Mitsubishi MOTORS Colt 2000 Instruction manual

00
11
12
13
14
15
16
17
23
General ........................
Engine .........................
Engine Lubrication .............
Fuel ...........................
Engine Cooling .................
Intake and Exhaust .............
Engine Electrical ...............
Engine and Emission Control ....
Automatic Transmission ........
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This manual outlines changes in servicing
procedures related to the chassis including vehicle
inspections, adjustments and improvements in the
newly equipped models.
Please read this manual carefully so that it will be of
assistance for your service activities.
Please note that the following service manuals are
also available and should be used in conjunction
with this manual.
TECHNICAL INFORMATION MANUAL
PYME9501
PYME9501-1
WORKSHOP MANUAL
CHASSIS GROUP PWME9511 (Basic)
PWME9511-A (Supplement)
PWME9511-B (Supplement)
ENGINE GROUP PWEE____
(Looseleaf edition)
ELECTRICAL WIRING PHME9511 (Basic)
PHME9511-A (Supplement)
PHME9511-B (Supplement)
PHME9511-C (Supplement)
BODY REPAIR MANUAL PBME9501 (Basic)
PBME9501-1 (Supplement)
PBME9501-2 (Supplement)
PARTS CATALOGUE B806F006A_
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
EMitsubishi Motors Corporation Jun. 2000

WARNING!
(1) Improper service or maintenance of any component of the SRS and any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag or to the driver and passenger (from rendering the SRS inoperative).
(2) SRS components should not be subjected to heat, so remove the SRS-ECU, air bag module
(driver’s side and front passenger’s side), clock spring, side impact sensor and front seat
assembly (side air bag module) before drying or baking the vehicle after painting.
SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more
(3) Service or maintenance of any SRS component and SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance
of any component of the SRS and any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

00-1
GENERAL
CONTENTS
VEHICLE IDENTIFICATION 2.................
Models 2......................................
Model Code 2.................................
Chassis Number 3.............................
MAJOR SPECIFICATIONS 4...................
Hatchback 4...................................

GENERAL - Vehicle Identification
00-2
VEHICLE IDENTIFICATION
MODELS
Model code Engine model Transmission model Fuel supply system
CJ1A MNDEL6/R6 4G13 (1,298 mL) F5M41 <5M/T> MPI
MNJEL6/R6
(Electronically Controlled
Multi Point Fuel Injection)
CJ4A MNJEL6/R6 4G92 MPI (1,597 mL)
MRJEL6/R6 F4A41
<INVECS-II 4A/T>
MODEL CODE
No. Items Contents
1Development CJ: MITSUBISHI (2-door)
2Engine type 1: 1,298 mL petrol engine
4: 1,597 mL petrol engine
3 Sort A: Passenger car
4 Body style M: 2-door hatchback
5Transmission type N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6Trim level D: GL
J: GLX or GLXi
7Specification engine
feature
E: SOHC-MPI
8Steering wheel
location
L: Left hand
R: Right hand
9Destination 6: For Europe
CJ 4MNJEL6
2345678
A
9
1

GENERAL - Vehicle Identification 00-3
CHASSIS NUMBER
The chassis number is stamped on the toeboard inside the
engine compartment.
12 3 456789 11
10
No. Items Contents
1Fixed figure J Asia
2Distribution channel MJapan channel
3Destination AFor Europe, right hand drive
BFor Europe, left hand drive
4 Body style M 2-door hatchback
5Transmission type N5-speed manual transmission
R4-speed automatic transmission
6Development order CJ COLT
7Engine 14G13: 1,298 mL petrol engine
44G92: 1,597 mL petrol engine
8 Sort A Passenger car
9Model year 12001
10 Plant U Mizushima Motor Vehicle Works
11 Serial number - -

GENERAL - Major Specifications
00-4
MAJOR SPECIFICATIONS
HATCHBACK
2
57
9
4
1
86
3
Items CJ1A
MNDEL6,
MNDER6
CJ1A
MNJEL6,
MNJER6
CJ4A
MNJEL6,
MNJER6
CJ4A
MNJEL6,
MNJER6
Vehicle Overall length 13,900 3,900 3,900 3,900
dimensions
mm Overall width 21,680 1,680 1,680 1,680
mm
Overall height (unladen) 3 1,365,
1,380*1,
1,385*2,
1,400*3
1,365,
1,380*1,
1,385*2,
1,400*3
1,365,
1,380*1,
1,385*2,
1,400*3
1,365,
1,380*1,
1,385*2,
1,400*3
Wheelbase 42,415 2,415 2,415 2,415
Track-front 5 1,450 1,450 1,450 1,450
Track-rear 61,460 1,460 1,460 1,460
Overhang-front 7825 825 825 825
Overhang-rear 8660 660 660 660
Ground clearance (unladen) 9 150, 165*1,*3150, 165*1,*3150, 165*1,*3150, 165*1,*3
Vehicle Kerb weight 950 955 975 995
weight kg Max. gross vehicle weight rating 1,445 1,445 1,470 1,480
Max. axle weight rating-front 810 810 810 810
Max. axle weight rating-rear 705 705 705 705
Seating capacity 5
Engine Model No. 4G13 4G92
Total displacement mL 1,298 1,597
Transmission Model No. F5M41 F4A41
Type 5 speed-manual 4 speed-
automatic
Fuel system Fuel supply system MPI (Electronically Controlled Multi Point Fuel Injection)
NOTE
1. *1: indicates vehicles with high ground suspension.
2. *2: indicates vehicles with rear spoiler.
3. *3: indicates vehicles with high ground suspension and rear spoiler.

11A-1
ENGINE
CONTENTS
ENGINE <4G1> 11A......................................................
ENGINE <4G9> 11B......................................................

11A-2
ENGINE <4G1>
CONTENTS
GENERAL 3.................................
Outline of Changes 3..........................
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
SPECIAL TOOLS 4..........................
ON-VEHICLE SERVICE 5.....................
Compression Pressure Check 5.................
Lash Adjuster Check 5.........................
CAMSHAFT AND CAMSHAFT OIL SEAL 8....
CRANKSHAFT FRONT OIL SEAL 11..........
CYLINDER HEAD GASKET 12...............

ENGINE <4G1> - General/General Information/
Service Specifications/Sealant 11A-3
GENERAL
OUTLINE OF CHANGES
The following service procedures have been
established due to the addition of the 4G13-SOHC
16 valve MPI engine. Furthermore, other items are
the same as for the 4G13-SOHC 12 valve MPI
engine.
DThe basic ignition timing has been changed
as a direct-mounted crank angle sensor has
been used.
DThe compression pressure has been changed.
DAn auto-lash adjuster has been adopted.
DCamshaft and camshaft oil seal removal and
installation
DCrankshaft front oil seal removal and installation
DCylinder head gasket removal and installation
GENERAL INFORMATION
Items 4G13
Compression ratio 10.0
Combustion chamber Pentroof type
Number of valve Intake 8
Exhaust 8
Valve timing Intake Opening BTDC 17_
Closing ABDC 39_
Exhaust Opening BBDC 49_
Closing ATDC 7_
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS
Items Standard value Limit
Basic ignition timing 5_BTDC ±3_-
Compression pressure (250 – 400 r/min) kPa 1,598 Min. 1,161
Cylinder head bolt shank length mm -103.2
SEALANT
Items Specified sealant Remarks
Camshaft position sensor support MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant

ENGINE <4G1> - Special Tools
11A-4
SPECIAL TOOLS
Tool Number Name Use
MB990767 Front hub and
flange yoke holder
Holding the camshaft sprocket
MD998719 Crankshaft pulley
holder pin
MD998443 Auto-lash adjuster
holder
Supporting of lash adjuster
MD998713 Camshaft oil seal
installer
Press-in of the camshaft oil seal
MD998304 Crankshaft front oil
seal installer
Press-fitting the crankshaft front oil seal
MD998305 Crankshaft front oil
seal guide
MB991653 Cylinder head bolt
wrench
Cylinder head bolt removal and installation

ENGINE <4G1> - On-vehicle Service 11A-5
ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK
The disconnection of the distributor connector has been
changed to the disconnection of the crank angle sensor
connector due to the change of the crank angle sensor. Other
service procedures are the same as before.
Standard value (at engine speed of 250 - 400 r/min):
1,598 kPa
Limit (at engine speed of 250 - 400 r/min):
Min. 1,161 kPa
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused by
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied.
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)

ENGINE <4G1> - On-vehicle Service
11A-6
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters.
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters. (Refer to the Engine
Workshop Manual.)
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
Good
High-
pressure
chamber

ENGINE <4G1> - On-vehicle Service 11A-7
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
Gradually open the
throttle valve.
Drive pattern for air bleeding
Close the throttle
valve.
Approx.
3,000 r/min
15
seconds
15
seconds
Idle speed
Once

ENGINE <4G1> - Camshaft and Camshaft Oil Seal
11A-8
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DAir Cleaner Removal and Installation
DIgnition Coil Removal and Installation
(Refer to GROUP16.)
12
4
5
6
7
8
9
11
14
10
15
16
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
14
3
12
13
10 - 12 Nm
10 - 12 Nm
88 Nm
3.5 Nm
5.0 Nm
12 - 15 Nm
22 Nm
28 - 34 Nm
10 - 12 Nm
Apply engine oil to all
moving parts during
installation.
Removal steps
1. Breather hose connection
2. PCV hose connection
3. Accelerator cable clamp
<LH drive vehicles>
4. Rocker cover
5. Rocker cover gasket
6. Spark plug guide
7. Timing belt front upper cover
AA""
CA8. Camshaft sprocket
"BA9. Camshaft oil seal
AB""
AA10. Lash adjuster, intake rocker arm
and shaft assembly
AB""
AA11. Lash adjuster, exhaust rocker arm
and shaft assembly
12. Ignition failure sensor connector
13. Camshaft position sensor connector
14. Camshaft position sensor support
15. Camshaft
16. Camshaft position sensing cylinder

ENGINE <4G1> - Camshaft and Camshaft Oil Seal 11A-9
REMOVAL SERVICE POINTS
AA"CAMSHAFT SPROCKET REMOVAL
1. Turn the crankshaft in the forward direction (clockwise)
to align the timing mark so that No.1 cylinder is at the
compression TDC.
Caution
Always turn the crankshaft in the forward direction
(clockwise).
2. Secure the camshaft sprocket and the timing belt with
band cables to prevent deviation from the relative positions
between the camshaft sprocket and the timing belt.
3. Use the special tool to stop the camshaft sprocket from
turning.
4. Remove the camshaft sprocket with the timing belt
attached.
Caution
Do not turn the crankshaft after the camshaft sprocket
is removed.
AB"LASH ADJUSTER, INTAKE ROCKER ARM AND
SHAFT ASSEMBLY/LASH ADJUSTER, EXHAUST
ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
Before removing the lash adjuster, rocker arm and shaft
assembly, install the special tools as shown in the illustration
so that the lash adjusters will not fall out.
INSTALLATION SERVICE POINTS
"AALASH ADJUSTER, EXHAUST ROCKER ARM AND
SHAFT ASSEMBLY/LASH ADJUSTER, INTAKE
ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
Position the rocker arm shaft so that their notches point the
direction shown, and install the lash adjuster, rocker arm
and shaft assembly.
Timing mark
Camshaft
sprocket
MB990767
MD998719
MD998443
Notch
Front of engine
Notch

ENGINE <4G1> - Camshaft and Camshaft Oil Seal
11A-10
"BACAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
"CACAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
Tightening torque: 88 Nm
MD998713

ENGINE <4G1> - Crankshaft Front Oil Seal 11A-11
CRANKSHAFT FRONT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DTiming Belt Removal and Installation
DCrank angle sensor Removal and Installation
(Refer to GROUP16.)
5
1
2
3
4
5
(Lip)
Engine oil
Removal steps
"BA1. Crankshaft sprocket
"BA2. Spring pin
"BA3. Crankshaft sensing blade
"BA4. Crankshaft spacer
"AA5. Crankshaft front oil seal
INSTALLATION SERVICE POINTS
"AACRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Tap the oil seal unit it flushes with the oil seal case.
Crankshaft
MD998304
MD998305
Oil seal

ENGINE <4G1> - Crankshaft Front Oil Seal/Cylinder Head Gasket
11A-12
"BACRANKSHAFT SPACER/CRANKSHAFT SENSING
BLADE/SPRING PIN/CRANKSHAFT SPROCKET
INSTALLATION
Install the crankshaft sprocket assembled with the spring pin,
the crankshaft sensing blade, and the crankshaft spacer to
the crankshaft.
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DPrevention of Fuel Discharge <before removal only>
DFuel Leak Check <after installation only>
DUnder Cover Removal and Installation
DEngine Coolant Draining and Supplying
DEngine Oil Draining and Supplying
DAir Cleaner Removal and Installation
Crankshaft
sensing blade
Crankshaft
sprocket
Crankshaft
spacer
Spring pin
Front of
engine

ENGINE <4G1> - Cylinder Head Gasket 11A-13
1
2
3
6
8
9
11
12
13
14
15
16
18
19
20
22
21
23
17
4
5
7
10
24
25
(Engine oil)
(Engine oil)
49 Nm ®0Nm®20 Nm ®+90°®+90°(Cold engine)
10 - 12 Nm
88 Nm
10 - 12 Nm
35 Nm
50 Nm
24 Nm
5.0 Nm
Removal steps
1. Crank angle sensor connector
2. Detonation sensor connector
3. Oxygen sensor (rear) connector
4. Vacuum sensor connector
5. Ignition coil connector
6. Injector connector
7. EGR solenoid valve connector
8. Throttle position sensor connector
9. Idle speed control servo connector
10. Purge control solenoid valve
connector
11. Engine coolant temperature gauge
unit connector
12. Oxygen sensor (front) connector
13. Engine coolant temperature sensor
connector
14. Ignition failure sensor connector
15. Camshaft position sensor connector
DRocker cover (Refer to P.11A-8.)
DIntake manifold
(Refer to GROUP 15.)
DWater inlet pipe (Refer to GROUP 14.)
16. Front exhaust pipe connection
17. Front exhaust pipe gasket
18. Exhaust manifold bracket
19. Oil level gauge assembly
20. O-ring
21. Timing belt front upper cover
AA""
CA22. Camshaft sprocket
AB""
BA23. Cylinder head bolts
24. Cylinder head assembly
"AA25. Cylinder head gasket

ENGINE <4G1> - Cylinder Head Gasket
11A-14
REMOVAL SERVICE POINTS
AA"CAMSHAFT SPROCKET REMOVAL
1. Turn the crankshaft in the forward direction (clockwise)
to align the timing mark so that No.1 cylinder is at the
compression TDC.
Caution
Always turn the crankshaft in the forward direction
(clockwise).
2. Secure the camshaft sprocket and the timing belt with
band cables to prevent deviation from the relative positions
between the camshaft sprocket and the timing belt.
3. Use the special tool to stop the camshaft sprocket from
turning.
4. Remove the camshaft sprocket with the timing belt
attached.
Caution
Do not turn the crankshaft after the camshaft sprocket
is removed.
AB"CYLINDER HEAD BOLT REMOVAL
Use the special tool to loosen the bolts in 2 or 3 steps in
order of the numbers shown in the illustration, and remove
the cylinder head assembly.
Timing mark
Camshaft
sprocket
MB990767
MD998719
Front of engine
MB991653
1
2
3
4
5
6
7
8
9
10