2006 MITSUBISHI COLT Service Repair Manual

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).

MAIN BODY
BODY42-3
MAIN BODY
BODY PANELINGM2420002000636
AB200766
AB400640AD : High-tensile steel panels : Anti-corrosion steel panels

MAIN BODY
BODY42-4
•RISE (Reinforced Impact Safety Evolution) has
been adopted for the main body in order to
ensure all-round impact safety at high level.
•The use range of rust-resistant steel plates has
been expanded and high strength steel plates
have been optimally arranged. In addition,
rust-resistant steel plates are adopted for items
such as the hood, doors, inner panels of tailgate,
and reinforcements in order to improve the rust
resistance of the main body and to reduce its
weight.
•Sealer has been applied to the entire folded area
of the flanges for the doors, hood, and tailgate in
order to improve rust resistance.
BODY SHELL
M2420003000651
IMPACT SAFETY BODY RISE (REIN-
FORCED IMPACT SAFETY EVOLUTION)
AB201266
AB201267AB502015
AB400214
AB
1
2
4
Front sidemember inner
Front sidemember outer
B AA
B
Section B – B Section A – A
Front sidemember inner
Front sidemember outer
3
The fron
t and re ar st ructure s to abso r b hig h ener gy ,
and the
high ly tough cabin str u cture reduce the risk
of p
a ssenger inju ries at fron t-, rear-, and side-imp a ct
collisions, se
cure the sp a c e fo r life protection , and
facilit
ate rescuing p a sse ngers. The structures also
have
the followin g feat ures:1.The front side of the front sidemember , for wh ich
oct a gonal section stru cture is a dopted , has been
enlarged for improved rigidity .
2.The rear side o f the fr ont sidememb e r , for which
8-shape cross section struct ure is adop ted, ha s
bee n enlarged for improved rig i dity .

MAIN BODY
BODY42-5
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, increas
-
ing 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.
UNEVEN THICKNESS STEEL PLATE
AB400963
AB400941
AC
The rear door inner panel
is thicker toward the front of the vehicle.The front sidemember rear
is increasingly thicker toward
the front of the vehicle.The front floor pan
is thicker at the inner part.
The front door inner panel
is thicker toward the front of the vehicle.
The centre pillar reinforcement
is thicker at the upper part. (With the side outer panel removed) The tailgate inner panel
is thicker at the upper part.
The rear floor sidemember
is thicker at the front part.
Uneven thickness steel plate* wit h inte grate d uneven
thickness structure ha
s bee n ado pted fo r imp r ove d
safet
y upo n imp a ct an d redu ced weight.NOTE: *: S t ee l p l a t es with di ffer ent th ickn ess welded
togethe
r to make one steel plate .

MAIN BODY
BODY42-6
DRIVING STABILITY
AB502016
AB400213
A
A
Cowl top lower panel
Spring house panel
Corner of door opening
Corner of tailgate opening
AB
Section A – A
1.
The cowl t op lo we r p a nel a nd the spring ho use
p a n e l h a ve be en dire ct ly inst alled , a n d th e rigidity
of the fro n t suspen sion inst allation area ha s b een
in creased, in orde r to improve drivin g st abilit y .2.In o r der to imp r ove h andling st ability , th e radius
of t he ope ning corne r s for the do or and t a ilgat e
has bee n enlarged t o driving rigidity of the frame
connection s.

MAIN BODY
BODY42-7
DRIVING STABILITY
AB400932
AB400232AB400233
AB400213A
A
Cowl top lower panel
Spring house
panel
Corner of door opening
Corner of tailgate opening
AB
Section A – A1
2
2
4,5
3
Upper frame to
front pillar brace
Front upper
outer plate
Front upper
frame outer
Cowl top extension lower
1.
The cowl t op lo we r p a nel a nd the spring ho use
p a n e l h a ve be en dire ct ly inst alled , a n d th e rigidity
of the fro n t suspen sion inst allation area ha s b een
in creased, in orde r to improve han dling st ab ility .
2.In o r der to imp r ove h andling st a b ility , the radius
of t he ope ning corne r s for the do or and t a ilgate
has bee n enlarged t o increase rigidity of th e
frame connection s.
3.The cowl t op extension lower has bee n adde d to
the cowl t op p anel and d i rectly secured t o the
sp ring house p anel. This improves rigidity a t the
su spen sio n mo untin gs.
4.Driving st ability has bee n improved by jo ining the
fron t uppe r frame outer a nd the front p illar by the
upp er frame-to-fro nt pillar b r ace . (RALL I AR T V e r
-
sion-R)
5.Rigidity has been impr ove d at the suspension
mountings b y joining the front u pper fra m e ou ter
and the cowl top lower p a n e l by the t h icker fro n t
upp er oute r plat e.

MAIN BODY
BODY42-8

AB600121
AB400213
AD
1
2
Rear pillar inner reinforcementRear wheel house inner gusset
COLT RAL L IAR T V e rsion-R h a s th e stre ngthen ed
point
s as fo llo ws.
1.The rear pilla r inne r reinf o rcement h a s b een
add ed to impro v e to rsional rigid i ty of the body .
2.The rear whee l hou se inner gu sset has been
add ed to impro v e re ar su spen sio n inst a lla tion
rigidity .
3.The sid e oute r p a nel, cowl t op oute r p anel, and
rear end inner p ane l have be en thickened to
imp r ove the rigidity of suspe n sion inst allat i o n a n d
bod y .
4.The number of spot welding poin t s on th e body
ope ning has been incre a sed by 1 . 5 times of the
co nve n t i on al n u mb er t o imp r o v e th e ri gid i t y o f th e
ent ire bo dy .

MAIN BODY
BODY42-9
QUIETNESS
M2420004000416
AB201000
AB400213
12
3
2
AB
1.The sid e me mbers have bee n stra ighte ned fro m
the front to the rea r in o r der to r educe vibratio ns.
2.The cowl t op lo we r p a nel a nd the spring ho use
p anel of the front suspension h a ve b een direct ly
in st alled, an d an ab sorbe r rein forcement has
bee n adop ted for the rea r suspension . Conse
-
quently , rigid i ty of the suspension inst allation
area
is increase d , and incoming roa d noise is
redu
ced.
3.The front floor p an has b een curve d to suppress
vibration an d noise.
BODY COLOUR CHARTS
M24200050 0120 7
ColourColour codeColour numberColour name (Previous name)Composition
of film
WARM SILVERA17CMA10017Warm Silver MetallicMetallic
SILVERA19CMA10019Cool Silver MetallicMetallic
DARK GREYA72CMA10072Dark Bluish MicaPearl
PA L E B L U ET68CMT10068Pale Blue MetallicMetallic
PALE GREENF07CMF10007Pale Green MicaPearl
BLACKX24CMX10024Black Mica (Pyrenees Black)Pearl
WHITEW23CMW10023White PearlPearl
WHITEW32AC11032White Solid (Fairy White)Solid
REDP26CMP10026Red MetallicMetallic
YELLOWY05CMY10005Light Yellow PearlPearl
NOTE: For p a intin g , in ner p anel colours sho u ld b e similar to t he oute r p anel colours.