Mitsubishi Colt Ralliart. Manual — part 657

ENGINE ASSEMBLY

ENGINE MECHANICAL <4G1>

11C-48

REMOVAL SERVICE POINTS
<<A>> GEARSHIFT AND SELECT CABLE
DISCONNECTION

AC311252AB

Transmission lever

Cable

Section A - A

Lever

Gearshift and select cables

A

A

A

A

1. Disconnect the transmission

assembly-transmission lever from the ends of the
gearshift and select cables.

2. With the bracket installed, remove the gearshift

and select cables from the transmission
assembly.

3. After removing the gearshift and the select cables,

tie them in a place where it will not be a hindrance
when removing and installing the engine and
transmission assembly.

<<B>> FUEL HIGH-PRESSURE HOSE
DISCONNECTION

AC402313AB

Fuel high-pressure hose

Stopper

1. Remove the fuel high-pressure hose stopper.

AC402314AC

Fuel high-pressure
hose

Retainer

2. Raise the retainer, and pull out the fuel

high-pressure hose.
NOTE: If the retainer is released, install it after
removing the fuel high-pressure hose.

<<C>> OXYGEN SENSOR REMOVAL

AC301966

AB

MB991953

Oxygen sensor

Remove the connection and clamp of oxygen sensor
connector, and then use special tool oxygen sensor
wrench (MB991953) to remove the oxygen sensor.

Main

Index

Group

TOC

ENGINE ASSEMBLY

ENGINE MECHANICAL <4G1>

11C-49

<<D>> A/C COMPRESSOR DRIVE BELT
REMOVAL

AC205665AB

Adjusting bolt

Tensioner
pulley

Locking nut

1. Loosen the locking nut of the tensioner pulley

CAUTION

To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
2. Turn the adjusting bolt in the anti-clockwise

direction (to the left) to remove the drive belt.

<<E>> ALTERNATOR DRIVE BELT
REMOVAL

AC402698

Adjusting
bolt

Nut

Locking bolt

AC

1. Loosen the nut for alternator pivot bolt and locking

bolt.

CAUTION

To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
2. Turn the adjusting bolt in the anti-clockwise

direction (to the left) to remove the drive belt.

<<F>> A/C COMPRESSOR AND MAGNET
CLUTCH ASSEMBLY REMOVAL

1. With the hose installed, remove the A/C

compressor and clutch assembly from the
bracket.

2. After removing the A/C compressor and clutch

assembly, secure it with a cord in the location
where the removal and installation of the engine
and transmission assembly cannot be hindered.

<<G>> CLUTCH RELEASE CYLINDER
ASSEMBLY REMOVAL

1. With the hose installed, remove the clutch release

cylinder assembly from the transmission
assembly.

2. Secure the removed clutch release cylinder

assembly with cord or rope at a position where
they will not interfere with the removal of the
engine and transmission assembly.

<<H>> ENGINE MOUNTING
INSULATOR/TRANSMISSION MOUNTING
INSULATOR CONNECTING BOLT AND
NUT REMOVAL

AC402239

AB

1. Place a cart below the engine and transmission

assembly.

2. Lower the lift to the position where the weight of

the engine and transmission assembly is not
applied to the engine mounting insulator and
transmission mounting insulator.

3. Remove each coupling bolt and nut of the engine

mounting insulator and transmission mounting
insulator.

Main

Index

Group

TOC

ENGINE ASSEMBLY

ENGINE MECHANICAL <4G1>

11C-50

<<I>> ENGINE AND TRANSMISSION
ASSEMBLY REMOVAL

AC402895AB

1. Secure the A/C condenser assembly to the front

end panel with a code to prevent the A/C
condenser from falling when removing the engine
and transmission assembly.

2. Confirm that the cables, the hoses, and the wiring

harness connectors are all disconnected.

CAUTION

Do not bend the fuel high-pressure hose.
3. Raise the body slowly with a lift, and remove the

engine and transmission assembly.

<<J>> ENGINE ASSEMBLY REMOVAL

AC402249

AB

MB991454

MB991527

1. Install the following special tools, and set a chain

block.

• Hanger (MB991527)

• Engine hanger balancer (MB991454)

2. Remove the transmission assembly connecting

bolts.

CAUTION

When lifting the engine assembly, operate with
care not to lift the transmission assembly.
3. Lift the engine assembly slowly using the chain

block, and remove the transmission assembly
when the engine assembly is lifted a little.

Main

Index

Group

TOC

ENGINE ASSEMBLY

ENGINE MECHANICAL <4G1>

11C-51

INSTALLATION SERVICE POINTS
>>A<< TRANSMISSION MOUNTING INSU-
LATOR CONNECTING BOLT AND
NUT/ENGINE MOUNTING INSULATOR
INSTALLATION

AC402239

AB

1. Place the engine and transmission assembly on

the cart below the lifted vehicle.

2. Lower the lift to the position where the mounting

bolts and nuts of the engine mounting insulator
and the transmission mounting insulator are
installed.

3. Install the mounting bolts and nuts of the engine

mounting insulator and the transmission mounting
insulator.

>>B<< TRANSMISSION HOUSING FRONT
LOWER COVER STAY INSTALLATION

Install the transmission housing front lower cover
stay as follows.
1. Tighten four mounting bolts of the engine side by

hand.

2. Tighten two mounting bolts of the transmission

side to the specified torque.

Tightening: 48

± 6 N⋅m

3. Tighten four mounting bolts of the engine side to

the specified torque.

Tightening: 23

± 4 N⋅m

>>C<< OXYGEN SENSOR
INSTALLLATION

AC301966

AB

MB991953

Oxygen sensor

1. Tighten the oxygen sensor to the specified torque

by using special tool oxygen sensor wrench
(MB991953).

Tightening torque: 50

± 10 N⋅m

2. Connect the oxygen sensor connector and install

the connector bracket.

>>D<< FUEL HIGH-PRESSURE HOSE
CONNECTION

AC208465AE

3 mm

Fuel high-pressure hose

Fuel delivery pipe

CAUTION

After connecting the fuel high-pressure hose,
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.

>>E<< INITIALISATION

When the engine-ECU is removed, initialise the elec-
tronic-controlled throttle valve system according to
the following procedure after installing the
engine-ECU.

Turn the ignition switch from "ON" position to
"LOCK" (OFF) position, and then hold "LOCK"
(OFF) position for approximately 10 seconds or
more.

Main

Index

Group

TOC