The story so far
My friend bend a rod 'sad face'. The reason is hard to say. The bore has suffered some minor damage. We should be able to bore it out to 1mm over size. This is the maximum the stock head gasket can take. For now we are thinking of doing a simple hone as the rings seem to not go down that far in the bore to cause issue.
http://ayu452.blogspot.com.au/2012/09/bent-rod-z27ag-4g15-more-to-come.html
Part of the rebuild is finding the parts which i have been doing -
http://ayu452.blogspot.com.au/2012/09/rcolt-rebuild-pick-list-part-numbers.html
I am now looking at new rings and conrod bearings. We will reuse a piston from the wreck I have.
Below is a collection of data I am compiling for engine re-assembly.
Specs
ENGINE SPECS
Item Specification
Total displacement mL 1,468
Bore × Stroke mm 75.5 × 82.0 (DO NOTE PART OF THE COLT PDF NOTES BORE AS 75mm)
Compression ratio 9.0
Compression chamber Pentroof
Camshaft arrangement DOHC
Number of valve Intake 2
Exhaust 2
Valve timing Intake opening BTDC 34° − ATDC 6°
Intake closing ABDC 30° − ABDC 70°
Exhaust opening BBDC 50°
Exhaust closing ATDC 10°
Fuel system Electronically controlled multipoint fuel injection
Rocker arm - Roller type
Auto-lash adjuster - Equipped
The 4G15-MIVEC-T/C engine employed in the Colt is designed to provide higher performance and higher output by using a turbocharger to the 4G15-MIVEC engine employed in the conventional Colt.
The main changes in the conventional 4G15-MIVEC engine are as follows:
• Cylinder head gasket changed
• Oil jet added
• Strength improved in piston and piston pin
Item 4G15-MIVEC-T/C
Total displacement mL 1,468
Bore × Stroke mm 75 × 82.0
Compression ratio 9.0
Compression chamber Pentroof-type
Valve t iming Intake opening BTDC 34° − ATDC 6°
Intake closing ABDC 30° − ABDC 70°
Exhaust opening BBDC 50°
Exhaust closing ATDC 10°
Maximum output kW (PS)/rpm 113 (154)/6,000
Maximum torque N⋅m (kg⋅m)/rpm 210 (21.4)/3,500
Fuel system Electronically controlled multipoint fuel injection
Ignition system Electronic-controlled 4-coil
Cam height mm Intake valves 35.08 34.58
Exhaust valves 34.26 33.76
CYLINDER HEAD AND VALVES
Std Val Limit
Cylinder head gasket surface warp mm 0.03 0.2
Cylinder head gasket surface grinding limit
(including cylinder block grinding amount) mm − 0.2
Cylinder head overall height mm 131.9 − 132.1 −
Valve margin mm - Intake valves 1.0 0.5
- Exhaust valves 1.5 1.0
Valve length mm - Intake valves 106.35 105.85
- Exhaust valves 106.85 106.35
Valve spring free height mm 54.8 55.8
Valve spring squareness 2° or less 4°
Valve stem-to-guide clearance mm
- Intake valves 0.02 − 0.05 0.10
- Exhaust valves 0.03 − 0.06 0.15
Valve guide length mm - Intake valves 48 −
- Exhaust valves 55 −
Valve guide projection mm 22.7 − 23.3 −
Valve face-to-seat contact width mm 0.9 − 1.3 −
Valve projection from valve spring
seat mm - Intake valves 48.8 49.3
- Exhaust valves 48.7 49.2
OIL PUMP AND OIL PAN
Std Val Limit
Oil pump tip clearance mm 0.06 − 0.18 −
Oil pump side clearance mm 0.10 − 0.18 −
Oil pump body clearance mm 0.040 − 0.095 −
PISTONS AND CONNECTING RODS
Piston pin press-in load (at ambient temperature)
N 4,900 − 14,700 −
Piston ring side clearance in ring
groove mm - No. 1 0.03 − 0.07 0.1
- No. 2 0.02 − 0.06 0.1
Piston ring end gap mm
- No. 1 0.15 − 0.30 0.8
- No. 2 0.30 − 0.45 0.8
- Oil ring 0.20 − 0.50 1.0
Connecting rod big end thrust clearance mm 0.10 − 0.25 0.4
Oil clearance at crankshaft pins mm 0.025 − 0.040 0.1
CRANKSHAFT AND CYLINDER BLOCK
Crankshaft end play mm 0.05 − 0.18 0.25
Oil clearance at crankshaft journals mm 0.02 − 0.04 0.1
Cylinder block gasket surface warp mm 0.05 0.1
Cylinder block gasket surface grinding limit
(including cylinder head grinding amount) mm − 0.2
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 −
TORQUE - Nm
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
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
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
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
Oil pump cover bolts 10 ± 2
Sealants
Camshaft position sensor support...Mitsubishi Genuine Part No. 970389
Rocker cover.......................Mitsubishi Genuine Part No. 970389
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
Oil pump case......................Mitsubishi Genuine Part No. 970389
Oil pressure switch................3M ATD No.8660 or equivalent
Rear oil seal case.................Mitsubishi Genuine Part No. 970389
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.
Assembly
HEAD ASSEMBLY
• Assemble to the cylinder block so the cylinder head gasket identification mark of "1.5" is at the top surface and on the inlet side.
1) When reusing a cylinder head bolt, check that its nominal length (shank length) is not greater than the limit. If the limit is exceeded, replace the bolt.
Limit: 103.2 mm
- Measured from under the head of the bolt
2) Apply engine oil to the threads and washer of the bolt.
3) Tighten the bolts to 49 ± 2 N⋅m in the indicated sequence.
4) Loosen all the bolts completely.
5) Tighten the bolts again to a torque of 20 ± 2 N⋅m in the indicated sequence.
<-INSTALL - Timing Belt [engine front]
8 6 1 3 9
10 4 2 5 7
*NOTE: Remove is opposite, therefore:
<-REMOVAL - Timing Belt [engine front]
3 5 10 8 2
1 7 9 6 4
• If the tightening angle is smaller than 90°, proper fastening performance could not be assured. Be sure to respect that angle.
• If the bolt is tightened to an angle greater than the specified angle, loosen the bolt com-pletely and then retighten it beginning with the first step.
6) Make paint marks on each boltÃs head and on the cylinder head.
7) Turn the bolts 90° in the tightening direction and in the indicated sequence.
8) Give another 90° turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the cylinder head are on the same line.
INSPECTION - CYLINDER HEAD
The thickness of the metal that can be removed by grinding from both the cylinder head and the mating cylinder block is limited to 0.2 mm in total.
Gasket surface warp
Standard value: 0.03 mm or less - Limit: 0.2 mm
Grinding limit: 0.2 mm
Cylinder head height (standard value for new part): 131.9 − 132.1 mm
Replace the valve if the length is less than the limit.
Standard values: Intake 106.35 mm - Exhaust 106.85 mm
Limits: Intake 105.85 mm - Exhaust 106.35 mm
