Mitsubishi Colt Ralliart. Manual - part 604

TIMING BELT

ENGINE OVERHAUL <4G1>

11D-16

>>E<< TENSIONER PULLEY 
INSTALLATION

AK202338 AC

Tensioner pulley

Machined hole

Install the tensioner pulley onto the tensioner arm, 
with the machined holes facing in front as shown.

>>F<< TIMING BELT INSTALLATION

1. For aligning the timing marks on the camshaft 

sprocket and V.V.T. sprocket, install the rocker 
cover temporarily.

AK202339AC

Timing mark

2. Align the timing mark on the camshaft sprocket.

AK202340AC

Timing mark

3. Align the timing mark on the V.V.T. sprocket.

AK202341AC

Timing mark

Timing mark

4. Align the timing mark on the crankshaft sprocket.
5. First fit the timing belt onto the crankshaft 

sprocket.

6. Fit the timing belt onto the idler pulley.

AK202342 AC

Paper clip

7. Fit the timing belt onto the camshaft sprocket, and 

bind it with paper clip in the illustrated shown in 
the illustration.

AK202343AC

Paper clip

8. Fit the timing belt onto the V.V.T. sprocket, and 

bind it with paper clip in the position shown in the 
illustration.

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AK202344AC

Tensioner 
pulley

TIMING BELT

ENGINE OVERHAUL <4G1>

11D-17

9. Fit the timing belt onto the tensioner pulley.

NOTE: To make belt installation easier, turn the 
V.V.T. sprocket a little counter-clockwise. 

AK201777AC

MD998767

10.Using the special tool of tensioner pulley socket 

(MD998767), apply the tension to the timing belt 
by turning the tensioner pulley counterclockwise, 
then temporally tighten the fixing bolt of the 
tensioner pulley and fix the tensioner pulley firmly.

11.Turn the crankshaft a quarter turn 

counter-clockwise, then turn it clockwise to align 
the timing marks.

AK201818AC

MD998738

12.Install the special tool Set screw (MD998738) in 

position and drive it in to such an extent that the 
wire inserted when the auto tensioner was 
installed lightly moves.

CAUTION

The timing belt is loosened with the rotation of 
the intake and exhaust camshafts. Take care that 
the timing belt does not slip out of place.

AK202345AC

MD998767

13.Loosen the lock bolt holding the tensioner pulley.
14.Turn the torque wrench attached to the special 

tool Tensioner pulley socket (MD998767) 
counter-clockwise until the slack in the timing belt 
is taken up.

15.Torque to 0.8 N

⋅m with the torque wrench.

16.Check that all the timing marks are in alignment.
17.Remove the special tool Set screw (MD998738) 

installed at step 12.

18.Give the crankshaft two turns clockwise, and 

leave it in that state for approximately 15 minutes.

AK201779AC

19.Check to see if the wire inserted when the auto 

tensioner was installed can be easily pulled out. If 
so, the belt tension is optimal and the wire may be 
removed. Alternatively, if the protrusion of the 
auto tensioner rod is within the specified range of 
standard values, the belt tension is optimal.

Standard value: 4.8 

− 5.5 mm

CAUTION

When the crankshaft bolt was turned coun-
ter-clockwise, be sure to check its tightening 
torque. If the bolt is loose, retighten it.
20.If the wire cannot be easily removed, repeat the 

steps from 12 to 18 above for proper tension of 
the belt.

21. Finally, remove the temporarily installed rocker 

cover.

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TIMING BELT

ENGINE OVERHAUL <4G1>

11D-18

>>G<< PLUG CAP INSTALLATION

CAUTION

Do not reuse washer.
1. Replace washer on the plug cap.

AK201780

2. Holding the hexagonal portion of the camshaft 

with a wrench, tighten the plug cap to a specified 
torque of 21 

± 3 N⋅m.

>>H<< ROCKER COVER INSTALLATION

1. Completely remove existing form-in-place gasket 

from the rocker cover and cylinder head.

AK201825 AD

10 mm

10 mm

10 mm

10 mm

2. Apply beads of FIPG on the surfaces of the rocker 

cover indicated in the illustration.

Specified sealant:

Mitsubishi Genuine Part No. 970389 or equiva-

lent

AC500202

1, 11

2, 12

4, 14

3, 13

8

9

10

7

6

5

Engine front

AB

3. Install the rocker cover to the cylinder head before 

the FIPG hardens, and tighten the tightening bolt 
to the specified torque of 3.5 

± 0.5 N⋅m.

INSPECTION

M1113002000812

TIMING BELT

Check closely the entire timing belt.
Replace it if any of the following conditions is found.

AK202794

1. Hardened back side rubber.

Back side surface is glossy, lacking in elasticity, 
and so hard that no impression is left when 
pressed with fingernail.

AK202793

Cracks

Peeling of canvas

Cracks in tooth roots

Cracks

AB

Cracks in sides

2. Cracks in back rubber surface.
3. Cracks in canvas.
4. Cracks in tooth roots.
5. Cracks in belt sides.

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AK202795

Rounded edge

Abnormal wear 
(Fluffy strand)

AB

TIMING BELT

ENGINE OVERHAUL <4G1>

11D-19

6. Abnormally worn belt sides.

NOTE: belt sides are normal if they have 
"knife-cut" surfaces.

AK202796

Missing 
Tooth

Canvas lost and 
rubber exposed

AB

7. Badly worn teeth.
Initial stage: Canvas is worn (canvas fiber is fluffy; 
teeth look whitish due to worn-out rubber; canvas 
texture is unclear)
Second stage: Canvas is lost and rubber is exposed 
(tooth width narrows down)
8. Missing tooth.

AUTO-TENSIONER

1. Check the auto-tensioner for leaks from the 

sealed sections.
Replace it if leaky.

2. Check the rod end for wear and other damage.

Replace the auto-tensioner if the rod is badly 
worn or damaged.

AK201826AC

12 mm

3. Measure the extension length of the rod.

If it is not within the standard value range, replace 
the auto-tensioner.

Standard value: 12 mm

AK201827AC

Movement

98 – 196 N

4. Press the rod with a force of 98 

− 196 N and 

measure the amount of retraction. If the 
measurement exceeds the standard value, 
replace the auto-tensioner.

Standard value: 1 mm maximum

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