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Home Colt Lancer Galant L200 Outlander Pajero Others
Colt 5 (1995-2003, petrol) Colt 4 and 5 (1991-2003) Colt 2 and 3 (1983-1993)

Engine Specifications

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  • 2 (1983-1993)
  • Power unit
  • Engine overhaul
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Are common



Compression pressure (at 250 rpm)192 psi
Oil pressure (the engine is warm)11 psi minimum at idle

1.5L engines



Cylinder head deformation
Rated0.05mm
Adjustable
1990 and later Colt, Lancer, Mirage models0.2 mm
All others0.1mm
Valve mechanism
Valve chamfer width
Inlet valves
Rated1.0 mm
Minimum allowable0.5mm
Exhaust valves
Rated1.5 mm
Minimum allowable1.0 mm
Valve stem diameter (inlet and outlet)6.6mm
Gap between valve stem and guide sleeve
Inlet valves (Colt, Lancer, Mirage models 1989 and later)
Nominal0.02-0.05mm
Maximum allowable0.10mm
Inlet valves (all other models)
Nominal0.03-0.06mm
Maximum allowable0.1mm
Exhaust valves (all models)
Nominal0.05-0.09mm
Maximum allowable0.15mm
Valve springs
Maximum allowable warp3°Pressure
1991 and later Colt, Lancer, Mirage models
Inlet valves32.5 kg when compressed to a length of 27 mm
Exhaust valves40.7kg when compressed to 27mm length
All other models (intake and exhaust valves)33.8kg when compressed to 27mm length
Installation height36mm
Valve mechanism (continuation)
Free length
1991 and later Colt, Lancer, Mirage models
Intake46.1 mm
Graduations46.8 mm
All other models (intake and exhaust valves)44.6mm
Thin mixture inlet valves
Valve stem diameter4.30 mm
Chamfer angle45°Spring
Free length29.6mm
Resistance3.5 kg with a length of 21.5 mm
Crankshaft and connecting rods
Connecting rod journal
Diameter42 mm
Maximum allowable ovality and taper0.01mm
Bearing lubrication gap0.014-0.044mm
Connecting rod side clearance0.10-0.25mm
Main journals
Diameter48mm
Maximum allowable ovality and taper0.01mm
Maximum runout allowed0.03mm
Bearing lubrication gap0.02-0.07mm
Crankshaft end play0.05-0.18mm
Cylinders
Diameter (nominal)75.5mm
Maximum allowable ovality and taper0.02mm
Pistons and piston rings
Pistons diameter (nominal) *75.5mm
Clearance between piston and cylinder walls0.02-0.04mm
Piston ring end clearance
Compression rings
Nominal0.20-0.35mm
Maximum allowable 0.8mm
Oil scraper ring
Nominal0.20-0.70mm
Maximum allowable1.0 mm
Piston ring side clearance
Top compression ring
Nominal0.03-0.07mm
Maximum allowable0.15mm
Second compression ring
Nominal0.02-0.06mm
Maximum allowable0.12mm
*At 2mm from the bottom of the piston skirt



Torques*, Ft-lbs



Main bearing cap bolts36-39
Connecting rod cap nuts
1990 and later Colt, Lancer, Mirage models
Step 115
Step 2Tighten a quarter of a turn
(90°)
All other models23-25
Different fuel mixture inlet valves13-16
*Also see Part A of this Chapter

1.6L engines



Cylinder head deformation
Rated0.05mm
Maximum allowable
1990 and later Colt, Lancer, Mirage models0.2 mm
All others0.1 mm.
Valve mechanism
Valve chamfer width
Inlet valves (DOHC)
Rated1.0 mm
Minimum allowable0.7mm
Inlet valves (SOHC)
Rated1.5mm
Minimum allowable1.0 mm
Exhaust valves (all models)
Rated1.5 mm
Minimum allowable1.0 mm
Valve stem diameter
SOHC (inlet and outlet)8.0 mm
DOHC
Inlet6.6 mm
Graduations6.5 mm
Gap between valve stem and guide sleeve
Inlet valves (SOHC)
Nominal0.03-0.06mm
Maximum allowable0.10 mm
Inlet valves (DOHC)
Nominal0.02-0.05mm
Maximum allowable0.10 mm
Exhaust valves (all models)
Nominal0.05-0.09mm
Maximum allowable0.15mm
Valve springs
Maximum allowable warp4°
Pressure24 kg when compressed to a length of 27.3 mm
Installation height
SOHC37.3mm
DOHC
Free length
SOHC44.6mm
DOHC48.3mm
Thin mixture inlet valves (only models with one camshaft)
(only models
Valve stem diameter4.30 mm
Chamfer angle45°Spring
Free length29.60mm
Resistance34.3 N at 21.5mm length
Crankshaft and connecting rods
Connecting rod journal
Diameter45mm
Maximum allowable ovality and taper0.015mm
Bearing lubrication gap0.02-0.05mm
Connecting rod side clearance0.10-0.25mm
Main journals
Diameter57.0mm
Maximum allowable ovality and taper0.015mm
Maximum runout allowed0.005 mm
Bearing lubrication gap0.02-0.05mm
Crankshaft end play0.05-0.18mm
Cylinders
Diameter (nominal)
SOHC76.9 mm
DOHC82.3mm
Maximum allowable ovality and taper
SOHC0.02mm
DOHC0.01mm
Pistons and piston rings
Pistons diameter (nominal) *
SOHC76.9 mm
DOHC82.3 mm
Clearance between piston and cylinder walls
SOHC
1985 and 1986 models0.02-0.04mm
1987 and 1988 models0.03-0.05mm
DOHC
1989 models0.03-0.05mm
1990 and later models0.02-0.04mm
Piston ring end clearance
Compression rings (SOHC)
Top ring
Nominal0.25-0.40mm
Maximum allowable0.08mm
Second ring
Nominal0.20-0.35mm
Maximum allowable0.08mm
Oil scraper ring (SOHC)
Nominal0.20-0.70mm
Maximum allowable0.10 mm
Compression rings (DOHC)
Top ring
Nominal0.25-0.40mm
Maximum allowable0.80mm
Second ring
Nominal0.35-0.50mm
Maximum allowable0.08mm
Oil scraper ring (DOHC)
Nominal0.20-0.70mm
Maximum allowable0.10mm
Piston ring side clearance
SOHC
Top compression ring
Nominal0.03-0.07mm
Maximum allowable0.10mm
Second compression ring
Nominal0.02-0.06mm
Maximum allowable0.10mm
DOHC (both compression rings)
Nominal0.03-0.07mm
Maximum allowable0.10mm
*At 2mm from the bottom of the piston skirt



Torques*, Ft-lbs



SOHC
Main bearing cap bolts36-39
Connecting rod cap nuts 23-25
Depressurization valve plug27-29
Thin mixture inlet valves13-16
DOHC
Main bearing cap bolts47-51
Connecting rod cap nuts36-38
Depressurization valve plug29-36
*Also see Part A of this Chapter

1.8, 2.0 and 2.4L engines



Cylinder head deformation
Nominal0.05mm
Adjustable0.2mm
Valve mechanism
Valve chamfer width
SOHC
Inlet valves
Nominal1.2mm
Minimum allowable0.7mm
Exhaust valves
Nominal2.0 mm
Minimum allowable1.5 mm
DOHC
Inlet valves
Nominal1.0 mm
Minimum allowable0.7mm
Exhaust valves
Nominal1.5mm
Minimum allowable1.0 mm
Valve stem diameter
SOHC (inlet and outlet)8.0 mm
DOHC
Intake6.58 mm
Graduations6.55 mm
Gap between valve stem and guide sleeve
SOHC
Inlet valves
Nominal0.03-0.06mm
Maximum allowable0.10 mm
Exhaust valves
Nominal0.05-0.09mm
Maximum allowable0.15mm
DOHC
Inlet valves
Nominal0.02-0.05mm
Maximum allowable0.10mm
Exhaust valves
Nominal0.05-0.09mm
Maximum allowable0.15mm
Valve springs
Maximum allowed deformation3°Pressure
Galant twin cam models 1990 and later300 N
All other models322 N
Installation height
2,4,1,8 and 2.0L models (except Galant)40.4mm
Galant models with 2.0L engine (SOHC and DOHC)-
Free length
Cordia/Tredia models with one junctionshaft
1.8L (1983-1986)47.5 mm
1.8L (1987 and 1988)49.8mm
2.0L (1984 and 1985)47.5mm
2.0L (1986-1988)49.8 mm
Galant single cam models
2.4L (1985-1987)49.8 mm
2.0L (1989 release and later)49.8mm
Dual camshaft Galant models
2.0L (release models before March 1988)45.8mm
2.0L (release models after April 1988)48.3mm
Thin mixture inlet valves
Valve stem diameter4.30mm
Chamfer angle45°
Spring
Free length29.60mm
Resistance34.3 N at 21.5mm length
Crankshaft and connecting rods
Connecting rod journal
Diameter45.0 mm
Maximum allowable ovality and taper0.01mm
Bearing lubrication gap0.02-0.05mm
Connecting rod side clearance0.10-0.25mm
Main journals
Diameter57.0 mm
Maximum ovality allowed0.016 m
Maximum allowable taper0.005mm
Bearing lubrication gap0.02-0.05mm
Crankshaft end play0.05-0.18mm
Cylinders
Diameter (nominal)
Cordia/Tredia
1983-1985 1.8L85.0 mm
1986-1988 1.8L80.6 mm
1984-1988 2.0L85.0 mm
Galant
2.4L86.5mm
2.0L (SOHC and DOHC)85.1 mm
Maximum allowable ovality and taper0.02mm
Pistons and piston rings
Pistons diameter (nominal) *
2.4L86.5mm
2.0L and 1.8L85.0 mm
1.8L turbo80.6mm
Clearance between piston and cylinder walls
2.4L0.02-0.04mm
2.0L and 1.8L0.01-0.03mm
1.8L turbo0.03-0.05mm
Piston ring end clearance
1.8L turbo and 2.0L SOHC (except 2.0L Galant)
Top compression ring
Nominal0.25-0.45mm
Maximum allowable
Second compression ring
Nominal0.20-0.40mm
Maximum allowable-
Oil scraper ring
Nominal0.20-0.70mm
Maximum allowable-
1.8L turbo SOHC
Top compression ring
Nominal0.30-0.45mm
Maximum allowable-
Second compression ring
Nominal0.20-0.35mm
Maximum allowable-
Oil scraper ring
Nominal0.20-0.70mm
Maximum allowable-
2.4L and 2.0L UNC
Top compression ring
Nominal0.25-0.40mm
Maximum allowable0.80 mm
Second compression ring (only for 2.4L models)
Nominal0.20-0.40mm
Maximum allowable0.80mm
Second compression ring (only for 2.0L models)
Nominal0.35-0.50mm
Maximum allowable0.80 mm
Oil scraper ring
Nominal0.20-0.70mm
Maximum allowable0.10mm
2.0L SOHC Galant
Top compression ring
Nominal0.25-0.40mm
Maximum allowable0.80 mm
Second compression ring
Nominal0.20-0.35mm
Maximum allowable0.80 mm
Oil scraper ring
Nominal0.20-0.70mm
Maximum allowable0.10 mm
Piston ring side clearance
2.4L (1985-1987)
Top compression ring
Nominal0.05-0.09mm
Maximum allowable-
Second compression ring
Nominal0.02-0.06mm
Maximum allowable-
2.4L (only 1988) and 2.0L S0HC Galant
Top compression ring
Nominal0.03-0.07mm
Maximum allowable0.10mm
Second compression ring
Nominal0.02-0.06mm
Maximum allowable0.10 mm
SOHC 2.0L and 1.8L (except 2.0L Galant)
Top compression ring
Nominal0.045-0.085mm
Maximum allowable-
Second compression ring
Nominal0.02-0.06mm
Maximum allowable-
2.0L D0HC
Both compression rings
Nominal0.03-0.07mm
Maximum allowable0.10mm
*At 2mm from the bottom of the piston skirt

Torques*, Ft-lbs



Main bearing cap bolts
SOHC36-39
DOHC47-51.
Connecting rod cap nuts
SOHC23-25
DOHC36-38
Different fuel mixture inlet valves13-16
Depressurization valve plug29-36
Also see Part A of this Chapter
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Colt 2 and 3: Engine overhaul
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Engine overhaul — general notes
Engine diagnostics using a vacuum gauge, compression check and dismantling of the power unit
Installation of the piston of the cylinder No. 1
Engine Removal — General Description
Engine — removal and installation
Engine overhaul — alternative methods
Engine overhaul — disassembly procedure
Cylinder head — disassembly
Cylinder head — cleaning and inspection
Cylinder Head — Assembly
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Colt 5 (1995-2003, petrol) 
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Colt 4 and 5 (1991-2003) 
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Colt 2 and 3 (1983-1993) 
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