roof MITSUBISHI COLT 2006 Service Repair Manual

GENERAL INFORMATION
ENGINE MECHANICAL <4G1>11B-2
GENERAL INFORMATION
M2112000101010
The 4G15-MIVEC-T/C engine employed in the Colt
is designed to provide higher performance and
higher output by using a turbocharger to the
4G15-MIVEC engine employed in the conventional
Colt. The main changes in the conventional
4G15-MIVEC engine are as follows:•Cylinder head gasket changed
•Oil jet added
•Strength improved in piston and piston pin
MAJOR SPECIFICATIONS
Item4G15-MIVEC-T/C
Total displacement mL1,468
Bore × Stro ke mm75 × 82.0
Compression ratio9.0
Compression chamberPentroof-type
Va l v e t i m i n gIntake openingBTDC 34° − AT D C 6°
Intake closingABDC 30° − ABDC 70°
Exhaust openingBBDC 50°
Exhaust closingATDC 10°
Maximum output kW (PS)/rpm113 (154)/6,000
Maximum torque N⋅m (kg⋅m)/rpm210 (21.4)/3,500
Fuel systemElectronically controlled multipoint fuel injection
Ignition systemElectronic-controlled 4-coil

GENERAL INFORMATION
ENGINE MECHANICAL <4A9>11A-2
GENERAL INFORMATION
M2112000100697
The newly developed 1.5L 4A91 engine features
4-cylinder, 16-valve, and double overhead camshafts
(DOHC).
The engine has the following features.
•Aluminum cylinder block
•MIVEC (Mitsubishi Innovative Valve timing Elec-
tronic Control system)
•Selective valve tappet of direct acting valve sys-
tem for valve clearance adjustment
•Timing chain
MAJOR SPECIFICATIONS
Item4A91
Total displacement mL1,499
Bore × Stro ke mm75 × 84.8
Compression ratio10.0
Compression chamberPentroof-type
Va l v e t i m i n gIntake openingBTDC 31° − AT D C 1 9°
Intake closingABDC 21° − ABDC 71°
Exhaust openingBBDC 39°
Exhaust closingATDC 5°
Maximum output kW (PS)/rpm77 (104)/6,000
Maximum torque N⋅m (kg⋅m)/rpm141 (14.4)/4,000
Fuel systemElectronically controlled multipoint fuel injection
Ignition systemElectronic-controlled 4-coil

BASE ENGINE
ENGINE MECHANICAL <4A9>11A-3
BASE ENGINE
M2112001000864
CYLINDER HEAD
AK305050AB
Spark plug guide
Intake
side
Exhaust
side
Valve guide
The cylinder head is made of aluminu m alloy , which
is light
we ight a nd ha s an excelle nt co oling ef ficiency .
The pentroof type comb ustion chamb e r has a sp a r k
plug in the
cent er . The valve an gle is relatively small,
contributing to size redu
ctio n.
The int a ke an d exhaust port s a r e arrang ed in a
cross-flow construction.
Ea ch cylinde r has a p a ir of
int
a ke port s on one side and a p a ir of e x hau st po rt s
on the
other side .
Each o f the int a ke a nd exhaust ca msh a f t s is sup-
ported by 5 bearin gs. On ea ch camshaf t, th e thrust
load
is suppo rted by No. 1 b earin g. The No . 1 bea r
-
ings for the int a ke and exha ust camshaf t s ha ve a
common bearing
ca p.
VALV E S E AT
AK305052
d
AB
d
DD h
h
Intake
Exhaust
Sintered
alloy valve seat
ItemIntakeExhaust
D (Outer
diameter) mm31.528
d (Inner
diameter) mm2622
h (height) mm6.67.3

GENERAL INFORMATION
ENGINE MECHANICAL <4A9>11A-18
GENERAL INFORMATION
M2112000101009
The newly developed 1.5L 4A91 engine features
4-cylinder, 16-valve, and double overhead camshafts
(DOHC).
The engine has the following features.
•Aluminum cylinder block
•MIVEC (Mitsubishi Innovative Valve timing Elec-
tronic Control system)
•Selective valve tappet of direct acting valve sys-
tem for valve clearance adjustment
•Timing chain
MAJOR SPECIFICATIONS
Item4A91
Total displacement mL1,499
Bore × Stro ke mm75 × 84.8
Compression ratio10.0
Compression chamberPentroof-type
Va l v e t i m i n gIntake openingBTDC 31° − AT D C 1 9°
Intake closingABDC 21° − ABDC 71°
Exhaust openingBBDC 39°
Exhaust closingATDC 5°
Maximum output kW (PS)/rpm77 (104)/6,000
Maximum torque N⋅m (kg⋅m)/rpm141 (14.4)/4,000
Fuel systemElectronically controlled multipoint fuel injection
Ignition systemElectronic-controlled 4-coil

BASE ENGINE
ENGINE MECHANICAL <4A9>11A-19
BASE ENGINE
M2112001000875
CYLINDER HEAD
AK305050AB
Spark plug guide
Intake
side
Exhaust
side
Valve guide
The cylinder head is made of aluminu m alloy , which
is light
we ight a nd ha s an excelle nt co oling ef ficiency .
The pentroof type comb ustion chamb e r has a sp a r k
plug in the
cent er . The valve an gle is relatively small,
contributing to size redu
ctio n.
The int a ke an d exhaust port s a r e arrang ed in a
cross-flow construction.
Ea ch cylinde r has a p a ir of
int
a ke port s on one side and a p a ir of e x hau st po rt s
on the
other side .
Each o f the int a ke a nd exhaust ca msh a f t s is sup-
ported by 5 bearin gs. On ea ch camshaf t, th e thrust
load
is suppo rted by No. 1 b earin g. The No . 1 bea r
-
ings for the int a ke and exha ust camshaf t s ha ve a
common bearing
ca p.
VALV E S E AT
AK305052
d
AB
d
DD h
h
Intake
Exhaust
Sintered
alloy valve seat
ItemIntakeExhaust
D (Outer
diameter) mm31.528
d (Inner
diameter) mm2622
h (height) mm6.67.3

GROUP 42
BODY
CONTENTS
GENERAL INFORMATION . . . . . . . .42-2
MAIN BODY . . . . . . . . . . . . . . . . . . . .42-3
BODY PANELING . . . . . . . . . . . . . . . . . . . . 42-3
BODY SHELL . . . . . . . . . . . . . . . . . . . . . . . 42-4
QUIETNESS . . . . . . . . . . . . . . . . . . . . . . . . 42-9
BODY COLOUR CHARTS . . . . . . . . . . . . . 42-9
HOOD <4G1> . . . . . . . . . . . . . . . . . . .42-10
STRUT TOWER BAR <4G1>. . . . . . .42-10
DOOR . . . . . . . . . . . . . . . . . . . . . . . . .42-11
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . 42-11
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . 42-13
POWER WINDOW . . . . . . . . . . . . . . . . . . . 42-15
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . 42-17
PROTECTOR FILM. . . . . . . . . . . . . . .42-17
WINDOW GLASS . . . . . . . . . . . . . . . .42-18
SUNROOF. . . . . . . . . . . . . . . . . . . . . .42-20
LOOSE PANELS <4G1> . . . . . . . . . .42-22

GENERAL INFORMATION
BODY42-2
GENERAL INFORMATION
M2420000100842
FEATURES
WEIGHT REDUCTION AND HIGH RIGID-
ITY
•Application ranges of high tension steel plate,
antirust steel plate, and uneven thickness steel
plate have been expanded.
•The upper frame outer and front pillar connection
has been strengthened by adopting the upper
frame-to-front pillar brace.
•The radius of each opening corner for the doors
and tailgate has been enlarged.
•Cowl top lower panel and spring house panel are
directly joined for higher rigidity.
•Strut tower bar has been adopted <4G1>.
•A front suspension axle side plate has been
adopted <4G1>.
•The air outlet garnish has been installed to the
hood, improving the sporty image and cooling
efficiency in the engine compartment. <4G1>
REDUCTION OF VIBRATION, NOISE, AND
AERODYNAMIC NOISE
•Straight frame structure has been adopted.
•Curved front floor and uneven thickness steel
plate have been adopted.
•Rigidity of the suspension installation part has
been improved.
IMPROVEMENTS IN SAFETY
•RISE (Reinforced Impact Safety Evolution) has
been used for the main body.
•Features a side door beam to boost safety upon
side impact.
•Direct combination key cylinder and inside lock
cables for the front doors have been adopted to
improve safety upon impact.
IMPROVEMENTS IN OPERATION
QUALITY
•The central door locking system, which
locks/unlocks all the doors and the tailgate, is
adopted.
•"P" position shift linked door-unlock function has
been introduced to the central door locking sys
-
tem(F1C1A).
IMPROVEMENTS OF PRODUCT
PACKAGE AND APPEARANCE
•Rigidity of door sash bottom section has been
improved.
•By improving the engaging sound between the
door latch and striker, the door locking sound
quality has been enhanced.
•UV & heat protect glass has been used for the
windshield.
•UV-reducing glass has been used for the front
door window glasses and rear door window
glasses.
•Privacy glasses have been used for rear door
window glasses, quarter window glasses, and
tailgate window glass (Option).
•Multi-mode keyless entry system (with door mir-
ror retraction/return control function) has been
adopted.
•Protector film has been attached on side sill
.
•Sunroof has been installed (Option).

PROTECTOR FILM
BODY42-17
WEATHERSTRIP
M2420020000223
Double weather strips have been installed along the
perimeter of the door window, improving sound-proof
and water-proof performances.
CONSTRUCTION DIAGRAM
AC510034AB
AA A
A
Door opening
weatherstrip
Door window
glass
Runchannel
Section A – A
PROTECT
O R FILM
M24200210 0018 5
A pr otector film h a s be en ad ded on the lower p a rt of
the side sill to pr
otect it ag ainst the chip ping ston es
and p
r even t the p a int peel dam>.
CONSTRUCTION DIAGRAM
AC510033AB
Protector film

WINDOW GLASS
BODY42-18
WINDOW GLASS
M2420015000669
Laminated glass is used for the windshield and rein-
forced glass for the other windows. The window
glasses have the following features.
•UV & heat protect glass has been used for the
windshield as standard.
•The ultraviolet (UV) shield glasses have been
used for the front door window glasses and rear
door window glasses as standard.
•Privacy glasses have been used for rear door
window glasses, quarter window glasses, and
tailgate window glass as an option.
VISIBLE RAY TRANSMISSIVITY RATE FOR WINDOW GLASS
AC401290AC206463AB
1
2 3
45 6
7
No.NameTy p eThick
ness
(mm)ColourVisible ray
transmissivity
rate (%)
1WindshieldLaminated glass
(UV & Heat
protect glass)4.4Green74.4
2Delta window glassTempered glass2.8Green83
3Front door window glass3.1Green (UV shield glass)75
4Rear door window glass3.1Green (UV shield glass)75
Dark grey (privacy glass)25
5Quarter window glass2.8Green83
Dark grey (privacy glass)28
6Tailgate window glass3.1Green83
Dark grey (privacy glass)25
7Sunroof lid glass4.0Dark grey10
NO
TE: The visible ray transmissivity ra t e (%) is a re ference va lue.

SUNROOF
BODY42-20
SUNROOF
M2420016000242
Electric sliding glass sunroof with tilt-up mechanism
has been adopted (Option). This sunroof features the
following characteristics.
•Lightweight sunroof have been adopted.
•The sunroof tilts up for approx. 30mm to improve
ventilation performance.
•The integrated switch allows for all slide
open/close, tilt up/down and stop operations.
•If external force is applied during slide closing or
tilt down operations that obstructs operations,
then the sunroof lid glass will stop according to
the jam prevention mechanism.
CONSTRUCTION DIAGRAM
AC206680 AB
Sunroof lid glass Drain hose
Drain hose
Sunroof motor assembly
(integrated into sunroof-ECU) Sunshade
Open switch
Tilt-up switch
Close/tilt-down switch
Drain hose
DESCRIPTION OF
STRUCTURE AND
OPERA
T ION
SUNROOF FUNCTION
The sunroof may operat e in the way similar to th e
jam preve
n tion function of the sunro o f due to so me
driving condition
s or environment. In the case, move
the sunroof t
o fully closed po sit i on a s described
below
.
1.T u rn ON and hold the sunroo f switch un til t he
sunroo f moves in the desired d i rection and stop s.
2.If the sunroof does not move to the fully closed
p o sit i on b y the operat ion in S t ep 1 and the jam
p r even tion f unction op erat es again, release the
sunroo f switch. Th en within the elap se of 3
seco nds, turn ON and ho ld it again until th e
sunroo f stop s at the fully closed position.
If the sunroof does not o perate corre ctly even af ter
step
2 is performed 4 times, re fer to th e W o rksh op
Manu
al.