Mitsubishi Colt Ralliart. Manual — part 612
PISTON AND CONNECTING ROD
ENGINE OVERHAUL <4G1>
11D-48
>>F<< CONNECTING ROD CAP
INSTALLATION
AK402390
Cylinder
number
AC
1. Install the bearing cap on the connecting rod while
aligning the marks made during disassembly. If
the connecting rod is new and has no alignment
mark, assemble it with the cap such that the both
bearing locating notches are on the same side as
shown in the illustration.
AK202821
2. Make sure that the thrust clearance of the
connecting rod big end is proper.
Standard value: 0.10
− 0.25 mm
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP NUT
INSTALLATION
1. The connecting rod cap bolts and nuts are
tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be
checked for elongation before installation.
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.
2. Apply engine oil to the threads and bearing
surface of each nut before installation.
3. Finger-tighten the nuts on the bolts, then tighten
the nuts alternately and repeatedly to install the
cap properly.
4. Tighten the nuts to a torque of 17
± 2 N⋅m.
AK202543
Paint marks
Nut
90˚ to 94˚
Paint marks
AB
Bolt
5. Make a paint mark on the head of each nut.
6. Make a paint mark on the bolt at a point 90
° to
94
° away from the paint mark made on the nut in
the tightening direction.
CAUTION
• If the tightening angle is less than 90°, ade-
quate tightness could not be assured.
• If the tightening angle exceeds 94°, loosen
the nut completely and then perform the tight-
ening procedure again beginning with the
first step.
7. Turn the nut 90
° to 94° to bring the mark on the
nut into alignment with that on the bolt.
Main
Index
Group
TOC
PISTON AND CONNECTING ROD
ENGINE OVERHAUL <4G1>
11D-49
INSPECTION
M1113008500848
PISTON RING
AK202787
1. Measure the clearance between each piston ring
and its groove. If the limit is exceeded, replace the
ring or piston, or both.
Standard values:
No. 1 ring 0.03
− 0.07 mm
No. 2 ring 0.02
− 0.06 mm
AK202788
Force ring down
with piston
End gap
Piston ring
AB
2. Install the piston ring into the cylinder bore and
force it down with the head of the piston until the
ring becomes right-angled to the cylinder wall.
Then, measure the end gap of the ring with a
thickness gauge. If the end gap is excessive,
replace the piston ring.
Standard values:
No. 1 ring 0.15
− 0.30 mm
No. 2 ring 0.30
− 0.45 mm
Oil ring 0.20
− 0.50 mm
Limits:
No. 1 ring 0.8 mm
No. 2 ring 0.8 mm
Oil ring 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIC GAUGE METHOD)
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastic gauge whose length is
equivalent to the width of the bearing and place it
on the crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten
the nuts according to INSTALLATION SERVICE
POINTS >>G<<
4. Remove the nuts, then remove the connecting rod
cap carefully.
AK202848
5. Measure the largest width of the crushed plastic
gauge using the ruler printed on the bag of the
plastic gauge.
Standard value: 0.025
− 0.040 mm
Limit: 0.1 mm
Main
Index
Group
TOC
CRANKSHAFT AND CYLINDER BLOCK
ENGINE OVERHAUL <4G1>
11D-50
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
M1113008701793
Apply engine oil to
all moving parts
before installation.
AK600558
5
1
4
2
3
10 ± 2 N·m
132 ± 5 N·m
7
12
6
11
14
17
8
7
10
11 ± 1 N·m
34 ± 2 N·m
→ +30˚ to 34˚
9
13
16
15
23 ± 2 N·m
AB
Removal steps
<<
A
>> >>
F
<< 1. Flywheel bolt
2. Flywheel
3. Rear plate
>>
E
<< 4. Rear oil seal case
>>
D
<< 5. Rear oil seal
>>
C
<< 6. Bearing cap bolt
>>
C
<< 7. Bearing cap
>>
C
<< 8. Bearing cap center
>>
C
<< 9. Bearing cap No.4
>>
B
<< 10. Crankshaft bearing, lower
>>
B
<< 11. Crankshaft bearing, center
12. Crankshaft
>>
B
<< 13. Crankshaft bearing, upper
>>
B
<< 14. Crankshaft bearing, center
15. Detonation sensor
<<
B
>> >>
A
<< 16. Oil jet
17. Cylinder block
Removal steps (Continued)
Main
Index
Group
TOC
CRANKSHAFT AND CYLINDER BLOCK
ENGINE OVERHAUL <4G1>
11D-51
REMOVAL SERVICE POINTS
<<A>> DRIVE PLATE BOLT REMOVAL
AK600409AD
MB991883
1. Using the special tool Flywheel stopper
(MB991883), hold the flywheel in place.
2. Remove the flywheel bolts.
<<B>> OIL JET REMOVAL
AK304984
CAUTION
Pay full attention not to damage the cylinder wall.
Using the metallic bar of the appropriate length,
strike to the oil jet.
INSTALLATION SERVICE POINTS
>>A<< OIL JET INSTALLATION
AK304985
Until reaching the bottom, strike the oil jet from the
crankshaft journal using the pin punch whose diame-
ter is 4.5mm.
Main
Index
Group
TOC
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