Mitsubishi Colt Ralliart. Manual — part 613

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4G1>

11D-52

>>B<< CRANKSHAFT BEARING
INSTALLATION

AK201859

No. 2

No. 4

No. 4

No. 5

No. 1

No. 5

No. 2

P

No. 1

No. 5

No. 2

No. 4

No. 3

No. 3

No. 3

No. 1

P

AB

Identification mark positions

Colour code positions

(marked as shown in either of the illustrations below)

1. Measure the crankshaft journal diameter and

select bearings according to identification marks
or color codes given in the table below. The
journal diameter can be identified if the crankshaft
is provided with identification markings in the
illustrated positions.

Bearing Selection Table

Crankshaft

Cylinder
block
identification
mark

Bearing
identification
mark

Identification
color or mark

Journal
diameter mm

Yellow or 1 47.994

−

48.000

0

1

1

2

2

3

No color or
2

47.988

−

47.994

0

2

1

3

2

4

White or 3

47.982

−

47.988

0

3

1

4

2

5

AK201809

No.5

No.4

No.2

No.3

No.1

AC

Timing belt side

2. Cylinder block bearing bore diameter identification

marks are stamped in the positions shown,
starting with No. 1 from the timing belt side.

AK304598

Crankshaft bearing

Identification
mark position

AC

3. Based on the identifiers verified in steps 1 and 2,

select bearings from the table above.

<Bearing selection example>

(1) If measured crankshaft journal diameter is

48.000mm, it means yellow in crankshaft color
code or 1 in crankshaft identification mark.

(2) Based on the above, if the cylinder block

bearing bore diameter identification mark is 1,
select a bearing with an identification mark of
2.

Bearing Selection Table

Crankshaft

Cylinder
block
identification
mark

Bearing
identification
mark

Identification
color or mark

Journal
diameter mm

Main

Index

Group

TOC

AK201875AC

Grooveless

Grooveless

Grooved

Lower bearing

(No. 1, 2, 4 and 5)

Center bearing (No. 3)

Upper bearing

(No. 1, 2, 4 and 5)

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4G1>

11D-53

4. Install grooved bearings to the cylinder block.

NOTE: Center bearings (with thrust flanges) are
grooveless.

5. Install grooveless bearings to the bearing caps.

>>C<< BEARING CAP/BEARING CAP
CENTER/BEARING CAP NO.4
INSTALLATION

AK201810AC

Arrow indicating front of engine

Cap No.

1. On the bottom surface of each bearing cap is the

cap’s number and an arrow. Starting at the timing
belt side, fit the bearing caps in numerical order.
Ensure that the arrows point toward the timing
belt side.

2. Apply engine oil to the threaded portion and

bearing surface of the bolt.

3. Tighten the bolts to the specified torque of 34

± 2

N

⋅m.

AK201811

270

300

330

0

30

60

90

120

1

MB991614

30˚ to 34˚

AD

4. Using the special tool Angle sensor (MB991614),

tighten the bolts to a further 30

° to 34°.

AK201815

5. After fitting the bearing caps, measure the end

play in the crankshaft. If the measurement
exceeds the specified limit, replace the crankshaft
bearings.

Standard value: 0.05

− 0.18 mm

Limit: 0.25 mm

>>D<< REAR OIL SEAL INSTALLATION

AK201812

MD998011

AD

Press-fit the rear oil seal using the special tool
Crankshaft rear oil seal installer plate (MD998011).

Main

Index

Group

TOC

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4G1>

11D-54

>>E<< REAR OIL SEAL CASE
INSTALLATION

1. Remove completely old FIPG remaining on the

rear oil seal case and cylinder block (oil seal case
mounting surface).

AK201874

2. Apply a bead of FIPG to the surface of the rear oil

seal case as shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No. 970389 or equiva-

lent

3. Install the oil seal into the cylinder block after

applying an appropriate amount of engine oil to
the entire circumference of its lip portion.

4. Install the rear oil seal case by tightening its bolts

to 11

± 1 N⋅m.

>>F<< DRIVE PLATE BOLT
INSTALLATION

AK600410AD

MB991883

1. Using the special tool Flywheel stopper

(MD998781) secure the flywheel.

2. Tighten the flywheel bolt to the specified torque of

132

± 5 N⋅m.

INSPECTION

M1113008800850

CRANKSHAFT OIL CLEARANCE
(PLASTIC GAUGE METHOD)

This plastic gauge method is recommended as the
simplest way of measuring the crankshaft oil clear-
ance.
Measure the crankshaft oil clearance using a plastic
gauge as follows:
1. Wipe off oil from the crankshaft journal surface

and the crankshaft bearing inner surface.

2. Install the crankshaft.

AK201813AD

Plastic gauge

3. Cut a piece of plastic gauge whose length is

equivalent to the width of the bearing and place it
on the crankshaft journal in parallel with its axis.

4. Install the crankshaft bearing cap carefully and

tighten the bolts to the specified torque according
to INSTALLATION SERVICE POINTS
>>B<<

P.11D-50

.

5. Remove the bolts, then remove the crankshaft

bearing cap carefully.

AK201814

6. Measure the largest width of the crushed plastic

gauge using the ruler printed on the bag of the
plastic gauge.

Standard value: 0.02

− 0.04 mm

Limit: 0.1 mm

NOTE: The crankshaft pins and journals are fil-
let-rolled and must not be machined to undersize
dimensions.

Main

Index

Group

TOC

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <4G1>

11D-55

CYLINDER BLOCK

1. Visually check the cylinder block for scratches,

rust, and any other corrosion. Also check it for
cracks using a flaw detecting penetrant.
If any defect is evident, replace the cylinder block.

AK201816

2. Use a straightedge and thickness gauge to check

the cylinder block top surface for warp.
If the warp exceeds the specified limit, correct by
grinding.
Make sure that the surface is free from remaining
gasket material and other foreign matter.

Standard value: 0.05 mm
Limit: 0.1 mm
Grinding limit: 0.2 mm

3. Check cylinder walls for scratches and seizure.

If defects are evident, rebore to oversize or
replace the cylinder block.

AK201817

12 mm

AD

4. Use a cylinder gauge to measure the cylinder

bore diameter and taper.
If the cylinder is worn badly, rebore it to an
oversize and replace the piston and piston rings
with ones matched with the new bore size.
The points at which the measurements should be
made are indicated in the illustration.

Standard value: 75.50

− 75.53 mm

Taper: 0.01 mm or less

BORING CYLINDERS

1. Select an oversize of the pistons to be used

based on the largest of the cylinder bores.

AK103813AC

Piston diameter

11.65 mm

2. Oversize pistons are available in two oversizes:

0.50 mm and 1.00 mm. Bore each cylinder to a
size that provides the standard clearance when
combined with the selected piston. The reference
position for piston diameter measurement is as
shown in the illustration.

3. Based on the piston diameter measurement,

calculate the boring finish dimension.

• Boring finish dimension = [Piston diameter] +

[0.02

− 0.04 mm (clearance between piston and

cylinder)]

− [0.02 mm (honing margin)]

CAUTION

To prevent deformation of cylinder block that
would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2

→ No. 4 → No. 1 → No. 3.

4. Bore all the cylinders to the calculated boring

finish dimension.

5. Hone the bored cylinders to the final finish

dimension (piston diameter + clearance between
piston and cylinder).

6. Check the clearance between the piston and

cylinder.

Standard value: 0.02

− 0.04 mm

Main

Index

Group

TOC