Mitsubishi Colt Ralliart. Manual - part 601

REWORK DIMENSIONS

ENGINE OVERHAUL <4G1>

11D-4

REWORK DIMENSIONS

M1113024300480

Item

Standard value

Standard value

CYLINDER HEAD AND VALVES
Cylinder head oversize valve guide hole diameter mm

0.05 O.S.

10.55 

− 10.57

0.25 O.S.

10.75 

− 10.77

0.50 O.S.

11.00 

− 11.02

Cylinder head oversize valve seat hole diameter, intake mm

0.30 O.S.

31.30 

− 31.33

0.60 O.S.

31.60 

− 31.63

Cylinder head oversize valve seat hole diameter, exhaust mm

0.30 O.S.

27.80 

− 27.82

0.60 O.S.

28.10 

− 28.12

TORQUE SPECIFICATIONS

M1113023401777

Cylinder bore diameter mm

75.50 

− 75.53

−

Taper of cylinder mm

0.01 or less

−

Cylinder-to-piston clearance mm

0.02 

− 0.04

−

Item

Standard value

Limit

Item

N

⋅m

ALTERNATOR AND IGNITION SYSTEM
Oil level gauge guide bolt

24 

± 4

Water pump pulley bolts

9.0 

± 2.0

Crankshaft bolts

181

Alternator brace bolt (alternator side)

22.5 

± 2.5

Alternator brace bolt (tightened with water pump)

24 

± 3

Alternator nut

44 

± 10

Adjusting bolt

5.0 

± 1.0

Ignition coil bolts

10 

± 2

Spark plug

25 

± 5

Cam position sensor bolt

8.8 

± 1.0

Cam position sensor support bolts

14 

± 1

TIMING BELT
Timing belt cover bolts

11 

± 1

Rocker cover bolts

5.0 

± 1.0 → 7.0 ± 1.0

Plug cap

21 

± 3

Tensioner pulley bolt

48 

± 6

Main

Index

Group

TOC

TORQUE SPECIFICATIONS

ENGINE OVERHAUL <4G1>

11D-5

Tensioner arm bolt

48 

± 6

Auto-tensioner bolts

23 

± 3

Idler pulley bolt

44 

± 10

Crank angle sensor bolts

9.8 

± 2.0

V.V.T. sprocket bolt

55 

± 5

Camshaft sprocket bolt

88 

± 10

Engine support bracket bolts, nut

36 

± 6

FUEL AND EMISSION PARTS
Throttle body bolts

13 

± 2

Solenoid valve bolts

9.0 

± 1.0

Purge valve bolts

5.0 

± 1.0

Delivery pipe and injector bolts

12 

± 1

Fuel pressure regulator bolts

12 

± 1

Vacuum pipe bolts

9.0 

± 1.0

Solenoid valve nut

5.0 

± 1.0

WATER PUMP AND WATER HOSE
Engine coolant temperature sensor

29 

± 10

Water inlet fitting bolts

22 

± 4

Water pipe bolts (M6)

10 

± 2

Water pipe bolt s(M8)

13 

± 2

Water inlet pipe bolts

13 

± 2

Water pump bolts

14 

± 1

INLET MANIFOLD
Inlet manifold stay bolts (M8)

18 

± 2

Inlet manifold stay bolts (M10)

31 

± 3

Inlet manifold bolts and nuts

18 

± 2

Engine hanger bolt

19 

± 3

EXHAUST MANIFOLD
Oxygen sensor

50 

± 10

Turbocharger cover bolts

10 

± 2

Oil return pipe bolts

10 

± 2

Exhaust fitting bracket bolts

35 

± 6

Exhaust fitting bolts

59 

± 5

Turbocharger bracket bolts (turbocharger side)

59 

± 5

Turbocharger bracket bolts (cylinder block side)

35 

± 6

Oil pipe bolt (flange bolt)

10 

± 2

Oil pipe bolt (eye bolt)

17 

± 2

Turbocharger bolts, nuts

59 

± 5

Water pipe bolt (eye bolt)

31 

± 2

Water pipe bolt (flange bolt)

10 

± 2

Item

N

⋅m

Main

Index

Group

TOC

TORQUE SPECIFICATIONS

ENGINE OVERHAUL <4G1>

11D-6

Exhaust manifold nuts (M8)

29 

± 3

Exhaust manifold nuts (M10)

49 

± 5

Thermostat housing hanger bolt

24 

± 4

Engine hanger bolt

19 

± 3

ROCKER ARMS AND CAMSHAFT
Oil feeder control valve bolt

11 

± 1

Oil pipe eye-bolt (cylinder block side)

30 

± 3

Oil pipe eye-bolt (cylinder head side)

42 

± 2

Cam position sensing cylinder bolt

22 

± 4

Front bearing cap bolt

21 

± 2

Rear bearing cap bolts

21 

± 2

Bearing cap bolts

11 

± 1

CYLINDER HEAD AND VALVES
Cylinder head bolts

49 

→ 0 → 20 → +90° +90°

OIL PUMP AND OIL PAN
Oil cooler bolt

27 

± 2

Oil pressure switch

10 

± 2

Drain plug

39 

± 5

Oil pan bolts

7.0 

± 1.0

Transmission stay bolts

23 

± 4

Oil screen bolts

19 

± 3

Baffle plate bolts

10 

± 2

Relief plug

44 

± 5

Oil pump case bolts

14 

± 1

Oil pump cover bolts

10 

± 2

PISTONS AND CONNECTING RODS
Connecting rod cap nuts

17 

± 2 → +90° to 94°

CRANKSHAFT AND CYLINDER BLOCK
Flywheel bolts

132 

± 5

Rear plate bolts

10 

± 2

Oil seal case bolts

11 

± 1

Bearing cap bolts

34 

± 2 → +30° to 34°

Detonation sensor bolts

20 

± 1

Item

N

⋅m

Main

Index

Group

TOC

SEALANTS

ENGINE OVERHAUL <4G1>

11D-7

SEALANTS

M1113000500899

Item

Specified sealant

Camshaft position sensor support*

Mitsubishi Genuine Part No. 970389 or 
equivalent

Rocker cover*

Mitsubishi Genuine Part No. 970389 or 
equivalent

Engine coolant temperature sensor

3M Nut Locking Part No.4171 or 
equivalent

Cylinder head (camshaft bearing cap fitting section)

3M ATD No.8660 or equivalent

Oil pan*

Mitsubishi Genuine Part No. 970389 or 
equivalent

Oil pump case*

Mitsubishi Genuine Part No. 970389 or 
equivalent

Oil pressure switch

3M ATD No.8660 or equivalent

Rear oil seal case*

Mitsubishi Genuine Part No. 970389 or 
equivalent

NOTE: *: Part to be sealed with a form-in-place gas-
ket (FIPG)

FORM-IN-PLACE GASKET (FIPG)

This engine has several areas where the 
form-in-place gasket (FIPG) is used for sealing. To 
ensure that the FIPG fully serves its purpose, it is 
necessary to observe some precautions when apply-
ing it.
Bead size, continuity and location are of paramount 
importance. Too thin a bead could cause leaks. Too 
thick a bead, on the other hand, could be squeezed 
out of location, causing blocking or narrowing of fluid 
passages. To prevent leaks or blocking of passages, 
therefore, it is absolutely necessary to apply the 
FIPG evenly without a break, while observing the 
correct bead size.
FIPG hardens as it reacts with the moisture in the 
atmospheric air, and it is usually used for sealing 
metallic flange areas.

Disassembly

Parts sealed with a FIPG can be easily removed 
without need for the use of a special method. In 
some cases, however, the FIPG in joints may have to 
be broken by tapping parts with a mallet or similar 
tool. 

Surface Preparation

Thoroughly remove all substances deposited on the 
FIPG application surface, using a gasket scraper. 
Make sure that the FIPG application surface is flat 
and smooth. Also make sure that the surface is free 
from oils, greases and foreign substances. Do not fail 
to remove old FIPG that may remain in the fastener 
fitting holes.

FIPG Application

Applied FIPG bead should be of the specified size 
and free of any break. FIPG can be wiped away 
unless it has completely hardened. Install the mating 
parts in position while the FIPG is still wet (in less 
than 15 minutes after application). Do not allow FIPG 
to spread beyond the sealing areas during installa-
tion. Avoid operating the engine or letting oils or 
water come in contact with the sealed area before a 
time sufficient for FIPG to harden (approximately one 
hour) has passed. FIPG application method may 
vary from location to location. Follow the instruction 
for each particular case described later in this man-
ual.

Main

Index

Group

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