Mitsubishi Colt Ralliart. Manual — part 271

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4A9>

11B-48

>>E<< BEARING CAP / BEARING CAP
BOLT INSTALLATION

AK305612

1

2

3

4

5

AB

Cap No.

1

2

3

4

5

6

7

8

9

10

1. Install the bearing cap, based on the identification

mark at the illustrated location.

AK402401

AC

Shank length

2. Before the bearing cap bolt is installed, make sure

the nominal length of the bolt is below the limit. If
above the limit, replace the bolt with the new one.

Standard value: 75.3 mm

3. Apply engine oil to the threaded portion and

seating face of the bolt.

4. Tighten the bearing cap bolts in the illustrated

sequence to 35

± 2 N⋅m.

CAUTION

• If the bolt is tightened less than the specified

lower limit of 60 degree angle, the bolt may
become loose. Be sure to tighten correctly.

• If the bolt is tightened in excess of the speci-

fied upper limit of 64 degree angle, loosen the
nut completely and repeat the entire proce-
dures.

AK304958AB

MB991614

5. Using the special tool Angle gauge (MB991614),

tighten the bearing cap bolts in the illustrated
sequence by a further 60 to 64 degree angle.

AK304956

6. With the bearing caps installed, check the

crankshaft end play. If the measured value
exceeds the limit, replace the crankshaft bearings.

Standard value: 0.09

− 0.27 mm

Limit: 0.30 mm

Main

Index

Group

TOC

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4A9>

11B-49

>>F<< OIL SEAL CASE INSTALLATION

1. Remove any liquid gasket remaining on the oil

seal case and the cylinder block.

CAUTION

The oil seal case should be installed within 3
minutes of applying liquid gasket.

AK305614AB

Cylinder block

2. Apply a 2.0

± 0.5 mm bead of liquid gasket as

illustrated.

Specified sealant:

LOCTITE 5971 or equivalent

3. Install the oil seal case, tightening the fittings to

7.6

± 0.6 N⋅m.

>>G<< DRIVE PLATE BOLT
INSTALLATION

1. Remove any sealant remaining on the drive plate

bolt or the threaded hole in the crankshaft.

CAUTION

Apply sealant correctly so that it will not be
squeezed out onto the end of the threaded por-
tion upon assembly.

AK401813 AC

2. Apply sealant to the threaded portion of the drive

plate bolt as illustrated.

Specified sealant:

LOCTITE 2701 or equivalent

AK600409AB

MB991883

<M/T>

AK600407

MD998781

Cylinder block

Drive plate

AB

<CVT>

3. Fix the drive plate or the flywheel in place using

the special tool Flywheel stopper.

• Flywheel Stopper (MD998781)

•

AK402712 AB

1

3

2

5

6

4

Flywheel Stopper (MB991883)

4. In accordance with the numerical order shown in

the illustration, tighten the drive plate bolt to the
specified torque of 100

± 5 N⋅m in several steps.

Main

Index

Group

TOC

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4A9>

11B-50

INSPECTION

M1113008800849

CRANKSHAFT OIL CLEARANCE (USING
PLASTIGAGE)

Oil clearance can be measured easily by using "plas-
tigage."
Use the "plastigage" in the following manner.
1. Wipe off oil from the surfaces of the crankshaft

journals as well as the inner surfaces of the
bearings.

2. Assemble the crankshaft.

AK304954

Plastigage

AB

3. Place a plastigage, with a length equal to the

width of the bearing, onto the journals in the axial
direction.

4. Carefully place the main bearing caps, and tighten

the bolts to the specified torque.

5. Remove the bolts. Carefully remove the main

bearing caps.

AK304955AB

Plastigage

6. Using the measure printed on the plastigage

package, measure the width (widest portion) of
the crushed plastigage.

Standard value: 0.014

− 0.034 mm

Limit: 0.1 mm

CYLINDER BLOCK

1. Check visually for scoring, rust, or corrosion.

Perform liquid penetrant test etc. to check for
cracks. If faulty, replace.

AK304960

2. Using a straight edge or a thickness gauge,

measure the flatness of the cylinder block top
surface. Ensure that no gasket or other foreign
matter is attached to the top face.

Standard value: 0.05 mm
Limit: 0.1 mm

3. Check the cylinder bore for scoring or seizure. If

faulty, correct (boring) or replace.

AK304959AB

12 mm

4. Using a cylinder gauge, measure the cylinder

bore and centricity. If excessively worn, bore the
cylinder and replace the piston and piston rings.

Standard value:

Inner diameter 75.0 mm
Cylindrically 0.007 mm

Main

Index

Group

TOC

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4A9>

11B-51

BORING CYLINDERS

AK401446AB

A

1. Oversize pistons should be based on the largest

bore cylinder.

Size

Size mark

0.25 mm oversize

25

NOTE: The size mark is stamped on the piston
top.

2. In case of 0.25 mm oversized piston, a hole shall

be bored through the cylinder block so that the
clearance can have the standard value. The
standard measuring point for the outside piston
diameter is at "A" shown in the illustration.

Standard measuring point A: 12.0 mm

3. Based on the measured piston outside diameter

(O.D.), calculate the boring finish dimension.

Boring finish dimension = Piston O.D. +
0.015

− 0.035 mm (Clearance between piston

O.D. and cylinder) - 0.02 mm (honing margin)

4. Bore each cylinders to the calculated boring finish

dimension.

CAUTION

To prevent distortion caused by heat increased
during boring, bore the cylinders in the following
order: No.2, No.4, No.1, No.3.
5. Hone the cylinders to the final finish dimension

(piston O.D. + piston-to-cylinder clearance).

6. Check the clearance between the pistons and

cylinders.

Standard value: 0.015

− 0.035 mm

NOTE: When boring cylinders, finish all of four
cylinders to the same oversize. Do not bore only
one cylinder to an oversize.

Main

Index

Group

TOC