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