MITSUBISHI COLT 2006 Service Repair Manual

GROUP 35A
BASIC BRAKE SYSTEM
CONTENTS
GENERAL INFORMATIO N . . . . . . . .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

GENERAL INFORMATION
BASIC BRAKE SYSTEM35A-2
GENERAL INFORMATION
M2350000100848
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.
•15-inch disc brake is installed on the front
wheels.
•8-inch leading trailing type drum brake is installed
on the rear wheels.
•14-inch disc brake is installed on the rear wheels.

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.
•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 inte-
grated to make them more compact and lighter.

GENERAL INFORMATION
BASIC BRAKE SYSTEM35A-3
CONFIGURATION DIAGRAM
AC601653
Brake booster (with variable
boosting mechanism)
Hydraulic unit
(Integrated with ABS-ECU)
Master cylinder
Front disc brake Rear drum brake

Brake booster (with variable
boosting mechanism)
Hydraulic unit
(Integrated with ABS-ECU)
Master cylinder
Front disc brake Rear disc brake

AB

GENERAL INFORMATION
BASIC BRAKE SYSTEM35A-4
SPECIFICATIONS
ItemSpecifications
Master cylinderTy p eTandem type
I.D. mmLS, VR20.6
VR-X22.2
RALLIART Version-R23.8
Brake boosterTy p eVacuum type, single
Effective dia. of power cylinder mm230
Boosting ratioLS, VR, VR-X6.0 (pedal pressure: 116 N)
7.0 (pedal pressure: 159 N)
RALLIART Version-R6.0 (pedal pressure: 87 N)
7.0 (pedal pressure: 125 N)
Rear wheel hydraulic control methodElectronic brake-force
distribution (EBD)
Front brakesTy p eLS, VRFloating caliper, 1 piston,
ventilated disc (V4-S51)
VR-X, RALLIART Version-RFloating caliper, 1 piston,
ventilated disc (V5-S54)
Disc effective dia. ×
thickness mmLS, VR206 × 20
VR-X226 × 24
RALLIART Version-R232 × 25.8
Cylinder I.D. mmLS, VR50.8
VR-X, RALLIART Version-R54.0
Pad thickness mmLS, VR, VR-X10
RALLIART Version-R10.5
Clearance adjustmentAutomatic
Rear disc brakes
Vers i on -R>
Ty p eVR-XFloating caliper, 1 piston,
solid disc (S4-S30P)
RALLIART Version-RFloating caliper, 1 piston,
solid disc (S4-S34P)
Disc effective dia. ×
thickness mmVR-X224 × 10
RALLIART Version-R200.6 × 10
Cylinder I.D. mmVR-X30.2
RALLIART Version-R34.0
Pad thickness mmVR-X9.5
RALLIART Version-R10.0
Clearance adjustmentAutomatic
Rear drum brakes

Ty p eLeading trailing drum
Drum I.D. mm203
Cylinder I.D. mm19.0
Lining thickness mm4.0
Clearance adjustmentAutomatic
Brake fluidDOT3 or DOT4

CONSTRUCTION DESCRIPTION
BASIC BRAKE SYSTEM35A-5
CONSTRUCTION DESCRIPTION
MASTER CYLINDERM2350001000509
AC505737ABMaster cylinder
Reserve tank
Primary piston
Secondary piston
The master
cylind e r is a t andem-typ e, with a stru c-
ture that emp hasizes sa fety .
BRAKE BOOSTER
M23500020 0063 2
AC505736AB
Reaction disc
Booster return spring Push rod
Diaphragm
Operating rod
9-inch brake booste r has been inst alled. T he brake
booster employs a
variable amplification ratio mech
-
anism that va ries amplifications ratios so that e v en
sma
ll p edal force can provide gre a t brea kin g force.

CONSTRUCTION DESCRIPTION
BASIC BRAKE SYSTEM35A-6
BRAKE PEDAL
M2350007000154
AC207749
AC207292
AC207291AE
Fixed bolt
Stopper plate
Brake booster
Collision load Before collision
After collision
Reinforced bracket
Deck crossmember
Retreat locus of brake pedal during collision
Brake pedal position before collision Brake pedal position after collision
(Conventional)
Brake pedal position after collision
(Brake pedal rearward displacement preventio
nmechanism operated)
Reinforced bracket
The bra
k e pe dal re arward displacement preve n tion
mechanism
has been adop ted in ord e r to reduce the
driver
’ s le g and foot injury during fron t a l co llisio n .The brak e bo oste r is force d to move backward
accordin
g to ret r eatin g engine bo dy d u ring front al
collision a
nd the n the r e info rced b r acket is release d
from
the stopper plat e. Af ter release d , the reinf o rced
bracket is forced to
move backward and do wn wa rd
by gu
iding the rear end of the reinf o rced bracket
along
the stoppe r plate slo pe and it preve n t the back
-
ward and upward displace ment of the b r ake pedal.

CONSTRUCTION DESCRIPTION
BASIC BRAKE SYSTEM35A-7
FRONT BRAKE
M2350003000538
AC403189AE
14-inch disc brake

15-inch disc brake
Pad
Brake disk
Wear indicator When new When worn
Conventional structure
Caliper support
bracket Knuckle
•Ventilate d disc b r ake (V4−S51 or V5−S54) is
in
st
alled.
•The callipe r sup port bra c ket int egrated with the
kn
uckle h a s be en in st alled, achie v in g weigh t
redu
ction and optimising it for b r ake perform
-
ance.
•Audible wear indicat o r that informs th e driver of
wear limit is inst
alle d to th e inn e r brake p ad.
(Only lef
t side)
DISC BRAKE DESIGNA T ION
S 4 - S 30 P
1 2 3 4 5
AC403539
No.ItemContent
1Brake disc typeV: Ventilated
2Brake size
(Minimum applicable
disc wheel)4: 14-inch
5: 15-inch
3No. of pistonS: 1piston (floating type)
4Piston size (rounded
to nearest integer)30: φ 30 mm
34: φ 34 mm
51: φ 51 mm
54: φ 54 mm
5Parking brake
mechanismP: Set

CONSTRUCTION DESCRIPTION
BASIC BRAKE SYSTEM35A-8
REAR BRAKE
M2350004000531
AC403060AD
<8-inch leading trailing type drum brake> <14-inch disc brake>
•8-inch leading tra iling type drum brake, which
assure
s st ab le bra k in g force during forward or
rearward
movement, ha s bee n inst alle d. VR>
•Disc brake (S4 - S3 0 P ) ha s be en in st a l le d. RALLIAR
T V e rsion - R>
•An audible wear indicator th at in forms the d r ive r
of a
pplication limit has been inst a lled to the lef t
brake p
ad.
NOTE: For d i sc brake de sign ation , refer t o P.35A-7.

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 CLASSIFICA TION 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

CVT
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)23-2
CVT
GENERAL INFORMATIONM2231000100165
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
ItemSpecification
Transmission modelF1C1A
Engine model4A91
Torque converterTy p e3-element, 1-stage, 2-phase type
Lock-upProvided
Stall torque ratio2.0
Transmission typeForward automatic continuously variable (steel belt type),
1st in reverse
Gear ratioForward2.319 − 0.445
Reverse2.588
ClutchA pair of multi-plate system
BrakeA pair of multi-plate system
Manual control systemP-R-N-D-Ds-L (smart shift)
FunctionVariable speed controlYe s
Line pressure controlYe s
Direct engagement controlYe s
N-D/N-R controlYe s
Shift pattern controlYe s
Self-diagnosisYe s
FailsafeYe s
Oil pumpTy p eExternal gear pump
ConfigurationBuilt-in (chain drive)
Control methodElectronic control (INVECS-III)
Transmission oilSpecified lubricantsDIA QUEEN ATF SP III
Quantity L8.1