Crankshaft and Cylinder Block
REMOVAL AND INSTALLATION
INSTALLATION SERVICE POINTS
]]A[[ CRANKSHAFT BEARING INSTALLATION
1. Measure the crankshaft journal diameter and confirm its classification from the provided table. In the case of a crankshaft supplied as a service part, identification marks of its journals are 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.
3. From the provided table, select a bearing whose size is appropriate for the crankshaft journal outside diameter. If the crankshaft journal outside diameter ID mark is "0" and the cylinder block bearing bore ID mark is "III", for example, select a bearing whose ID mark is "3". If there is no ID mark 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.
]]B[[ 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.
]]C[[ BEARING CAP/BEARING CAP 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: 94 Nm ± 4 (69 ± 3 ft. lbs.)
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)
]]D[[ CRANKSHAFT REAR OIL SEAL INSTALLATION
Using special tool MD998718, press-fit a new crankshaft rear oil seal into the oil seal case.
]]E[[ 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 applying liquid gasket.
^ Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.
INSPECTION
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 Nm (54 ± 3 ft. lbs.)
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.
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.
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use also 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): 210.4 - 210.6 mm (8.283 - 8.291 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 cylindricity. 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: 91.1 mm (3.587 inches) Cylindricity: 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.
5. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
Standard value: Cylinder Inside Diameter: 91.1 mm (3.587 inches) Cylindricity: 0.01 mm (0.0003 inch)
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.0015 inch)
NOTE: When boring cylinders, finish all six cylinders to the same oversize. Do not bore only one cylinder to an oversize.