Service Manual Diagrams - Swaybar/Stabilizer Bar/Swaylink/Steering Rack/Crossmember Install & Removal Z27AG/4G1

In preparation of my Cusco Swaybar I did some research on the installation.
It doesn't look easy @_@
Might be something i will not do straight away.

Service Manual Diagrams - Front & Rear Suspenion Z27AG/4G1

In preparation of my coilover installation.
Coilovers are Blitz, further information can be found here.
I am currently running Tein coilovers. They don't have adjustable camber (however i did add camber pins and manage -1degree).

Below are extracts from the Mitsubishi Service Manual for the Ralliart Colt.

Blitz Coilovers 92765 - Z27AG - Ｆ：5.0kgf／mm Ｒ：4.0kgf／mm

Items have arrived. Waiting on Cusco Swaybars and RSRS rear suspension mounts (RSRS.JP)as the Blitz don't come with them.
More info here: RnD Suspension

To Suit: Mitsubishi Colt Ralliart








Rear assembly is different from the BC racing.












Pillow mount front tops.

Timing belt for Colt / Plus Z27A/Z27AG/Z27W/WG

---------------------Mitsubishi P#---------------------
PART NUMBER - DESCRIPTION - PRICE (EXC GST)

MI-MN119379 - BELT(VALVE TIMING) - $118.99
MI-MN119741 - PULLEY(TIMING BELT IDLER) - $107.41
MI-MR984714 - PULLEY(TIMING BELT TENSIONER) - $84.11
MI-MD372536 - OIL SEAL - $18.22
MI-MD377999 - OIL SEAL (CRANKSHAFT-FR) - $23.17
MI-MN155686 - WATER PUMP ASSY - $231.00
in AUD
--------------Rcolt Forum Background Info--------------
by Runuts

Timing belt sounds about right.
There are two belt pulleys, the Idler (MN119741), tensioner pulley(MR984714) and the hydraulic tensioner(MN119189). The two pulleys, you can check to see what condition they are in, the later, I would never risk. I would change that as a must. If it fails, you will more than likely skip teeth on the belt and have piston to valve contact.

Water pump's are always around that price from Mitsi. It will eventually fail, but its not necessary to change it unless there is an issue. Same with the oil seals, however, for the cost of the crank seal, I'd change it anyway. The other seal, is the seal from the oil pump to the block, its just an O-ring.

As for the gasket kit costing $570, thats just stupid. Considering how many gaskets this car has, from memory, head gasket, inlet man, exhaust and thats almost it, I cannot justify the cost. Don't know what else they include, but I wouldn't waste my money. Almost everything on these motors is sealed by liquid gasket maker(ie threebond etc). You could save yourself over $350 and just get the gaskets necessary when building the motor, ie headgasket, inlet, exhaust.

Either way, doing the job is very simple. The only part people may have issues with, is getting correct adjustment on the timing belt. The hydraulic tensioner, you either need the compression tool, or a press to depress it to insert the pin, before adjusting the tension.

Line up the timing marks, adjust the tensioner, make sure the pin(if you don't have one, use a suitable sized piece of wire or allen key) fits in and out of the hole when the belt is tensioned. Turn the engine over a couple of times to make sure. Then leave it for about 20-30 mins. If it still goes in perfectly, the tension is spot on.

---------------------Rcolt Forum P#---------------------

Gates Belt     MB 087 (MN158706 or MN119379) or TBMB087
Mitsubishi Tensioner MN11989
Bearings (NTN) TT658 + TT657 (You need both bearings)
Water Pump (GMB) GW M-82A

---------------------Rakuten Auctions---------------------
The set    Reference No.
Timing belt    TBMB087
Auto tensioner    MN119819
Tensioner    GT4030
Tensioner idler    GT4031
Water pump    GWM-82A


Car's name    Colt
Type    Z27A
Engine type    4G15
Model year    H14.10 ~ H22.08
The set    Reference No.
Timing belt    TBMB087
Auto tensioner    MN119819
Tensioner    GT4030
Tensioner idler    GT4031
Water pump    GWM-82A
     Oil service element


---------------------Yahoo Auctions---------------------
Timing belt (Kit) + W + other pump + tensioners etc. (new)
Timing belt for SET ☆ ☆ ▼ Colt / Plus Z27A/Z27AG/Z27W/WG
Product Code: STB622
☆ ☆ ☆ ☆ Product details are listed below please refer to product description of
various automobile parts supplies Jewels handling car!
Questions such as product inventory and compliance ◎, please contact us.
☆ Part guide you through the vehicle of your choice to fit ☆ 　　mail: Buhinkan@Titan.ocn.ne.jp　
please inform classified segment number / type designation number / chassis number of car registration ※.　　
Fits ◇: Colt / Colt Plus
Model ·: Z27A/Z27AG/Z27W/Z27WG
type □ E / G: Year 4G15 ○: H14.10 ~ - ~ - 02.10
including Ralliart ※
☆ oil each service element will be 1!
Contents ■ SET: TBMB087 + GWM-82A (manufactured by GMB) + TT657 + MN119819 + TT658 + V91110107(drive joy oil filter)
※ With auto-tensioner is
on the product features ◎, the car is fine fit product number is divided.
And compliance questions, please feel free to contact us
[Packaging segment number: 7]
Price: 32,183 yen (tax included)  deals and sales: ¥ 20,711 (tax included)
Sale Price: 19,109 yen (tax included)


-----------Conclusion
Timing belt for SET ☆ ☆ ▼ Colt / Plus Z27A/Z27AG/Z27W/WG
Fits ◇: Colt / Colt Plus
Model ·: Z27A/Z27AG/Z27W/Z27WG
type □ E / G: Year 4G15 ○: H14.10 ~ - ~ - 02.10
including Ralliart ※

- Timing belt                TBMB087(gates?)     or    MN119379(mitsu pn)
 - Auto tensioner/hydraulic tensioner    MN119819(mitsu pn)
     NOTE: most sources referred to it as MN119819 but i also found a MN119189, could be an error TBC
- PULLEY(TIMING BELT TENSIONER) / Tensioner    GT4030        or    MR984714(mitsu pn)
- PULLEY(TIMING BELT IDLER) / Tensioner idler    GT4031        or     MN119741(mitsu pn)
- Water pump    GWM-82A (manufactured by GMB) or MN155686(mitsu pn)

NTN Bearings - [tensioner, tensioner idler] - TT657, TT658

Other parts:

MI-MD372536 - OIL SEAL
MI-MD377999 - OIL SEAL (CRANKSHAFT-FR)

Blitz Coils Z27AG & Suspension Research

I am finally gonna change my suspension. I have been using Tein Compact Series see here >>>
I wanna get more into track, hence the change. I researched springs and camber tops for the current suspension and came to the conclusion that it will work out cheaper buying a new set.
The original plan was sway bars and camber tops see here >>>
I ended up ordering the Blitz Coilover (which apparently comes from the same factory as BC Racing).
Why?
Someone has to try it ^_^
I did pick it because its shipped from Sydney (from JustJap) so I didn't have to worry about importing from Japan.
It was between the Cusco and the Blitz. Tein mono were out of $$ range and so were the HKS unit and the Fullblast BFM and the YR-Advance.

I have also ordered:
CUSCO B.C.S. -525 561 A
(Brake Cylinder Stoppers)    ¥10,694
Brake Cylinder Stopper. 06/5~ .

Ralliart Bush Rearshock Upper A    Ralliart Bush Rearshock Upper A -RA594483K1 x 2
(Bushes and Collars)    ¥5,740
Set of 2.
Ralliart Bush Rearshock Upper B    Ralliart Bush Rearshock Upper B -RA594484K1 x 2
(Bushes and Collars)    ¥5,740
Set of 2.
These are no longer available :(

CUSCO Stabiliser Bar -525 311 B14
(Stabiliser (Sway) Bars)    ¥25,872
Rear. Stabiliser Bar. 14mm. Not adjustable.

Some info on Suspensions:

Cusco Compact Zero Minkara Review
Tein/Fullblast BFM Hybrid Minkara Review I believe BFM do their own model now
YR Advance Standard Coilover Minkara Review
Blitz ZZR Minkara Review
Tein Super Compact Minkara Review
Ralliart Suspension Minkara Review

BLITZ
[BLITZ (BLITZ), double harmonic damper all major polynomial Z-car made ​​ares "Z27A/Z27AG Colt" - 32 stage adjustable damping formula Furutappu
《適合車種》 "Fits"
●Ｚ２７Ａ／Ｚ２７ＡＧコルト (Ｈ16.10～) ● Z27A/Z27AG Colt (H16.10 ~)
[エンジン型式]４Ｇ１５ [Model Engines] 4G15

【スペック】 [Specs]
●バネレート・・・Ｆ：5.0kgf／mm Ｒ：4.0kgf／mm Spring rate ● F: 5.0kgf/mm R: 4.0kgf/mm
●自由長・・・・・Ｆ：200mm Ｒ：180mm Free length F ●: 200mm R: 180mm
●アッパー・・・・Ｆ：調整式ピロアッパー Ｒ：純正ゴムマウント ● Upper F: Adjustable Piroappa R: OE rubber mount
【品番(コードNo.)】９２７６５ No.] (Code No.)] 92 765
■メーカー／ＢＬＩＴＺ(ブリッツ) ●メーカーホームページ： http://www.blitz.co.jp/index.htm ■ Manufacturer / BLITZ (BLITZ) ● Manufactured Home: Http://Www.blitz.co.jp/Index.htm
■商品名／ＤＡＭＰＥＲ ＺＺーＲ / DAMPER ZZ ■ Product names over R
(ダンパーダブルゼットアール) (Z-double damper ares)

FEATURES:
- Single Cylinder Type
- 32 stage adjustment method
- Practical use for street circuit and wide range of events
- Designed with large diameter piston at 44mm (some vehicles)
- Forged aluminum upper mount
- Forged aluminum sheet for reduced weight and increased durability and strength
- Rigid bracket coated with special pain to achieve durability
- Aluminum bracket coated in black anodized paint to improve corrosion resistance
- Included height adjustment wrench

SPECIFICATION:
Materials:
- Springs: Special high-tension Steel (SAE9245)
- Cylinder Case: High-strength Steel (STKM13C)

- Z27A, Z27AG -
Upper Mount Configuration:
- Front: Adjustable Pillow Upper Mount
- Rear: OEM

Spring Spec.:
- Spring Rate (kgf.mm):
-- Front: 5.0
-- Rear: 4.0

- Free Length (mm):
-- Front: 200
-- Rear: 180

Height adjustment range:
- Front: -60 ~ +5
- Rear: -40 ~ 0

------------------------------------------------------

Tein Monoflex
COLT RALLIART Version-R
Z27AG 2006.05+  FWD 1500        
Controller    EDK04-K4469(Black)
     EDK04-P2756(Silver)
Motor    EDK05-10120
Strut    -
    w/ Spring
GSE10-F1AS1
¥218,000 (MSRP)
¥228,900 (incl TAX)     φ70
5.0 k 225mm     Exclusive Spring
4.0 k     Ft:-30
Rr:-25     Ft:-40 to -20
Rr:-35 to -15     Ft:-60 to 0
Rr:-37 to -14     Includes H.A.S.
Both Ft/Rr are full-length ride height adjustable.
[Upon EDFC installation]
Front:
MONO FLEX: Motor and harness need to be waterproofed with silicon sealant.

Rear:
Service hole cover needs to be cut or removed.
MONO FLEX: Motor angle needs to be adjusted to avoid interference.

------------------------------------------------------

Ralliart
RAZ27301S1 = Sports Suspension Kit (This kit lowers the car height ~10mm / 30% more siffter than stock)
RAZ27A01R1 = Suspension Kit For Competition (rise the car height ~20mm)


Ltd. Larry Art (Masao Taguchi president), add set Colt RALLIART Version-R for the "competition suspension kit", Ralliart pit each store and Mitsubishi dealers nationwide, and test than (Sunday) April 1 I sell through the service.

Racing suspension kit RAZ27A01R1 99,750 yen (95,000 yen) Damping force fixed, vehicle height about 20mm up

Front strut RAZ27301R1 13,650 yen (13,000 yen) Damping force fixed, white paint
Rear shock absorber RAZ27302R1 11,025 yen (10,500 yen)
Front springs RAZ27303R1 12,600 yen (12,000 yen) Spring constant up, car sales up about 20mm, red paint
Rear spring RAZ27304R1 12,600 yen (12,000 yen) Spring constant up, car sales up about 20mm, red paint

FJ TRD Brake Upgrade

Installing some new TRD brake kit on my mates new Toyota FJ. Thought it was gonna be easy until i had to remove the original heat shield.
The TRD kit came with rotors, calipers, pads and new stainless steel lines.
Tools were pretty basic e.g. sockets, spanners, flared spanner (for brake lines), 1/2" hex drive (caliper replacement bolts were hex), grinder or tin snips

The rear of the caliper and the brake line connection.





Brake assembly removed.
Two bolts from the back, standard stuff
I also removed the brake line bracket and the ABS speed sensor brake so i could move it out the way









The original hardware.












After some serious cutting the heat shield has been cut back







110NM I believe it was for the brake caliper bolts.
Added some locktite.
My mate runs some bad ass wheels hence the 25mm spacer in the photo.




















Bleed process requires the FJ keys to be in the ON position, this activates the ABS/Brake pump solenoids.
Gave it 3-4 presses and on the last press with the foot held down opened the nipple then closed it.
Done this 2 times per nipple. 4 nipples in total, then hit the once each.
Almost 1litre of fluid was used.

---------------------From the Manual---------------------

3.BLEED BRAKE LINE
(a)Turn the ignition switch to ON, and wait until the pump motor has stopped.
HINT: Pump operating sound can be heard.
(b)Front brake line.
(1)Connect the vinyl tube to the brake caliper.
(2)Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down (step D).
(3)At the point when the fluid stops coming out, tighten the bleeder plug, then release the brake pedal (step E).
(4)Repeat steps D and E until all the air in the fluid has been bled out.
Torque:11 N*m (110 kgf*cm, 8 ft.*lbf)
(5)Repeat the above procedures to bleed the other brake line.
(c)Rear brake line.
(1)Connect the vinyl tube to the brake caliper.
(2)Depress the brake pedal, hold it, and then loosen the bleeder plug.
HINT: Brake fluid is pumped out automatically.
(3)Loosen the bleeder plug and release the air.
NOTICE:
Keep the brake fluid in the reservoir tank above the MIN line during the above procedures.
(4)When the air is completely bled out of the brake fluid through the bleeder plug, tighten the bleeder plug.
Torque:11 N*m (110 kgf*cm, 8 ft.*lbf)
(5)Repeat the above procedures to bleed the other brake line.