Mitsubishi Colt Ralliart. Manual — part 601
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REWORK DIMENSIONS
ENGINE OVERHAUL <4G1>
11D-4
REWORK DIMENSIONS
M1113024300480
Item
Standard value
Standard value
CYLINDER HEAD AND VALVES
Cylinder head oversize valve guide hole diameter mm
0.05 O.S.
10.55
− 10.57
0.25 O.S.
10.75
− 10.77
0.50 O.S.
11.00
− 11.02
Cylinder head oversize valve seat hole diameter, intake mm
0.30 O.S.
31.30
− 31.33
0.60 O.S.
31.60
− 31.63
Cylinder head oversize valve seat hole diameter, exhaust mm
0.30 O.S.
27.80
− 27.82
0.60 O.S.
28.10
− 28.12
TORQUE SPECIFICATIONS
M1113023401777
Cylinder bore diameter mm
75.50
− 75.53
−
Taper of cylinder mm
0.01 or less
−
Cylinder-to-piston clearance mm
0.02
− 0.04
−
Item
Standard value
Limit
Item
N
⋅m
ALTERNATOR AND IGNITION SYSTEM
Oil level gauge guide bolt
24
± 4
Water pump pulley bolts
9.0
± 2.0
Crankshaft bolts
181
Alternator brace bolt (alternator side)
22.5
± 2.5
Alternator brace bolt (tightened with water pump)
24
± 3
Alternator nut
44
± 10
Adjusting bolt
5.0
± 1.0
Ignition coil bolts
10
± 2
Spark plug
25
± 5
Cam position sensor bolt
8.8
± 1.0
Cam position sensor support bolts
14
± 1
TIMING BELT
Timing belt cover bolts
11
± 1
Rocker cover bolts
5.0
± 1.0 → 7.0 ± 1.0
Plug cap
21
± 3
Tensioner pulley bolt
48
± 6
Main
Index
Group
TOC
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TORQUE SPECIFICATIONS
ENGINE OVERHAUL <4G1>
11D-5
Tensioner arm bolt
48
± 6
Auto-tensioner bolts
23
± 3
Idler pulley bolt
44
± 10
Crank angle sensor bolts
9.8
± 2.0
V.V.T. sprocket bolt
55
± 5
Camshaft sprocket bolt
88
± 10
Engine support bracket bolts, nut
36
± 6
FUEL AND EMISSION PARTS
Throttle body bolts
13
± 2
Solenoid valve bolts
9.0
± 1.0
Purge valve bolts
5.0
± 1.0
Delivery pipe and injector bolts
12
± 1
Fuel pressure regulator bolts
12
± 1
Vacuum pipe bolts
9.0
± 1.0
Solenoid valve nut
5.0
± 1.0
WATER PUMP AND WATER HOSE
Engine coolant temperature sensor
29
± 10
Water inlet fitting bolts
22
± 4
Water pipe bolts (M6)
10
± 2
Water pipe bolt s(M8)
13
± 2
Water inlet pipe bolts
13
± 2
Water pump bolts
14
± 1
INLET MANIFOLD
Inlet manifold stay bolts (M8)
18
± 2
Inlet manifold stay bolts (M10)
31
± 3
Inlet manifold bolts and nuts
18
± 2
Engine hanger bolt
19
± 3
EXHAUST MANIFOLD
Oxygen sensor
50
± 10
Turbocharger cover bolts
10
± 2
Oil return pipe bolts
10
± 2
Exhaust fitting bracket bolts
35
± 6
Exhaust fitting bolts
59
± 5
Turbocharger bracket bolts (turbocharger side)
59
± 5
Turbocharger bracket bolts (cylinder block side)
35
± 6
Oil pipe bolt (flange bolt)
10
± 2
Oil pipe bolt (eye bolt)
17
± 2
Turbocharger bolts, nuts
59
± 5
Water pipe bolt (eye bolt)
31
± 2
Water pipe bolt (flange bolt)
10
± 2
Item
N
⋅m
Main
Index
Group
TOC
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TORQUE SPECIFICATIONS
ENGINE OVERHAUL <4G1>
11D-6
Exhaust manifold nuts (M8)
29
± 3
Exhaust manifold nuts (M10)
49
± 5
Thermostat housing hanger bolt
24
± 4
Engine hanger bolt
19
± 3
ROCKER ARMS AND CAMSHAFT
Oil feeder control valve bolt
11
± 1
Oil pipe eye-bolt (cylinder block side)
30
± 3
Oil pipe eye-bolt (cylinder head side)
42
± 2
Cam position sensing cylinder bolt
22
± 4
Front bearing cap bolt
21
± 2
Rear bearing cap bolts
21
± 2
Bearing cap bolts
11
± 1
CYLINDER HEAD AND VALVES
Cylinder head bolts
49
→ 0 → 20 → +90° +90°
OIL PUMP AND OIL PAN
Oil cooler bolt
27
± 2
Oil pressure switch
10
± 2
Drain plug
39
± 5
Oil pan bolts
7.0
± 1.0
Transmission stay bolts
23
± 4
Oil screen bolts
19
± 3
Baffle plate bolts
10
± 2
Relief plug
44
± 5
Oil pump case bolts
14
± 1
Oil pump cover bolts
10
± 2
PISTONS AND CONNECTING RODS
Connecting rod cap nuts
17
± 2 → +90° to 94°
CRANKSHAFT AND CYLINDER BLOCK
Flywheel bolts
132
± 5
Rear plate bolts
10
± 2
Oil seal case bolts
11
± 1
Bearing cap bolts
34
± 2 → +30° to 34°
Detonation sensor bolts
20
± 1
Item
N
⋅m
Main
Index
Group
TOC
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SEALANTS
ENGINE OVERHAUL <4G1>
11D-7
SEALANTS
M1113000500899
Item
Specified sealant
Camshaft position sensor support*
Mitsubishi Genuine Part No. 970389 or
equivalent
Rocker cover*
Mitsubishi Genuine Part No. 970389 or
equivalent
Engine coolant temperature sensor
3M Nut Locking Part No.4171 or
equivalent
Cylinder head (camshaft bearing cap fitting section)
3M ATD No.8660 or equivalent
Oil pan*
Mitsubishi Genuine Part No. 970389 or
equivalent
Oil pump case*
Mitsubishi Genuine Part No. 970389 or
equivalent
Oil pressure switch
3M ATD No.8660 or equivalent
Rear oil seal case*
Mitsubishi Genuine Part No. 970389 or
equivalent
NOTE: *: Part to be sealed with a form-in-place gas-
ket (FIPG)
FORM-IN-PLACE GASKET (FIPG)
This engine has several areas where the
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when apply-
ing it.
Bead size, continuity and location are of paramount
importance. Too thin a bead could cause leaks. Too
thick a bead, on the other hand, could be squeezed
out of location, causing blocking or narrowing of fluid
passages. To prevent leaks or blocking of passages,
therefore, it is absolutely necessary to apply the
FIPG evenly without a break, while observing the
correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
Disassembly
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.
Surface Preparation
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
Make sure that the FIPG application surface is flat
and smooth. Also make sure that the surface is free
from oils, greases and foreign substances. Do not fail
to remove old FIPG that may remain in the fastener
fitting holes.
FIPG Application
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 15 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installa-
tion. Avoid operating the engine or letting oils or
water come in contact with the sealed area before a
time sufficient for FIPG to harden (approximately one
hour) has passed. FIPG application method may
vary from location to location. Follow the instruction
for each particular case described later in this man-
ual.
Main
Index
Group
TOC
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