Mitsubishi Montero (2004+). Manual — part 119

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL

11B-35

3. Before fitting the valve seat, either heat the cylinder head up

to approximately 250

°C (482°F) or cool the valve seat in

liquid nitrogen, to prevent the cylinder head bore from
galling.

4. Using a valve seat cutter, correct the valve seat to the

specified width and angle. Using a valve seat cutter, correct
the valve seat to the specified width and angle. See "VALVE
SEAT RECONDITIONING PROCEDURE" on the previous
page.

.

VALVE GUIDE REPLACEMENT PROCEDURE
1. Remove the snap ring from the exhaust valve guide.
2. Using a press, remove the valve guide toward the cylinder

head gasket surface.

CAUTION

Do not install a valve guide of the same size again.
3. Re bore the valve guide hole of the cylinder head so that it

fits the press-fitted oversize valve guide.

Valve guide hole diameter:

0.05 oversize 11.05

− 11.07 mm (0.4350 − 0.4358 inch)

0.25 oversize 11.25

− 11.27 mm (0.4429 − 0.4457 inch)

0.50 oversize 11.50

− 11.52 mm (0.4528 − 0.4535 inch)

4. Install the new snap ring into the groove of exhaust valve

guide.

5. Press-fit the valve guide until it protrudes 14 mm (0.55 inch)

from the cylinder head top surface as shown in the
illustration.

NOTE: When press-fitting the valve guide, work from the cylin-
der head top surface.
NOTE: After installing the valve guides, insert new valves in
them to check for sliding condition.

AKX00712

REMOVAL

INSTALLATION

PRESS

PRESS

PUSH ROD

VALVE
GUIDE

VALVE
GUIDE

AB

AKX00727

14 mm
(0.55 in)

AB

OIL PAN AND OIL PUMP

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ENGINE OVERHAUL

11B-36

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

M1113008100367

Required Special Tool

• MD998717: Crankshaft Front Oil Seal Installer

AK201079

1

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

11

23 ± 3 N·m
17 ± 2 ft-lb

39 ± 5 N·m
29 ± 4 ft-lb

19 ± 3 N·m
14 ± 2 ft-lb

44 ± 5 N·m
33 ± 4 ft-lb

10 ± 2 N·m
87 ± 17 in-lb

14 ± 1 N·m
124 ± 9 in-lb

9 ± 3 N·m
80 ± 26 in-lb

10 ± 2 N·m
87 ± 17 in-lb

11 ± 1 N·m
97 ± 9 in-lb

11 ± 1N·m
97 ± 9 in-lb

AB

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

54 ± 5 N·m
40 ± 4 ft-lb

21

14 ± 1 N·m
124 ± 9 in-lb

9 ± 3 N·m
80 ± 26 in-lb

9 ± 3 N·m
80 ± 26 in-lb

REMOVAL STEPS

>>F<<

1. ENGINE OIL PRESSURE SWITCH
2. OIL COOLER BY-PASS VALVE

>>E<<

3. OIL FILTER
4. OIL FILTER BRACKET
5. OIL FILTER BRACKET GASKET
6. DRAIN PLUG

>>D<<

7. DRAIN PLUG GASKET
8. COVER

<<A>> >>C<<

9. OIL PAN
10. BAFFLE PLATE
11. OIL SCREEN

12. OIL SCREEN GASKET
13. RELIEF PLUG
14. RELIEF SPRING
15. RELIEF PLUNGER

>>B<<

16. CRANKSHAFT OIL SEAL
17. OIL PUMP CASE
18. OIL PUMP CASE GASKET
19. OIL PUMP COVER

<<B>> >>A<<

20 OIL PUMP OUTER ROTOR

<<B>> >>A<<

21. OIL PUMP INNER ROTOR

REMOVAL STEPS (Continued)

OIL PAN AND OIL PUMP

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ENGINE OVERHAUL

11B-37

REMOVAL SERVICE POINTS

.

<<A>> OIL PAN REMOVAL
1. Remove the bolts A shown in the illustration first.
2. Remove all other bolts.

CAUTION

Do not use a scraper or special tool to remove the oil pan.
3. Remove the oil pan.

4. Thread the bolt into the illustrated bolt hole to remove the oil

pan.

.

<<B>> OUTER ROTOR/INNER ROTOR REMOVAL
Make alignment dots on the outer and inner rotors for assem-
bly.

INSTALLATION SERVICE POINTS

.

>>A<< INNER ROTOR/OUTER ROTOR INSTALLATION
Apply engine oil to the rotors. Then, install the rotors ensuring
that the alignment dots made at disassembly are properly
aligned.

.

AKX01450 AB

TIMING BELT SIDE

A

AKX01451

ENGINE REAR SIDE

AB

AKX00742AB

ALIGNMENT DOTS

AKX00742AB

ALIGNMENT DOTS

OIL PAN AND OIL PUMP

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ENGINE OVERHAUL

11B-38

>>B<< CRANKSHAFT OIL SEAL INSTALLATION
1. Install the guide of special tool MD998717 to the front end of

the crankshaft.

2. Apply engine oil to the lip area of a new oil seal and push it

in until it contacts the oil pump case.

3. Using special tool MD998717, press-fit the oil seal into the

oil pump case.

.

>>C<<OIL PAN INSTALLATION
1. Clean the gasket surfaces of the cylinder block and upper oil

pan.

CAUTION

When installing the upper oil pan, be sure not to expel the
sealant from the oil pan flange at portion A in the illustra-
tion.
2. Apply a 4 mm (0.2 inch) diameter bead of sealant Mitsubishi

Genuine Parts number MD970389, or equivalent to the oil
pan. Be sure to install the oil pan quickly while the sealant is
wet.
NOTE: Install the oil pan within 15 minutes after applying liq-
uid 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.

3. Tighten the upper oil pan bolts in the sequence shown.

Tightening torque: 9

± 3 N⋅m (80 ± 26 in-lb)

4. After installation, keep the sealed area away from the oil and

coolant for approximately one hour.

.

AKX00659 AB

MD998717 (GUIDE)

OIL SEAL

AKX00660

MD998717

AB

AKX01403AB

LIQUID GASKET APPLICATION AREA

(TOP VIEW)

A

AKX01404AC

1

5

11

14

15

10

6

2

3

7

12

16

9

13

8

4

FLANGE BOLT TIGHTENING

SEQUECE(BOTTOM VIEW)