Mitsubishi Colt Ralliart. Manual - part 267

CAMSHAFT

ENGINE OVERHAUL <4A9>

11B-32

INSPECTION

M1113027000091

CAMSHAFT

AK304883

Measure the cam height. If the measured value 
exceeds the limit, replace the camshaft.

Standard value:

Intake: 44.71 mm
Exhaust: 44.28 mm

Limit:

Intake: 44.21 mm
Exhaust: 43.78 mm

VALVE TAPPET 

AK304938

AB

Wall
thickness

1. Measure the valve tappet at the illustrated 

location. If the measured valve is discord to 
instruction valve by identification mark and 
following table, replace the tappet.

AK305693

Identification mark

AB

2. Every valve tappet has an identification mark 

stamped at the illustrated location.
Valve tappets are available in 31 sizes, at 0.02 
mm intervals in the 2.70 

− 3.30 mm range, as 

shown in the following table.

Thickness mm ID mark

Thickness mm ID mark

Thickness mm ID mark

2.70

70

2.92

92

3.14

14

2.72

72

2.94

94

3.16

16

2.74

74

2.96

96

3.18

18

2.76

76

2.98

98

3.20

20

2.78

78

3.00

00

3.22

22

2.80

80

3.02

02

3.24

24

2.82

82

3.04

04

3.26

26

2.84

84

3.06

06

3.28

28

2.86

86

3.08

08

3.30

30

2.88

88

3.10

10

2.90

90

3.12

12

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CYLINDER HEAD AND VALVES

ENGINE OVERHAUL <4A9>

11B-33

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION

M1113006900992

AK402342

AC

7

10

11

8

1

6

5

4

3

9

24.5 ± 2 N·m 

→ +180˚ to 184˚

21

19

20

17

18

16

15

14

13

12

2

Apply engine oil to
all moving parts
before installation.

Removal steps 

>>

C

<< 1. Cylinder head bolt

2. Cylinder head bolt washer
3. Cylinder head assembly
4. Cylinder head gasket

<<

A

>> >>

B

<< 5. Retainer lock

6. Valve spring retainer
7. Valve spring
8. Intake valve

<<

A

>> >>

B

<< 9. Retainer lock

10.Valve spring retainer
11. Valve spring

12.Exhaust valve

>>

A

<< 13.Valve stem seal

14.Valve spring seat

>>

A

<< 15.Valve stem seal

16.Valve spring seat
17.Valve guide
18.Valve guide
19.Intake valve seat
20.Exhaust valve seat
21.Cylinder head

Removal steps (Continued)

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CYLINDER HEAD AND VALVES

ENGINE OVERHAUL <4A9>

11B-34

REMOVAL SERVICE POINTS
<<A>> RETAINER LOCK REMOVAL

AK304941AB

MD999597

While compressing the valve spring using the special 
tool Valve spring compressor (MD999597), remove 
the retainer lock.
NOTE: To facilitate reassembly, the valve, spring and 
other parts removed should be kept together and 
attached with a tag showing where it has been 
assembled including the cylinder number.

INSTALLATION SERVICE POINTS
>>A<< VALVE STEM SEAL INSTALLA-
TION

AK304886AB

MB991994

Valve
stem
seal

1. Install the valve spring seat.

CAUTION

• The valve stem seal should not be reused.
• A new valve stem seal should be installed 

correctly using the special tool. Incorrectly 
installed valve stem seal will allow engine oil 
to leak through into the combustion chamber.

2. Lightly coat a new valve stem seal with engine oil.
3. Insert the new valve stem seal into the valve 

guide using the special tool Valve stem seal 
installer (MB991994).
NOTE: . Use the special tool, on which the 
number "MB991994A" is stamped.

>>B<< RETAINER LOCK INSTALLATION

AK304941AB

MD999597

While compressing the valve spring using the special 
tool Valve spring compressor (MD999597), install the 
retainer lock.

>>C<< CYLINDER HEAD BOLT 
INSTALLATION

AK401051

15 mm

29 mm

40 mm

A

B

AB

1. Inspect all reused cylinder bolts according to the 

following procedure.
(1) Measure the outside diameter shown in the 

illustration (arrow "A").

(2) Measure the smaller outside diameter shown 

in the illustration (arrow "B").

(3) When the difference between the smaller 

outside diameters (arrow "A" and "B") exceeds 
the standard value, replace the cylinder head 
bolt.

Standard value: 0 

− 0.15 mm

2. Install the cylinder head bolt and washer 

assembly onto the cylinder head.

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AK305406AB

Timing chain side

6

3

4

7

8

9

2

1

5

10

CYLINDER HEAD AND VALVES

ENGINE OVERHAUL <4A9>

11B-35

3. In accordance with the installation order, tighten 

them to the specified torque of 24.5 

± 2 N⋅m in 

several steps.

4. Make sure all bolts reach the specified torque.

AK304945

Paint mark

Paint mark

AB

180

˚

 to 184

˚

5. Put paint marks on the bolt heads and the cylinder 

as illustrated.

CAUTION

• If the head bolt is tightened less than the 

specified lower limit of 180 degree angle, the 
bolt may become loose. Be sure to tighten 
correctly.

• If the head bolt is tightened in excess of the 

specified upper limit of 184 degree angle, 
loosen the bolt completely and repeat the 
entire procedures.

6. Tighten the bolts in the correct sequence by 180 

to 184 degree angle.
Ensure that the paint marks on the bolt heads and 
the cylinder are aligned in a straight line.

INSPECTION

M1113007000862

CYLINDER HEAD

1. Before cleaning, check the cylinder head for 

leakage of coolant or exhaust gas as well as 
cracks or other damage.

2. Remove oil, scale, sealant, carbon and other 

residues completely. Clean the oil passages and 
blow compressed air through them to verify that 
they are free of restriction.

AK304943

CAUTION

The grinding limit for the cylinder head and block 
combined is 0.2 mm.
3. Using a straight edge and a thickness gauge, 

measure the flatness of the cylinder head bottom 
surface. If the distortion exceeds the limit, correct 
it by grinding.

Bottom face distortion

Standard value: 0.03 mmor less
Limit: 0.2 mm
Grinding limit: 0.2 mm

Cylinder head height (standard value for new 
part): 113.0 mm

VALVE

AK305408AB

Margin

The bottom of valve
seat contact facet

1. If the valve face-to-seat contact is uneven or 

interrupted, correct the valve seat.

2. Measure the valve head margin. If the measured 

value exceeds the limit, replace with a new valve.

Standard value:

Intake 1.35 mm
Exhaust 1.85 mm

Limit:

Intake 0.85 mm
Exhaust 1.35 mm

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