . . 35A-5

MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-5

BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . 35A-5

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . 35A-6

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . 35A-7

REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . 35A-8

35A-2

BASIC BRAKE SYSTEM

GENERAL INFORMATION

FEATURES

Brake system with high reliability and durability have achieved distinguished braking performance.

BRAKING PERFORMANCE

• Brake booster with 9-inch variable amplification ratio mechanism by which greater braking force can be obtained with a less pedal pressure has been installed (with brake assist function).

• 14-inch disc brake is installed on the front wheels. <LS, VR>

• 15-inch disc brake is installed on the front wheels. <VR-X, RALLIART Version-R>

• 8-inch leading trailing type drum brake is installed on the rear wheels. <LS, VR>

• 14-inch disc brake is installed on the rear wheels. <VR-X, RALLIART Version-R>

STABILITY

• 4-wheel anti-lock braking system (4ABS) is adopted to prevent slipping caused by the vehicle wheels locking up, in order to maintain appropri ate braking distance, and also to maintain vehicle stability and steering function.

M2350000100848

• Electronic brake-force distribution (EBD) is adopted to maintain the maximum amount of rear braking force even when the vehicle's load is var ied.

• Diagonal split (X-type) brake fluid line is adopted.

• Ventilated discs have been adopted to front

brakes to improve anti-fading performance.

• A brake pedal retraction suppression structure that restrains the retraction of the brake pedal and reduces the shock to the feet of the driver in the event of a frontal collision has been adopted.

SERVICEABILITY

• Diagnosis function is adopted for the ABS system in order to make inspection easier.

• For the front disc brakes, brake disc separated front hub is adapted to make removal and instal lation easier.

• ABS-ECU and hydraulic unit have been integrated to make them more compact and lighter.

CONFIGURATION DIAGRAM

<LS, VR>

Brake booster (with variable boosting mechanism)

Master cylinder

Front disc brake

BASIC BRAKE SYSTEM

GENERAL INFORMATION

Hydraulic unit (Integrated with ABS-ECU)

35A-3

Rear drum brake

<VR-X, RALLIART Version-R>

Brake booster (with variable boosting mechanism)

Master cylinder

Front disc brake

Hydraulic unit (Integrated with ABS-ECU)

Rear disc brake

AC601653

35A-4

BASIC BRAKE SYSTEM

GENERAL INFORMATION

SPECIFICATIONS

Item Specifications

Master cylinder Ty pe Ta nd em ty pe

I.D. mm LS, VR 20.6

VR-X 22.2

RALLIART Version-R 23.8

Brake booster Type Vacuum t y p e , s i n g le

Effective dia. of power cylinder mm 230

Boosting ratio LS, VR, VR-X 6.0 (pedal pressure: 116 N)

7.0 (pedal pressure: 159 N)

RALLIART Version-R 6.0 (pedal pressure: 87 N)

7.0 (pedal pressure: 125 N)

Rear wheel hydraulic control method Electronic brake-force

distribution (EBD)

Front brakes Type LS, VR Floating caliper, 1 piston,

ventilated disc (V4-S51)

VR-X, RALLIART Version-R Floating caliper, 1 piston,

ventilated disc (V5-S54)

Disc effective dia. × thickness mm

LS, VR 206 × 20

VR-X 226 × 24

Rear disc brakes <VR-X, RALLIART Version-R>

Rear drum brakes <LS, VR>

RALLIART Version-R 232 × 25.8

Cylinder I.D. mm LS, VR 50.8

VR-X, RALLIART Version-R 54.0

Pad thickness mm LS, VR, VR-X 10

RALLIART Version-R 10.5

Clearance adjustment Automatic

Type VR-X Floating caliper, 1 piston,

solid disc (S4-S30P)

RALLIART Version-R Floating caliper, 1 piston,

solid disc (S4-S34P)

Disc effective dia. × thickness mm

Cylinder I.D. mm VR-X 30.2

Pad thickness mm VR-X 9.5

Clearance adjustment Automatic

Type Leading trailing drum

Drum I.D. mm 203

Cylinder I.D. mm 19.0

Lining thickness mm 4.0

VR-X 224 × 10

RALLIART Version-R 200.6 × 10

RALLIART Version-R 34.0

RALLIART Version-R 10.0

Clearance adjustment Automatic

Brake fluid DOT3 or DOT4

BASIC BRAKE SYSTEM

CONSTRUCTION DESCRIPTION

35A-5

MASTER CYLINDER

M2350001000509

Reserve tank

Master cylinder

The master cylinder is a tandem-type, with a structure that emphasizes safety.

Secondary piston

BRAKE BOOSTER

Diaphragm

Primary piston

AC505737

M2350002000632

Push rod

Booster return spring

9-inch brake booster has been installed. The brake booster employs a variable amplification ratio mech anism that varies amplifications ratios so that even small pedal force can provide great breaking force.

Reaction disc

Operating rod

AC505736

35A-6

BRAKE PEDAL

BASIC BRAKE SYSTEM

CONSTRUCTION DESCRIPTION

M2350007000154

Collision load

Reinforced bracket

After collision

Fixed bolt

Reinforced bracket

Retreat locus of brake pedal during collision

Before collision

AC207292

Deck crossmember

Stopper plate

Brake booster

The brake pedal rearward displacement prevention mechanism has been adopted in order to reduce the driverís leg and foot injury during frontal collision.

Brake pedal position before collision

Brake pedal position after collision (Conventional)

Brake pedal position after collision (Brake pedal rearward displacement preventio mechanism operated)

AC207291

AC207749

The brake booster is forced to move backward according to retreating engine body during frontal collision and then the reinforced bracket is released from the stopper plate. After released, the reinforced bracket is forced to move backward and downward by guiding the rear end of the reinforced bracket along the stopper plate slope and it prevent the back ward and upward displacement of the brake pedal.

FRONT BRAKE

14-inch disc brake <LS, VR>

BASIC BRAKE SYSTEM

CONSTRUCTION DESCRIPTION

M2350003000538

Conventional structure

Caliper support bracket

35A-7

15-inch disc brake <VR-X, RALLIART Version-R>

• Ventilated disc brake (V4−S51 or V5−S54) is installed.

• The calliper support bracket integrated with the knuckle has been installed, achieving weight reduction and optimising it for brake perform ance.

• Audible wear indicator that informs the driver of wear limit is installed to the inner brake pad. (Only left side)

DISC BRAKE DESIGNATION

Knuckle

When new When worn

Pad

Wear indicator

Brake disk

AC403189

No. Item Content

1 Brake disc type V: Ventilated

2 Brake size

(Minimum applicable

4: 14-inch 5: 15-inch

disc wheel)

3 No. of piston S: 1piston (floating type)

4 Piston size (rounded

to nearest integer)

30: φ 30 mm 34: φ 34 mm 51: φ 51 mm 54: φ 54 mm

S 4 - S 30 P

1 2 3 4 5

AC403539

5 Parking brake

mechanism

P: Set

35A-8

REAR BRAKE

<8-inch leading trailing type drum brake> <14-inch disc brake>

BASIC BRAKE SYSTEM

CONSTRUCTION DESCRIPTION

M2350004000531

• 8-inch leading trailing type drum brake, which assures stable braking force during forward or rearward movement, has been installed. <LS, VR>

• Disc brake (S4-S30P) has been installed. <VR-X, RALLIART Version-R>

AC403060

• An audible wear indicator that informs the driver of application limit has been installed to the left brake pad. <VR-X, RALLIART Version-R>

NOTE: For disc brake designation, refer to P.35A-7.

GROUP 35B

ANTI-SKID BRAKE

SYSTEM (ABS)

CONTENTS

GENERAL INFORMATION . . . . . . . . 35B-2 CONSTRUCTION DESCRIPTION . . . 35B-6

SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-6

ABS-ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . 35B-6

35B-2

ANTI-SKID BRAKE SYSTEM (ABS)

GENERAL INFORMATION

FEATURES

The ABS ensures directional stability and controllability during hard braking. For vehicles with this type of ABS, 4 sensors (4 channels) are installed on front and rear wheels allowing independent left and right control. The system has the following features:

• EBD (Electronic Brake-force Distribution system) control has been added to provide the ideal brak ing force for the rear wheels.

• Magnetic encoder for wheel speed detection has been installed as a sensing device instead of the rotor.

• For wiring harness saving and secure data communication, CAN* bus has been adopted as a

tool of communication with another ECU.

NOTE: *: For more information about CAN (Controller Area Network), refer to Group 54C, General Information P.54C-2.

M2351000100409

EBD CONTROL

In ABS, electronic control is used so the rear wheel brake hydraulic pressure during braking is regulated by rear wheel control solenoid valves in accordance with the vehicle's rate of deceleration, and the front and rear wheel slippage which are calculated from the signals received from the various wheel speed sensors. EBD control provides a high level of control

for both vehicle braking force and vehicle stability. The system has the following features:

• Because the system provides the optimum rear wheel braking force regardless of vehicle load condition and the condition of the road surface, the system reduces the required pedal depres sion force, particularly when the vehicle is heavily loaded or driven on road surfaces with high fric tional coefficients.

• Because the duty placed on the front brakes is reduced, the increase in pad temperature can be controlled during brakes application to improve the wear resistance characteristics of the pad.

• Control valves such as the proportioning valve are not required.

SPECIFICATIONS

Item Specification

ABS control method 4-sensor, 4-channel

Wheel speed sensor

Magnetic encoder Front 86 (N pole:43 S pole:43)

Rear 86 (N pole:43 S pole:43)

Type Semiconductor

CONSTRUCTION DIAGRAM

ANTI-SKID BRAKE SYSTEM (ABS)

GENERAL INFORMATION

35B-3

3, 7

AC400129

Name of part Number Outline of function

Sensor Wheel speed sensor 1 Sends alternating current signals at frequencies which are

proportional to the rotation speeds of each wheel to the ABS-ECU.

Stop lamp switch 2 Sends a signal to the ABS-ECU to indicate whether the

brake pedal is depressed or not.

Actuator Hydraulic unit 3 Drives the solenoid valves according to signals from the

ABS-ECU in order to control the brake hydraulic pressure for each wheel.

ABS warning lamp 4 Illuminates in response to signals from the ABS-ECU

when a problem develops in the system.

Brake warning lamp 5 Illuminates in response to signals from the ABS-ECU

when a problem develops in the EBD system.

Diagnosis connector 6 Outputs the diagnosis codes and allows communication

with the M.U.T.-III.

ABS-ECU 7 Controls actuators (described above) based on the signals

coming from each sensor.

Controls the self-diagnosis and fail-safe functions.

Controls the diagnostic function (M.U.T.-III compatible).

35B-4

ANTI-SKID BRAKE SYSTEM (ABS)

GENERAL INFORMATION

SYSTEM CONFIGURATION DIAGRAM

Front-left wheel speed sensor

Rear-left wheel speed sensor

Rear-right wheel speed sensor

Front-right wheel speed sensor

Stop lamp switch

ABS-ECU power supply

Front-right wheel (FR)

ABS-ECU

Engine-CVT-ECU

Front-right solenoid valve (out)

Front-right solenoid valve (in)

Front-left solenoid valve (out)

Front-left solenoid valve (in)

Rear-right solenoid valve (out)

Rear-right solenoid valve (in)

Rear-left solenoid valve (out)

Rear-left solenoid valve (in)

Brake warning lamp

ABS warning lamp

Diagnosis connector

Stop lamp switch

Rear-right wheel (RR)

Rear-right wheel speed

sensor

Front right wheel speed

sensor

Hydraulic unit

Front-left wheel speed

sensor

Front-left wheel (FL)

NOTE: Broken lines show CAN-bus line.

Rear-left wheel speed

sensor

Rear-left wheel (RL)

AC314168

ANTI-SKID BRAKE SYSTEM (ABS)

GENERAL INFORMATION

ABS ELECTRICAL CIRCUIT DIAGRAM

35B-5

Fusible link No.1

J/B (Fuse)

No.42 15A

Stop lamp switch

Off

Ignition switch (IG1)

No.40

7.5A

Fusible link No.5

ABS-ECU

Motor power supply

Fusible link No.3

Solenoid valve power supply

Fusible link No.6

J/B (Fuse)

No.33 15A

Hydraulic unit

Solenoid valve

Motor power supply

Front wheel speed sensor

(rear, left)

Rear wheel speed sensor

(rear, right)(front, right)(front, left)

Engine-CVT-ECU

J/C (CAN2)

J/C (CAN1)

Combination meter (ABS warning lamp and brake warning lamp)

Diagnosis connector

AC314169

35B-6

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

SENSORS

M2351001000427

WHEEL SPEED SENSORS AND MAGNETIC ENCODER FOR WHEEL SPEED DETECTION

Front Rear <Drum> Rear <Disc>

Front wheel speed sensor

Encoder for wheel speed detection

Wheel speed sensor is a kind of a pulse generator consisted of a magnetic encoder (a plate on which north and south pole sides of the magnet are arranged alternately) for wheel speed detection which rotates at the same speed of the wheels, and a speed sensor (semiconductor sensor), sends fre quency pulse signals in proportion to wheel speed. Front wheel speed sensor consists of a front wheel speed sensor secured on the knuckle, and a mag netic encoder for wheel speed detection fitted to the inside of the front wheel bearing. Rear wheel speed sensor consists of a rear wheel speed sensor secured on the rear hub, and a magnetic encoder for wheel speed detection press fitted to the rear hub inner ring.

Rear wheel speed sensor

Encoder for wheel speed detection

Rear wheel speed sensor

Encoder for wheel speed detection

ABS-ECU

• By integrating ABS-ECU into the hydraulic unit, no more wiring harnesses for sending signal that operates the solenoid valve and pump motor is required, assuring higher reliability.

• Self-diagnostic programs and memory functions are integrated into ABS-ECU. If any malfunction is detected by the self-diagnostic function, ABS-ECU activates a fail-safe function and illuminates ABS warning lamp and brake warning

lamp

NOTE: *: ABS-ECU illuminates the brake warning

lamp as EBD control warning lamp.

• ABS-ECU detects vehicle speed from the wheel speed sensor signal, recognizes the wheel rota tion, estimates the wheel slip condition based on the preprogrammed algorithm, and then controls the solenoid valve in the hydraulic unit so that the wheels do not lock.

AC601358

M2351003000252

ABS FLUID PRESSURE CONTROL FOUR-WHEEL CONTROL

ABS fluid pressure is controlled independently for four wheels.

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

EBD FLUID PRESSURE CONTROL

Ideal distribution curve when seated by fixed persons

Rear braking force

Ideal distribution curve when seated by one persons

EBD operating conceptual design

Braking force distribution by EBD control

Braking force distribution curve by the existing proportioning valve

Front braking force

35B-7

Braking Force Improved

EBD control is activated within the lower slip ratio area where ABS is disabled. ABS-ECU calculates vehicle deceleration and slip amount of the four wheels based on the wheel speed sensor signal. If the rear wheel speed differs from the vehicle speed by a certain level or more, ABS-ECU boost, holds, and depressurises the rear wheel control solenoid valve in the hydraulic unit, and then adjusts rear wheel brake fluid pressure fairly close to an ideal dis tribution curve.

INITIAL CHECK

ABS-ECU internally activates the self-diagnostic function. ABS-ECU illuminates ABS warning lamp for

3 seconds (including the initial check)

after the ignition switch is turned ON. If any malfunction is detected, ABS-ECU continues illuminating ABS warning lamp and disables ABS control.

NOTE: *: ABS warning lamp may stay ON after the ignition switch is turned ON until the startup vehicle speed reaches approximately 10km/h. As far as ABS-ECU memorizes any diagnosis code related to the wheel speed sensor malfunction recorded during previous ignition ON status, ABS-ECU continues illu minating ABS warning lamp until it verifies that the malfunction for that code is resolved (Startup check).

STARTUP CHECK

When the startup vehicle speed reaches approximately 10 km/h, ABS-ECU performs the following checks.

• Motor, solenoid valve check (only in initial startup*)

AC208548

Operates the motor relay in ECU and checks the

pump motor operation. At the same time, ABS-ECU sequentially energizes each solenoid valve in a very short period and checks the valve operation.

NOTE: *: Initial startup indicates a first startup after

the system has started.

• Wheel speed sensor check

ABS-ECU checks for any wheels that have not

received wheel speed sensor signal from the startup.

CONSTANT CHECK

ABS-ECU constantly checks the following item.

• ABS-ECU

Performs self-diagnosis in ECU.

• ECU power supply

Checks if ECU power supply voltage reaches within

the operational range.

• Wheel speed sensor

• Monitors the output voltage of the sensor sig-

nal wiring harness and checks for abnormal output voltage (open/short circuit).

• Checks for any wheels that do not send pulse signal while the vehicle is in motion.

• Checks if wheel speed which is abnormally higher or lower than the vehicle speed is input.

• Pump motor and solenoid valve

Checks that ABS-ECU output signal and the operat-

ing condition of the pump motor and solenoid valve agree with each other.

35B-8

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

CAN COMMUNICATION

ABS-ECU outputs ABS warning lamp and EBD

warning lamp combination meter through CAN communication.

NOTE: *: ABS-ECU illuminates the brake warning lamp as EBD control warning lamp.

Diagnosis code No.

C1200 Open or short

C1201 Wheel speed

C1205 Open or short

C1206 Wheel speed

C1210 Open or short

illumination request signals to the

Item Action during fail-safe operation

ABS control EBD control CAN output Brake

Prohibits circuit in wheel speed sensor (FR)

sensor (FR) system

circuit in wheel speed sensor (FL)

sensor (FL) system

circuit in wheel speed sensor (RR)

control of

malfunctioning

wheel.

Prohibits all

wheel control

after control is

completed.

FAIL - SAFE FUNCTION

If any malfunction is detected by the self-diagnostic function, ABS-ECU illuminates ABS warning lamp

and brake warning lamp EBD as shown in the following table.

NOTE: *: ABS-ECU illuminates the brake warning lamp as EBD control warning lamp.

Two or less wheel Abnormal: Enabled Three or more wheels Abnormal: Prohibits

Output permitted

, and it controls ABS and

ABS warning lamp

Two or less wheel Abnormal: OFF Three or more wheels Abnormal: ON

warning

lamp

C1211 Wheel speed

sensor (RR) system

C1215 Open or short

circuit in wheel speed sensor (RL)

C1216 Wheel speed

sensor (RL) system

C1225 Wheel speed

sensor malfunction

System shut-down

Output permitted

ON ON

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

35B-9

Diagnosis code No.

C1226 Control solenoid

C1231 Control solenoid

C1236 Control solenoid

C1241 Control solenoid

C1246 Control solenoid

Item Action during fail-safe operation

valve (FR) pressure holding system

valve (FR) decompressing system

valve (FL) pressure holding system

valve (FL) pressure reducing system

valve (RR) pressure holding system

ABS control EBD control CAN output Brake

warning lamp

Prohibited Prohibited Output

permitted

ON ON

ABS

warning

lamp

C1251 Control solenoid

valve (RR) pressure reducing system

C1256 Control solenoid

valve (RL) pressure holding system

C1261 Control solenoid

valve (RL) decompressing system

C1266 Motor system

(stuck)

C1273 Motor relay stuck

off

C1274 Motor relay stuck

C1276 Valv e r elay system System

C1278 Valv e r elay system

stuck off

C1279 Valv e r elay system

stuck on

Prohibited Enabled Output

shut-down

System shut-down

Prohibited Enabled Output

System shut-down

permitted

Output permitted

permitted

OFF ON

ON ON

OFF ON

35B-10

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

Diagnosis code No.

C1607 Trouble in

C1860 High voltage at

C1861 Low voltage at

U1073 Trouble in CAN bus

Item Action during fail-safe operation

ABS-ECU

Trouble in ABS-ECU (CAN Initialisation malfunction)

ABS-ECU power supply

system

ABS control EBD control CAN output Brake

warning lamp

System shut-down

Enabled Enabled Output

Wait Wait Output

Enabled Enabled Output

System shut-down

Output permitted (Output may be impossible).

impossible

permitted

impossible

ON ON

ABS

warning

lamp

NOTE: .

•

: If any trouble occurs in CAN communication, the brake warning lamp and ABS warning lamp on the combination meter turns ON.

•

Prohibit: Any controls are not performed until the ignition switch is turned OFF.

•

System shut-down: Control will be disabled until valve power supply is turned off, and then ignition switch is turned to the OFF position.

•

Wait: ABS control is restarted when the normal condition is resumed even though the ignition switch is not turned OFF.

DIAGNOSTIC FUNCTION

ABS-ECU has the following functions for easier system checks. The following items can be diagnosed using the M.U.T.-III (ABS warning lamp illuminates and ABS control is prohibited while the ABS-ECU communicates with the M.U.T.-III).

• Diagnosis code set

• Service data output

• Actuator test

DIAGNOSIS CODE SET

There are 28 diagnostic items. Since all the diagnostic results are recorded in volatile memory (EEPROM*), they are stored in the memory even though the battery terminals are disconnected.

NOTE: .

•

*EEPROM (Electrical Erasable &;Programmable ROM): Special type of memory that can be pro grammed or erased electrically

•

For each diagnostic item, refer to Fail-safe Function.

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

35B-11

SERVICE DATA OUTPUT

The following items of the ECU input data can be read using M.U.T.-III.

Item No. Check item Check condition Normal condition

01 FR wheel speed sensor Perform a test run of the vehicle. Speedometer display and

02 FL wheel speed sensor

03 RR wheel speed sensor

04 RL wheel speed sensor

05 Power supply voltage Always 10 V or more

06 Stop lamp switch The brake pedal is depressed ON

The brake pedal is released. OFF

07 Valve relay When ABS is operating ON

When ABS is not operating OFF

10 FL inlet valve When ABS is operating ON

When ABS is not operating OFF

11 FL outlet valve When ABS is operating ON

M.U.T.-III display almost agree with each other.

When ABS is not operating OFF

12 FR inlet valve When ABS is operating ON

When ABS is not operating OFF

13 FR outlet valve When ABS is operating ON

When ABS is not operating OFF

14 RL inlet valve When ABS is operating ON

When ABS is not operating OFF

15 RL outlet valve When ABS is operating ON

When ABS is not operating OFF

16 RR inlet valve When ABS is operating ON

When ABS is not operating OFF

17 RR outlet valve When ABS is operating ON

When ABS is not operating OFF

20 Pump motor When ABS is operating ON

When ABS is not operating OFF

35B-12

ANTI-SKID BRAKE SYSTEM (ABS)

CONSTRUCTION DESCRIPTION

ACTUATOR TEST

Activation Pattern

Solenoid valve

Pump motor

Off

Note

Hydraulic pressure increases

Hydraulic pressure holds

Hydraulic pressure decreases

Start of activation

1 s

2 s

End of activation

AC300188

NOTE: .

•

When ABS-ECU is disabled, the actuator test cannot be performed.

•

The actuator test can be performed only when the vehicle is stationary. When the vehicle speed reaches 10km/h, the forcible actuator operation is disabled.

•

During actuator test, the ABS warning lamp illuminates, and ABS control is prohibited.

Item No. Check item Drive Contents

01 Solenoid valve for

front-right wheel

02 Solenoid valve for

front-left wheel

Solenoid valves and pump motor in the hydraulic unit (simple inspection mode)

03 Solenoid valve for

rear-right wheel

04 Solenoid valve for

rear-left wheel

The M.U.T.-III can be used to force-drive all solenoid valves and the pump motor.

GROUP 36

PARKING BRAKES

CONTENTS

GENERAL INFORMATION . . . . . . . . 36-2

STRUCTURAL DESCRIPTION

<CVT> . . . . . . . . . . . . . . . . . . . . . . . . 36-4

OPERATIONAL DESCRIPTION

<CVT> . . . . . . . . . . . . . . . . . . . . . . . . . 36-5

36-2

PARKI N G B R A K E S

GENERAL INFORMATION

<CVT>

Employment of the parking brake pedal clears front centre space to allow a walk through design. PUSH-ON/PUSH-RELEASE type pedal has been installed for easier operation.

Parking brake pedal assembly

M2360000100656

The parking brake pedal retreat suppression mechanism that restraints the retraction of the brake pedal during collision has been adopted in order to reduce the shock to the driver's feet. The mechanism of the parking brake pedal is basically the same as that of the brake pedal.

NOTE: For more information about brake pedal retreat suppression mechanism, refer to GROUP 35A, Brake Pedal

P.35A-6.

Parking brake cable cover

<LS>

<VR-X>

AC506311

PARKING BRAKES

GENERAL INFORMATION

36-3

Parking brake pedal bracket

Collision load

Brake pedal position before collision

AC207360

After collision

Fixed bolt

Deck crossmember

Retreat trajectory of brake pedal during collision

Brake pedal surface position after collision (Brake pedal retreat suppression mechanism operated)

Parking brake pedal bracket

Before collision

AC207354

AC207757

<M/T>

The parking brake is of a mechanical rear-wheel acting type, and its operation utilises a parking brake lever.

Parking brake lever (Leather grip)

Parking brake cable

<LS, VR>

Parking brake lever

Parking brake cable

AC601652

36-4

Return spring

PARKI N G B R A K E S

STRUCTURAL DESCRIPTION <CVT>

M2360000200192

The parking brake pedal assembly consists of the parking brake pedal, sector, release lever, pawl return spring, pawl, and return spring. The sector is secured to the parking brake pedal bracket body. The pawl and release lever are fixed to the pin axle by the section with an oblong hole. The pawl and release lever are connected by the pawl returning spring, and move together with the pedal.

Pawl

Sector

Release lever

Pawl return spring

AC207357

PARKI N G B R A K E S

OPERATIONAL DESCRIPTION <CVT>

PARKI N G B RA K E P ED AL OP E RAT I ON OPERATION WHEN PEDAL IS

DEPRESSED

Spring force

Sector

Pawl axle

Release lever

Pawl

Pawl return spring

AC405464

When the parking brake is released, the pawl receives the left-rotation force (the direction of engagement) around the pawl axis from the pawl return spring. Then, depressing the pedal engages the pawl and sector, releasing a clicking sound.

36-5

M2360000300207

OPERATION AFTER PEDAL IS DEPRESSED

Contact point of release lever and pawl

Release lever rotates

AC405465

Depressing the pedal and removing one's foot causes the pawl axis to slide the section with an oblong hole from the repulsive force of the cable. Then, the release lever affixed to the pawl axis is pushed by the pawl and rotates, the pawl return spring position is inverted, and right-rotation force (in the release direction) is applied to the pawl. At this time, the engagement force of the pawl and sector prevents release.

OPERATION WHEN PEDAL IS DEPRESSED

Disengaged

AC405466

Depressing the pedal again for release disengages it, rotating the pawl from the spring force and releas ing the lock.

36-6

OPERATION WHEN PEDAL IS RETURNED

PARKI N G B R A K E S

OPERATIONAL DESCRIPTION <CVT>

Lever returning part

AC405467

When returning the pedal, the release lever returns to the starting position from the lever returning sec tion as the spring position is inverted, causing the pawl to return to the position of release for the park ing break.

GROUP 12

ENGINE

LUBRICATION

CONTENTS

GENERAL INFORMATION . . . . . . . . 12-2

OIL PUMP<4A9> . . . . . . . . . . . . . . . . 12-4

RELIEF VALVE<4A9> . . . . . . . . . . . . 12-4

OIL SCREEN<4A9> . . . . . . . . . . . . . . 12-5

OIL FILTER<4A9> . . . . . . . . . . . . . . . 12-5

OIL PAN<4A9> . . . . . . . . . . . . . . . . . . 12-6

OIL LEVEL GAUGE, OIL FILLER CAP,

OIL DRAIN PLUG<4A9> . . . . . . . . . . 12-6

OIL COOLER<4G1> . . . . . . . . . . . . . . 12-7

12-2

ENGINE LUBRICATION

GENERAL INFORMATION

LUBRICATION SYSTEM SCHEMATIC<4A9>

M2120000100175

Oil screen

Oil pump

Relief valve

Oil pressure switch

Cylinder head oil passage

No.1 Camshaft journal

Intake camshaft journal

Timing chain case oil passage

Cylinder block oil passage(right side)

Oil filter

Cylinder block oil passage (main gallery)

Crankshaft journal

Crankshaft pin

Exhaust camshaft journal

The lubrication system of the 4A9 engine has a full pressure delivery system and a full flow oil filtering system. The oil stored in the oil pan is pumped up/out by the oil pump. After the relief valve regulates the oil pressure, the oil is delivered to the cylinder block through the oil filter, the oil passage of the cylinder block and the each journal of the crankshaft.

AK402024

The oil delivered to the each journal of the crankshaft is supplied to the pin through the inner passage of the crankshaft. The oil delivered to the cylinder head is supplied to the each journal of the camshaft through the cylinder head.

ENGINE LUBRICATION

GENERAL INFORMATION

LUBRICATION SYSTEM SCHEMATIC<4G1>

12-3

Oil screen

Oil pump

Lash adjuster

Cam

Relief valve

Turbo charger

Cylinder head oil passage

No.1 Camshaft journal

Intake camshaft journal

Oil pan

Oil cooler

Oil filter

Cylinder block oil passage (main gallery)

Crankshaft journal

Crankshaft pin

Exhaust camshaft journal

Oil pressure switch

Oil jet

Piston

AK402151

To correspond with the improved engine output performance by employing the turbocharger, the oil cooler and the oil jet are used for 4GI engine.

12-4

ENGINE LUBRICATION

OIL PUMP<4A9>

M2120002000044

The oil pump is of a cycloid type, directly driven by the crankshaft.

Specifically, oil is sucked into the expanding space and is pushed out from the shrinking space.

Timing chain case

Machine screw

Cover

On the cycloid oil pump, as the inner rotor is rotated by the crankshaft, the outer rotor also rotates. The resultant change in spatial volumes between the rotors generates pumping action.

Item Specification

Type Cycloid pump

No. of lobes Inner rotor 10

Outer rotor 11

A-A

Oil seal

Oil pump inner rotor

Oil pump outer rotor

AK305367

Displacement L/min(6,000 r/min.) 35

RELIEF VALVE<4A9>

The relief valve is of a plunger type. The valve regulates the maximum pressure of lubrication oil being sent to the engine.

When the pressure of oil from the oil pump exceeds the specified value, the valve opens to relieve the excess flow. The excess oil is returned to the suction side of the oil pump.

A-A

Timing chain case

Relief plunger

Relief spring

Plug

AK305369

M2120003000047

ENGINE LUBRICATION

OIL SCREEN<4A9>

Timing chain case

OIL SCREEN<4A9>

The oil screen is located in the position with the least disturbance to the oil suction volume that results from oil level variation in the oil pan while the vehicle is driven.

12-5

M2120004000039

Oil screen

Oil filter

Oil pan

AK305372

Oil filter bracket

Oil filter

AK401817

OIL FILTER<4A9>

The oil filter is installed to the oil filter bracket attached to the cylinder block.

Item Specification

Filtering method Full-flow filtering, Paper

Filtration area cm

Rated flow L/min. 25

M2120005000032

element

750

Element

AK305373

12-6

ENGINE LUBRICATION

OIL PAN<4A9>

M2120006000035

Oil drain plug installation side

The oil pan, located below the engine, is made of sheet metal.

OIL LEVEL GAUGE, OIL FILLER CAP, OIL DRAIN

PLUG<4A9>

Oil level gauge

Oil filler cap

AK305374

M2120007000038

Oil drain plug

The oil level gauge, oil filler cap, and oil drain plug are all located in the front of the engine for excellent serviceability.

AK402349

Coolant inlet (from throttle body)

ENGINE LUBRICATION

OIL COOLER<4G1>

Coolant outlet (to water inlet pipe)

To cylinder block

Oil inlet

12-7

M2120008000020

Oil cooler bolt

From oil filter

An oil cooler is used for the vehicle with a turbocharger to improve the performance of cooling lubricant.

Oil cooler

Oil outlet

AK402142

By circulating the coolant and the oil within the oil cooler, heat is exchanged and the oil is cooled.

GROUP 16

ENGINE

ELECTRICAL

CONTENTS

GENERAL INFORMATION . . . . . . . . 16-2

16-2

ENGINE ELECTRICAL

GENERAL INFORMATION

The electronic device is basically the same as that in the conventional 4G1 engine. The employed alternator is a lightweight type in which the electronic voltage regulator for detecting the battery voltage is built.

M2160000100038

The employed starter motor is a small planetary gear reduction drive type. The employed spark plug is a long reach type with iridium. The employed ignition coil is a plug top type in which the powertrain per cylinder is built.

GROUP 00

GENERAL

CONTENTS

HOW TO USE THIS MANUAL. . . . . . 00-2

TARGETS OF DEVELOPMENT . . . . 00-2

PRODUCT FEATURES . . . . . . . . . . . 00-3

TECHNICAL FEATURES. . . . . . . . . . 00-4

EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . 00-4

INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6

SPACIOUS CABIN . . . . . . . . . . . . . . . . . . . 00-8

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9

TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 00-10

SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . 00-14

BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-15

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . 00-18

ACTIVE SAFETY. . . . . . . . . . . . . . . . . . . . . 00-19

PASSIVE SAFETY . . . . . . . . . . . . . . . . . . . 00-24

EQUIPMENTS. . . . . . . . . . . . . . . . . . . . . . . 00-27

ENVIRONMENTAL PROTECTION . . . . . . . 00-28

SERVICEABILITY AND RELIABILITY . . . . 00-28

VEHICLE IDENTIFICATION . . . . . . . . 00-30

MAJOR SPECIFICATIONS . . . . . . . . 00-31

<CVT> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-31

<M/T> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-32

00-2

HOW TO USE THIS MANUAL

MODEL INDICATIONS

The following abbreviations are used in this manual for identification of model types. DOHC. Indicates an engine with the double over-

head camshaft.

MIVEC. Indicates Mitsubishi innovative valve timing

electronic control system.

MPI. Indicates the multipoint injection. M/T. Indicates the manual transmission. CVT. Indicates the continuously variable transmis-

sion.

A/C. Indicates the air conditioner.

TARGETS OF DEVELOPMENT

EXCEPT RALLIART Version-R

The New COLT featuring "exciting feeling and freedom" has been developed for realising "safety, running, quality" and "free-to-select enjoyment" as well as "true convenience and economical efficiency." That makes NEW COLT a new generation compact car.

GENERAL

M2000029000628

M2000004001066

RALLIART Version-R

This "COLT RALLIART Version-R" has been developed as a hot version in which the Mitsubishi Motors' concept "Sporty In the midst of this recent wave of the sport model launches in the compact car class, COLT RALLIART Version-R has acquired users of the competitors and the younger generation, and has improved the over all image of the COLT series by appealing to the sport-oriented users as the only high-powered turbo charger vehicle in the class.

−DNA" was further refined.

GENERAL

PRODUCT FEATURES

• COLT has been equipped with the new 1,500 mL aluminium die-cast engine (4A9-engine) for fur ther refinements of comfort driving, excellent power performance, fuel economy, and ecology performance.

• The body and suspension of COLT RALLIART Version-R have been thoroughly tuned to increase the 4G1-engine output which enables dynamic driving.

• The robust image suited for the dynamic driving has been adopted for the appearance.

SPORTY AND STYLISH DESIGN

• Bucket-like front seats <Except RALLIART Version-R>

• Sport seats exclusive to the models with turbocharger <RALLIART Version-R>

• 15-inch aluminium wheel <VR-X>

• High-contrast combination meter <Except RALLI-

ART Version-R, LS, VR-X (M/T) >

• Robust appearance by new shaped front bumper adaptation and rear bumper change <RALLIART Version-R>

• Black overfender <RALLIART Version-R>

• 16-inch aluminium wheel <RALLIART Version-R>

ACTIVE DRIVING AND HIGH QUALITY

• For 4A9-engine, the aluminium die-cast cylinder

block has been installed for weight reduction of the vehicle. <Except RALLIART Version-R>

• For 4G1-engine, turbo-charger model has been introduced to increase output and torque, enhancing sporty image. <RALLIART Version-R>

• Sporty driving has been ensured by the "GETRAG" 5-speed manual transmission (floor shift). <M/T>

• The suspension has been tuned to improve cornering and stability at high speed. <RALLIART Version-R>

• A strut tower bar has been adopted to improve the body rigidity. <RALLIART Version-R>

• Electric power steering system has been improved and EPS-ECU has been additionally equipped with the return control logic, resulting in superior steering wheel return control and better steering feel equal to or better than that for other models with hydraulic power steering.

00-3

M2000005000475

00-4

GENERAL

TECHNICAL FEATURES

EXTERIOR

M2000017000825

<ES, LS, VR-X>

1, 2

MAIN CHARACTERISTICS

1. The radiator grille has been renewed in shape to provide the superior and high-quality design.

2. A chrome-plated embellisher has been installed to emphasize the feelings of luxury and sporty.

3. The front bumper has been renewed in shape to provide the superior and high-quality design.

AC601279

4. The rear bumper has been renewed in shape to emphasize the sporty image in rear appearance together with modification in the tailgate glass and rear combination lamps.

5. Due to the change of the front bumper, the shape of front fog lamp has been changed.

6. The design of the rear combination lamp assembly has been changed. In addition, the locations of the tail lamps have been moved upward to increase visibility.

GENERAL

TECHNICAL FEATURES

00-5

DESIGN PURPOSE

• Sporty hot hatchback with high quality and premium image resulting from the function-oriented styling

• Exterior design which attracts users to driving

MAIN CHARACTERISTICS

1. Air outlet garnish has been added.

2. Sporty-imaged front bumper and radiator grille dedicated to the RALLIART Version-R

AC601260

3. The overfender which provides a sense of unity with the front bumper, side air dam, and rear bumper

4. Large side air dam design which provides a sense of unity with the overfender

5. The tailgate lower garnish dedicated to RALLIART Version-R

6. The rear bumper dedicated to RALLIART Version-R

7. Equipped large size muffler cutter

00-6

TECHNICAL FEATURES

INTERIOR

M2000018000828

Functionality, interior comfort, and safety have been emphasised, providing the interior design with ele

GENERAL

gance and comfortable space. Various measures have been taken actively to protect the environment and recycle resources.

Instrument panel <Smart shift CVT>

Centre operation panel

Instrument panel and floor console <Floor shift M/T>

Centre operation panel

Ashtray

Ashtray

Floor console

Convenience hook

Cup hoder

Accessory box

Combination meter <RALLIART Version-R>

Tachometer

Time setting button

<LS, VR-X (M/T) >

Speedometer

Tachometer

Time setting button

Liquid-crystal-display type odometer and trip meter (Clock function incorporated)

High-contrast meter <VR-X (CVT) >

Speedometer

Water temperature gauge

Fuel gauge

Reset button

Liquid-crystal-display type odometer and trip meter (Clock function incorporated)

Water temperature gauge

Fuel gauge

Reset button/Rheostat (Meter illumination control)

Water temperature gauge

Seatback pocket

Tachometer

Time setting button

Liquid-crystal-display type odometer and trip meter (Clock function incorporated)

Fuel gauge

Reset button/Rheostat (Meter illumination control)

AC601391

GENERAL

TECHNICAL FEATURES

00-7

FEATURES

Quality improvement

• Full interior trim

• Two-tone interior

• Cloth covered part door trim

Usability improvement

• Movable ashtray <M/T>

• Front RECARO seat (Option)

• Cup holder of right/left separation type (for front

seats) <M/T>

• Convenience hook (passengerís side) <LS>

• Wide variety of seat arrangement

• Reclining adjustment, slide adjustment

• Luggage hook

• High-contrast meter <LS, VR-X (M/T), Excpet

RALLIART Version-R>

• Combination meter of 240km/h scale <RALLIART Version-R>

Convenient boxes

• Centre panel box

• Glove box

• Seatback pocket

• Bottle holder (front door trim)

• Door pocket (front door trim)

Safety improvement

• ELR three-point seat belt (front)

• Front seat belt with force limiter mechanism

• ELR three-point seat belt/child seat fastening

mechanism (ALR) switching seat belt (rear)

• Floor carpet with heel stopper structure

• Instrument panel and trims which adopt

fire-retarding materials

Consideration for the optimum driving position

• Seat height adjustment (driverís seat)

• Head restraint with height adjustment (front, rear)

• One-touch adjustable seat belt anchor (front seat

belt)

Measures for resource recycling

Aggressively use PP materials that are easy to recycle and easy to stamp material symbols on the plastic (resin) parts.

00-8

SPACIOUS CABIN

GENERAL

TECHNICAL FEATURES

M2000000400230

• Spacious interior space leading the compact car

•

Seating ground clearance offering easy access

AC313513

field

No. Item Dimension mm

1 Front shoulder room 1,340

2 Interior effective length 1,805

3 Head room Front 920/875*

4 Rear 855/850*

5 Hip-point height Front 325

6 Rear 375

7 Seating ground clearance Front 600

8 Rear 650

9 Brake pedal room 900

10 Hip point couple 805

NOTE: .

•

*:Vehicles with sunroof

•

Refer to P.00-31 <CVT>, P.00-32 <M/T> for the body dimensions.

GENERAL

TECHNICAL FEATURES

ENGINE

M2000020000579

<4A9>

The newly-developed 4A9 engine has been installed to realise small-size, light-weight, high-performance, and better fuel economy with the state-of-the-art technologies such as the aluminium die-cast cylinder block, direct attack driven-type DOHC MIVEC, timing chain-type cam drive, and rear exhaust.

MAJOR SPECIFICATIONS

Item 4A91

To ta l di sp la ce me nt m L 1,499

Bore × Stroke mm 75 × 84.8

Compression ratio 10.0

Compression chamber Pentroof-type

Valve timing Intake opening BTDC 31° − ATDC 19°

Intake closing ABDC 21° − ABDC 71°

Exhaust opening BBDC 39°

Exhaust closing AT D C 5°

00-9

Maximum output kW (PS)/rpm 77 (105)/6,000

Maximum torque N⋅m (kg⋅m)/rpm 141 (14.4)/4,000

Fuel system Electronically controlled multipoint fuel injection

Ignition system Electronic-controlled 4-coil

<4G1>

Based on the 4G1 engine fitted on the existing COLT, the power performance leading the compact car field has been secured by Turbocharger.

MAJOR SPECIFICATIONS

Item 4G15 (with Intercooler Turbocharger)

To ta l di sp la ce me nt m L 1,468

Bore × Stroke mm 75 × 82.0

Compression ratio 9.0

Compression chamber Pentroof-type

Valve timing Intake opening BTDC 34° − ATDC 6°

Intake closing ABDC 30° − ABDC 70°

Exhaust opening BBDC 50°

Exhaust closing AT D C 10 °

Maximum output kW (PS)/rpm 113 (154)/6,000

Maximum torque N⋅m (kg⋅m)/rpm 210 (21.4)/3,500

Fuel system Electronically controlled multipoint fuel injection

Ignition system Electronic-controlled 4-coil

00-10

GENERAL

TECHNICAL FEATURES

TRANSMISSION

M2000021000594

MANUAL TRANSMISSION

Due to the addition of vehicles with M/T, a "GETRAG" F5MGA type <4A9 engine>, F5MGB type<4G1 engine> transmission has been adopted.

SPECIFICATIONS

Transmission model F5MGA F5MGB

Engine model 4A91 4G15

Transmission type 5-speed, floor-shift

Transmission gear ratio 1st 3.308 3.538

2nd 1.913 1.913

3rd 1.258 1.344

4th 0.943 1.027

5th 0.763 0.833

Reverse 3.231 3.357

Final reduction ratio 4.158 3.737

GEARSHIFT CONTROL

Select cable

Gearshift cable or Select cable assembly

Gearshift knob

Gearshift lever assembly

Gearshift cable

The cable type of gear shift control is adopted.

AC600701

GENERAL

TECHNICAL FEATURES

00-11

CVT

The F1C1A transmission is adopted for the CVT. This transmission is basically the same as conven tional transmission. The ATF warmer (ATF cooler) is adopted.

SPECIFICATIONS

Item Specification

Transmission model F1C1A

Engine model 4A91

Tor qu e co nv er te r Type 3-element, 1-stage, 2-phase type

Lock-up Provided

Stall torque ratio 2.0

Transmission type Forward automatic continuously variable (steel belt type),

Gear ratio Forward 2.319 − 0.445

Reverse 2.588

Clutch A pair of multi-plate system

Brake A pair of multi-plate system

Manual control system P-R-N-D-Ds-L (smart shift)

1st in reverse

Function Variable speed control Yes

Line pressure control Yes

Direct engagement control Yes

N-D/N-R control Ye s

Shift pattern control Yes

Self-diagnosis Yes

Failsafe Ye s

Oil pump Type External gear pump

Configuration Built-in (chain drive)

Control method Electronic control (INVECS-III)

00-12

ATF WARMER (ATF C OOL ER) <4 A9>

Thermo valve

ATF Warmer (ATF Cooler)

GENERAL

TECHNICAL FEATURES

Sectional view

Engine coolant

ATF

Thermostat

Thermo

Radiator

valve

ATF warmer (ATF cooler)

Engine

CVT CVT CVT

<Engine coolant temperature: 75˚C or less> Engine coolant flows through the heater only.

Heater

Radiator

ATF warmer (ATF cooler)

<Engine coolant temperature: 75 - 85˚C> Engine coolant flows through the heater and the ATF warmer.

Thermostat

Thermo valve

The ATF warmer (ATF cooler) is adopted for the models with 4A9 engine. (the ATF cooler incorporat ing the radiator is not adopted) At the start of running, the temperature of the engine coolant rises earlier than that of the ATF. The ATF warmer utilizes this characteristic to raise the ATF temperature as early as possible to an appropriate level (70

−80 °C). It also controls fluid temperature

AC403052

: Engine coolant

: ATF

Thermostat

Engine

: Valve open

: Valve closed

Heater

Thermo

Radiator

valve

ATF warmer (ATF cooler)

<Engine coolant temperature: 85˚C or more> Engine coolant flows through all the sections.

AC403006

stably and reduces ATF agitation resistance to

improve fuel consumption ratio. In addition, a thermo-valve has been adopted to restrict the engine coolant supply to the ATF warmer (ATF cooler) until the engine coolant temperature reaches the appropriate temperature when low tem perature start in winter, giving the priority to the heating performance.

Heater

GEARSHIFT CONTROL

Smart shift CVT

AC206842

GENERAL

TECHNICAL FEATURES

00-13

Transmission control cable

Inhibitor switch

• A smart shift type selector lever has been adopted in order to facilitate walkthrough between the seats.

• A gun grip type selector lever knob has been adopted for better operation and easier visual recognition of the switches arranged in the centre panel.

• The selector lever assembly has been a single unit made by aluminium die casting for better accuracy and fewer parts, resulting in the light weight and compact structure.

Selector lever assembly

AC206864

AC207638

• The selector lever has been designed to be compact and appropriately configured not to interfere with the energy absorbing mechanism on the steering column upon impact of the vehicle.

• In order to prevent abrupt start by erroneous operation of selector lever, a CVT erroneous operation prevention mechanism (the shiftlock mechanism and key interlock mechanism) has been adopted.

00-14

SUSPENSION

<FRONT>

GENERAL

TECHNICAL FEATURES

M2000023000460

<4A9> <4G1>

Lower arm

Front axle No.1 crossmember

<REAR>

Coil spring

Strut assembly

Stabilizer bar

Shock absorber

Coil spring

Strut assembly

Stabilizer bar

Lower arm

Front axle No.1 crossmember

Torsion beam and arm assembly

• The MacPherson Strut suspension with compatible characteristics of high rigidity and light weight has been adopted for the front suspension to realise sufficient driving comfort.

AC405092

• H-shaped torsion beam type suspension has been introduced for the rear suspension. This suspension has large suspension stroke and pro vides sufficient driving comfort. With its compact design, specious interior space has been reserved.

GENERAL

TECHNICAL FEATURES

BRAKE

M2000024000270

SERVICE BRAKE

Brake system with high reliability and durability have achieved distinguished braking performance.

Brake booster (with variable boosting mechanism)

Hydraulic unit (Integrated with ABS-ECU)

Master cylinder

Front disc brake

00-15

Rear drum brake

Brake booster (with variable boosting mechanism)

Hydraulic unit (Integrated with ABS-ECU)

Master cylinder

Front disc brake

BRAKING PERFORMANCE

• Brake booster with 9-inch variable amplification ratio mechanism by which greater braking force can be obtained with a less pedal pressure has been installed (with brake assist function).

• 14-inch disc brake is installed on the front wheels.<LS, VR>

• 15-inch disc brake is installed on the front wheels.<VR-X, RALLIART Version-R>

• 8-inch leading trailing type drum brake is installed on the rear wheels.<LS, VR>

• 14-inch disc brake is installed on the rear wheels.<VR-X, RALLIART Version-R>

STABILITY

• 4-wheel anti-skid braking system (4ABS) is adopted to prevent slipping caused by the vehicle wheels locking up, in order to maintain appropri ate braking distance, and also to maintain vehicle stability and steering function.

Rear disc brake

• Electronic brake-force distribution (EBD) is adopted to maintain the maximum amount of rear braking force even when the vehicle's load is var ied.

• Diagonal split (X-type) brake fluid line is adopted.

• Ventilated discs have been adopted to front

brakes to improve anti-fading performance.

SERVICEABILITY

• Diagnosis function is adopted for the ABS system in order to make inspection easier.

• For the front disc brakes, brake disc separated front hub is adapted to make removal and instal

lation easier.

• ABS-ECU and hydraulic unit have been integrated to make them more compact and lighter.

AC601327

00-16

TECHNICAL FEATURES

BRAKE BOOSTER

PARKING B RAK E <M/T>

The parking brake is of a mechanical rear-wheel acting type, and its operation utilises a parking brake lever.

Parking brake lever

Parking brake cable

GENERAL

AC601277

GENERAL

TECHNICAL FEATURES

00-17

<CVT>

Employment of the parking brake pedal clears front centre space to allow a walk through design. PUSH-ON/PUSH-RELEASE type pedal has been installed for easier operation.

Parking brake pedal assembly

Parking brake cable cover

NOTE: For more information about brake pedal retreat suppression mechanism, refer to GROUP 35A, Brake Pedal P.35A-6.

AC506311

00-18

STEERING

GENERAL

TECHNICAL FEATURES

M2000040000140

Transmission control cable

Tie-rod end

Crossmember

<CVT>

Steering column assembly

Torque sensor

Steering gear and linkage

Dash panel cover

Motor

Steering wheel

Selector lever assembly

Electric power steering-ECU

Tie-rod end

<M/T>

Steering wheel

Steering column assembly

Torque sensor

Dash panel cover

Motor

Electric power steering-ECU

Yoke-bearing

Pinion-driven electric power steering system (ESP*) with further improvements has been adopted. EPS* has been improved and EPS-ECU has been addi

tionally equipped with the return control logic, resulting in superior steering wheel return control and better steering feel equal to or better than that for other vehicles with hydraulic power steering.

Crossmember

Steering gear and linkage

AC403622

NOTE: *EPS: Electronic Control Power Steering

For the models with turbo-charger, the quick steering gear ratio and turbo-tuned assist characteristics increase sporty taste.<Vehicles for 4G1 engine>

GENERAL

TECHNICAL FEATURES

ACTIVE SAFETY

M2000031000528

ANTI-SKID BRAKE SYSTEM (ABS)

The ABS ensures directional stability and controllability during hard braking. For vehicles with this type of ABS, 4 sensors are installed on front and rear wheels allowing independ ent left and right control.

<LS, VR> <VR-X> <RALLIART Version-R>

Brake warning lamp

00-19

Brake warning lamp

ABS warning lamp

Stop lamp switch

Diagnosis connector

Hydraulic unit and ABS-ECU

CONSTRUCTION DIAGRAM

The system has the following features:

• EBD (Electronic Brake-force Distribution system) control has been added to provide the ideal brak ing force for the rear wheels.

• Magnetic encoder for wheel speed detection has been installed as a sensing device instead of the rotor.

ABS warning lamp

Wheel speed sensor

ABS warning lamp

Wheel speed sensor

AC601759

• For wiring harness saving and secure data communication, CAN* bus has been adopted as a

tool of communication with another ECU.

NOTE: *: For more information about CAN (Controller Area Network), refer to GROUP 54C, General Information

P.54C-2.

00-20

TECHNICAL FEATURES

ELECTRONIC BRAKE FORCE DISTRIBUTION SYSTEM (EBD) CONTROL

GENERAL

TECHNICAL FEATURES

SYSTEM CONFIGURATION DIAGRAM

GENERAL

00-21

Front-left wheel speed sensor

Rear-left wheel speed sensor

Rear-right wheel speed sensor

Front-right wheel speed sensor

Stop lamp switch

ABS-ECU power supply

Front-right wheel (FR)

ABS-ECU

Engine-CVT-ECU Front-right solenoid valve (out) Front-right solenoid valve (in) Front-left solenoid valve (out) Front-left solenoid valve (in) Rear-right solenoid valve (out) Rear-right solenoid valve (in) Rear-left solenoid valve (out) Rear-left solenoid valve (in)

Brake warning lamp

ABS warning lamp

Diagnosis connector

Stop lamp switch

Rear-right wheel (RR)

Rear-right wheel speed

sensor

Front right wheel speed

sensor

Hydraulic unit

Front-left wheel speed

sensor

Front-left wheel (FL)

The system has the following features:

Rear-left wheel speed

sensor

Rear-left wheel (RL)

AC314168

• Because the duty placed on the front brakes is reduced, the increase in pad temperature can be controlled during brakes application to improve the wear resistance characteristics of the pad.

• Control valves such as the proportioning valve are not required.

00-22

TECHNICAL FEATURES

ACTIVE STABILITY CONTROL SYSYEM (ASC) <RALLIART Version-R>

The active stability control system (ASC) has been installed to the M/T vehicle.

Combination meter

Brake warning lamp

ASC indicator lamp

GENERAL

ABS warning lamp

Stoplamp switch

Brake fluid level sensor

Diagnosis connector

ASC OFF indicator lamp

Steering wheel sensor

ASC OFF switch

Engine-ECU

ABS/ASC-ECU

Magnetic encoder for wheel speed detection

• The active stability control system (ASC) has the stability control and the traction control (TCL) functions. By the integrated control with the anti-lock brake system, the system stabilizes the vehicle attitude and at the same time secures the driving force.

• When the stability control function determines that the vehicle is in a dangerous condition, it reduces the engine output and applies brake force to four wheels independently to control the vehicle behaviour, avoiding the critical state.

Parking brake switch

G and yaw rate sensor

Wheel speed sensor

Magnetic encoder for wheel speed detection

AC601760

• The traction control (TCL) function prevents the driving wheel slip on a slippery road surface, ensuring easy startup, and at the same time, secures proper driving force and improves steer ing performance during cornering acceleration.

• Fail-safe function assures the security.

• Serviceability improvement

• For wiring harness saving and secure data com-

munication, the CAN* communication has been adopted as a tool of communication with another ECU.

NOTE: .

•

For more information about CAN (Controller

Area Network), refer to GROUP 54C

•

ABS and ASC are controlled by ASC-ECU.

P.54C-2.

TECHNICAL FEATURES

SYSTEM CONFIGURATION DIAGRAM

Front-left wheel speed sensor

Rear-left wheel speed sensor

Rear-right wheel speed sensor

Front-right wheel speed sensor

Master cylinder pressure sensor

Stop lamp switch

Brake fluid level switch

Parking brake switch

Power supply to active stability control system-ECU

Steering wheel sensor

G and yaw rate sensor

Engine-ECU

GENERAL

Active stability control system-ECU

00-23

Combination meter ABS warning lamp

· Brake warning lamp

· Active stability control indicator lamp

· Active stability control OFF indicator lamp

Diagnosis Connector

Control solenoid valve (FR) OUT

Control solenoid valve (FR) IN

Control solenoid valve (FL) OUT

Control solenoid valve (FL) IN

Control solenoid valve (RR) OUT

Control solenoid valve (RR) IN

Control solenoid valve (RL) OUT

Control solenoid valve (RL) IN

Suction valve (FR)

Suction valve (FL)

Cut valve (FR)

Cut valve (FL)

Pump motor

Front-right wheel (FR)

Engine-ECU

Front-left wheel (FL)

Note : CAN-bus line

Steering wheel sensor

Wheel speed sensor

Stop lamp switch

Hydraulic unit

G and yaw rate sensor

Rear-right wheel (RR)

Parking brake switch

Wheel speed sensor

Rear-left wheel (RL)

AC600637

00-24

TECHNICAL FEATURES

PASSIVE SAFETY

M2000032000628

IMPACT SAFETY BODY, RISE*

NOTE: RISE*: Reinforced Impact Safety Evolution

The front and rear structures to absorb high energy, and the highly tough cabin structure reduce the risk of passenger injuries at front-, rear-, and side-impact collisions, secure the space for life protection, and facilitate rescuing passengers.

GENERAL

Section A – A

Front sidemember outer

AB201266

Front sidemember inner

Section B – B

Front sidemember inner

AB400214

Front sidemember outer

1. The front side of the front sidemember, for which octagonal section structure is adopted, has been enlarged for improved rigidity.

2. The rear side of the front sidemember, for which 8-shape cross section structure is adopted, has been enlarged for improved rigidity.

AB201267

AB502015

3. The dash side brace has been manufactured as an unit in order to strengthen the joint between the front sidemember and the front pillar, increasing the rigidity of the entire body.

4. The installation position of the steering gearbox has been lowered, and the sidemember from the front to the rear has been straightened in order to improve rigidity of the entire body.

Mitsubishi Colt 2006 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual