Mitsubishi Montero (2004+). Manual — part 123

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-51

3. From the above 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 the groove toward 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

Red

II

Black

Green

III

Brown

Black

CRANKSHAFT JOURNAL OUTSIDE
DIAMETER

CYLINDER BLOCK
BEARING BORE

CRANKSHAFT
BEARING No.1, 4

CRANKSHAFT
BEARING No.2, 3

IDENTIFICATION
COLOR

SIZE mm (in)

IDENTIFICATION
MARK

IDENTIFICATION
COLOR

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-52

>>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-53

>>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

M1113008800430

.

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

CRANKSHAFT AND CYLINDER BLOCK

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ENGINE OVERHAUL

11B-54

CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use a flaw

detecting agent for the check. If defects are evident, correct,
or replace.

2. Using a straightedge and feeler gauge, check the block top

surface for warpage. Make sure that the surface is free from
gasket chips and other foreign matter.

Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 inch)

3. If the distortion is excessive, correct within the allowable

limit or replace.

Grinding limit: *0.2 mm (0.008 inch)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
227.9

− 228.1 mm (8.972 − 8.980 inches)

4. Check the cylinder walls for scratches and seizure. If defects

are evident, correct (bored to an oversize) or replace.

5. Using a cylinder gauge, measure the cylinder bore and

cylindricality. If worn badly, correct by boring the cylinders to
an oversize and replace pistons and piston rings. Measure
at the points shown in the illustration.

Standard value:

Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)

.

BORING CYLINDER
1. Oversize pistons to be used should be determined on the

basis of the largest bore cylinder.

Piston size identification

NOTE: Size mark is stamped on the piston top.

2. Measure the outside diameter of the piston to be used.

Measure it in the thrust direction as shown.

3. Based on the measured piston Outside Diameter (OD),

calculate the boring finish dimension.

Boring finish dimension = Piston OD + (clearance
between piston OD and cylinder)

− 0.02 mm (0.0008

inch) (honing margin)

CAUTION

To prevent distortion that may result from temperature rise
during honing, bore cylinders in the order of number 2,
number 4, number 6, number 1, number 3 and number 5.
4. Bore all cylinders to the calculated boring finish dimension.

AKX00738

AKX00739AB

12 mm (0.47 in)

BOTTOM

CENTER

SIZE

IDENTIFICATION MARK

0.25 mm (0.010 in) Oversize
diameter

0.25

0.50 mm (0.020 in) Oversize
diameter

0.50

AKX00740

PISTON OUTSIDE
DIAMETER

THRUST
DIRECTION

AB