Mitsubishi Montero (2002-2004). Manual — part 454
CRANKSHAFT AND CYLINDER BLOCK
TSB Revision
ENGINE OVERHAUL
11B-49
INSTALLATION SERVICE POINTS
.
>>A<< KNOCK SENSOR BRACKET INSTALLATION
Check that the bracket is in proper contact with the cylinder
block boss and tighten to the specified torque in the order
shown.
Tightening torque: 28
± 2 N⋅m (21 ± 1 ft-lb)
.
>>B<< CRANKSHAFT BEARING INSTALLATION
1. Measure the crankshaft journal diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors/
marks of its journals are painted/stamped at the positions
shown in the illustration.
2. The cylinder block bearing bore diameter identification
marks are stamped at the position shown in the illustration
from left to right, beginning at No.1.
AKX00649
TIMING BELT SIDE
AB
1
2
3
4
AKX01391
No.4 JOURNAL
No.1 JOURNAL
No.2 JOURNAL
No.3 JOURNAL
LOCATION OF IDENTIFCATION COLOR
AB
AKX00648
BEARING BORE
DIAMETER
IDENTIFICATION
MARK
CYLINDER INSIDE
DIAMETER SIZE MARK
TIMING BELT SIDE
AB
No.4
No.2
No.3
No.1
CRANKSHAFT JOURNAL OUTSIDE
DIAMETER
CYLINDER BLOCK
BEARING BORE
CRANKSHAFT BEARING
IDENTIFICATION
COLOR
SIZE mm (in)
IDENTIFICATION MARK
IDENTIFICATION COLOR
Yellow
63.994
− 64.000
(2.5194
− 2.5197)
I
Pink
II
Red
III
Green
None
63.988
− 63.994
(2.5192
− 2.5194)
I
Red
II
Green
III
Black
CRANKSHAFT AND CYLINDER BLOCK
TSB Revision
ENGINE OVERHAUL
11B-50
3. From the following table, select a bearing whose size is
appropriate for the crankshaft journal outside diameter. If the
crankshaft journal outside diameter ID color is "yellow" and
the cylinder block bearing bore ID mark is "III", for example,
select a bearing whose ID color is "green".
If there is no ID color paint on the crankshaft, measure the
journal outside diameter and select a bearing appropriate for
the measured valve.
4. Install bearings with a groove to the cylinder block.
5. Install the bearings having no groove to the bearing cap.
.
>>C<< CRANKSHAFT THRUST BEARING INSTALLATION
1. Install the thrust bearing in the No.3 bearing bore in the
cylinder block and in the bearing cap. For easier installation,
apply engine oil to the bearings; this will help hold them in
position.
2. The thrust bearings must be installed with their groove
toward the crankshaft web.
.
White
63.982
− 63.988
(2.5190
− 2.5192)
I
Green
II
Black
III
Brown
CRANKSHAFT JOURNAL OUTSIDE
DIAMETER
CYLINDER BLOCK
BEARING BORE
CRANKSHAFT BEARING
IDENTIFICATION
COLOR
SIZE mm (in)
IDENTIFICATION MARK
IDENTIFICATION COLOR
AKX00621
IDENTIFICATION COLOR
AB
AKX00623
GROOVE
FOR UPPER
FOR LOWER
AB
AKX01393AB
GROOVE
THRUST
BEARING
CRANKSHAFT AND CYLINDER BLOCK
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ENGINE OVERHAUL
11B-51
>>D<< BEARING CAP/BEARING BOLT INSTALLATION
1. Attach the bearing cap on the cylinder block as shown in the
illustration.
2. Tighten the bearing cap bolts to specified torque in the
sequence shown in the illustration.
Tightening torque: 74
± 4 N⋅m (54 ± 3 ft-lb)
3. Check that the crankshaft rotates smoothly.
4. Check the end play. If it exceeds the limit value, replace the
thrust bearing.
Standard value: 0.05
− 0.25 mm (0.002 − 0.009 inch)
Limit: 0.3 mm (0.01 inch)
.
>>E<< CRANKSHAFT REAR OIL SEAL INSTALLATION
Using special tool MD998718, press-fit a new crankshaft rear
oil seal into the oil seal case.
.
AKX01395AB
FRONT MARK
BEARING CAP BOLT
NUMBERS ARE
TIGHTENING SEQUENCE
BEARING CAP
CRANKSHAFT
CYLINDER BLOCK
AK201528
AKX00693
MD998718
OIL SEAL
CASE
AB
CRANKSHAFT AND CYLINDER BLOCK
TSB Revision
ENGINE OVERHAUL
11B-52
>>F<< OIL SEAL CASE INSTALLATION
1. Apply the sealant Mitsubishi Genuine Part number
MD970389 or equivalent to the oil seal case.
2. Apply a small amount of engine oil to the entire
circumference of the oil seal lip section, and place the oil
seal case on the cylinder block.
NOTE: Install the oil seal case within 15 minutes after apply-
ing liquid gasket.
NOTE: Then wait at least one hour. Never start the engine
or let engine oil or coolant touch the adhesion surface during
that time.
INSPECTION
M1113008800281
.
CRANKSHAFT JOURNAL OIL CLEARANCE
<PLASTIC GAUGING MATERIAL METHOD>
1. Remove oil from the crankshaft journal and crankshaft
bearing inner surface.
2. Install the crankshaft.
3. Cut plastic gauging material to the same length as the width
of the bearing and place it on the journal in parallel with its
axis.
4. Install the crankshaft bearing cap carefully and tighten the
bolts to the specified torque.
Tightening torque: 74
± 4 N⋅m (54 ± 3 ft-lb)
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastic gauging material
at its widest section by using a scale printed on the plastic
gauging material bag.
Standard value: 0.02
− 0.04 mm (0.0008 − 0.0016 inch)
Limit: 0.1 mm (0.003 inch)
.
CRANKSHAFT REAR OIL SEAL
1. Check the oil seal lip for wear and damage.
2. Check the rubber for deterioration or hardening.
3. Check the oil seal case for cracks and damage.
.
AK201083
AK101043AB
PLASTIC
GAUGING
MATERIAL
AK201526
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