Mitsubishi 380. Manual - part 458

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL <3.8L ENGINE>

11B-58

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 

− 0.03 mm (0.0008 − 0.0012 inch) <No.1, 4>

0.03 

− 0.04 mm (0.0012 − 0.0016 inch) <No.2, 3>

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.

.

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)

.

AK201526

AKX00738

AKX00739AB

12 mm (0.47 in)

BOTTOM

CENTER

SPECIFICATIONS

ENGINE OVERHAUL <3.8L ENGINE>

11B-59

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: 95.0 mm (3.740 inches) 
Cylindricality: 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.

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1113023400688

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

ITEMS

SPECIFICATIONS

Alternator and drive belt

Adjusting bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Crankshaft bolt

185 

± 5 N⋅m (137 ± 3 ft-lb)

Drive belt tensioner nut

49 

± 9 N⋅m (37 ± 6 ft-lb)

Alternator bolt

49 

± 9 N⋅m (37 ± 6 ft-lb)

Alternator bracket bolt

49 

± 9 N⋅m (37 ± 6 ft-lb)

Idler pulley nut

49 

± 9 N⋅m (37 ± 6 ft-lb)

SPECIFICATIONS

ENGINE OVERHAUL <3.8L ENGINE>

11B-60

Oil dipstick guide bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Power steering pump bracket bolt

41 

± 8 N⋅m (30 ± 6 ft-lb)

Power steering pump bracket stay bolt M8

24 

± 4 N⋅m (18 ± 3 ft-lb)

Power steering pump bracket stay bolt M10

44 

± 10 N⋅m (33 ± 7 ft-lb)

Tensioner bracket bolt (Flange bolt)

49 

± 9 N⋅m (37 ± 6 ft-lb)

Tensioner bracket bolt (Bolt, washer assembly)

41 

± 8 N⋅m (30 ± 6 ft-lb)

Intake manifold plenum and throttle body

Boost sensor bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Intake manifold plenum bolt

28 

± 4 N⋅m (21 ± 3 ft-lb)

Intake manifold plenum stay bolt M8

18 

± 2 N⋅m (13 ± 1 ft-lb)

Intake manifold plenum stay bolt M10

36 

± 6 N⋅m (27 ± 4 ft-lb)

Solenoid valve bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Throttle body bolt

28 

± 4 N⋅m (21 ± 3 ft-lb)

Throttle body stay bolt

18 

± 2 N⋅m (13 ± 1 ft-lb)

Ignition system

Ignition coil bolt

10 

± 2 N⋅m (87 ± 17 in-lb)

Spark plugs

25 

± 5 N⋅m (18 ± 4 ft-lb)

Camshaft position sensor bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Camshaft position sensor support bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Camshaft position sensing cylinder bolt

22 

± 4 N⋅m (16 ± 3 ft-lb)

Timing belt

Adjusting bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Auto-tensioner bolt

23 

± 3 N⋅m (18 ± 2 ft-lb)

Bracket bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Camshaft sprocket bolt

88 

± 10 N⋅m (65 ± 7 ft-lb)

Crankshaft position sensor bolt

8.5 

± 0.5 N⋅m (76 ± 4 in-lb)

Engine support bracket bolt

45 

± 5 N⋅m (34 ± 4 ft-lb)

Idler pulley bolt

44 

± 5 N⋅m (33 ± 4 ft-lb)

Tensioner pulley bolt

48 

± 6 N⋅m (35 ± 4 ft-lb)

Tensioner arm bolt

44 

± 10 N⋅m (33 ± 7 ft-lb)

Timing belt front cover bolt M6

11 

± 1 N⋅m (95 ± 9 in-lb)

Timing belt front cover bolt M8, M10

14 

± 1 N⋅m (122 ± 9 in-lb)

Timing belt rear cover bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Intake manifold and fuel parts

Injector and fuel rail bolt

12 

± 1 N⋅m (104 ± 9 in-lb)

Intake manifold nut

20 

− 23 N⋅m (15 − 17 ft-lb)

Water pump and water pipes

Engine coolant temperature sensor

29 

± 10 N⋅m (22 ± 7 ft-lb)

Thermostat housing bolt M6

11 

± 1 N⋅m (95 ± 9 in-lb)

Thermostat housing bolt M8

19 

± 1 N⋅m (14 ± 1 ft-lb)

ITEMS

SPECIFICATIONS

SPECIFICATIONS

ENGINE OVERHAUL <3.8L ENGINE>

11B-61

Water inlet fitting bolt

19 

± 1 N⋅m (14 ± 1 ft-lb)

Water pump bolt M8

24 

± 3 N⋅ (17 ± 2 ft-lb)

Water pump bolt M10

42 

± 8 N⋅m (31 ± 6 ft-lb)

Exhaust manifold 

Connector bracket bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Engine hanger bolt

35 

± 6 N⋅m (26 ± 4 ft-lb)

Exhaust manifold nut

44 

± 5 N⋅m (33 ± 4 ft-lb)

Exhaust manifold stay bolt M8

19 

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust manifold stay bolt M10

44 

± 8 N⋅m (33 ± 5 ft-lb)

Exhaust manifold stay bolt M12

75 

± 10 N⋅m (56 ± 7 ft-lb)

Heat protector bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Heated oxygen sensor

44 

± 5 N⋅m (33 ± 4 ft-lb)

Rocker arms and camshaft

Thrust case bolt

13 

± 2 N⋅m (115 ± 17 in-lb)

Positive crankcase ventilation valve

10 

± 2 N⋅m (87 ± 17 in-lb)

Rocker arms and shaft bolt

31 

± 3 N⋅m (23 ± 2 ft-lb)

Rocker cover bolt

3.5 

± 0.5 N⋅m (31 ± 4 in-lb)

Cylinder head and valve

Cylinder head bolt

108 

± 5 N⋅m (80 ± 4 ft-lb) → 0 N⋅m (0 in-lb) 

→ 108 ± 5 N⋅m (80 ± 4 ft-lb)

Oil pan and oil pump

Baffle plate bolt

9.0 

± 2.0 N⋅m (80 ± 17 in-lb)

Cover bolt

10.8 

± 0.9 N⋅m (96 ± 7 in-lb)

Drain plug

39 

± 5 N⋅m (29 ± 4 ft-lb)

Engine oil pressure switch

10 

± 2 N⋅m (87 ± 17 in-lb)

Oil filter bracket bolt M8

23 

± 3 N⋅m (18 ± 2 ft-lb)

Oil filter bracket bolt M10

41 

± 8 N⋅m (30 ± 6 ft-lb)

Oil filter bracket cover bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Oil pan, lower bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Oil pan, upper bolt

9.0 

± 3.0 N⋅m (80 ± 26 in-lb)

Oil pump case bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Oil pump cover bolt 

10 

± 2 N⋅m (87 ± 17 in-lb)

Oil screen bolt

19 

± 3 N⋅m (14 ± 2 ft-lb)

Relief plug

44 

± 5 N⋅m (33 ± 4 ft-lb)

Piston and connecting rod

Connecting rod cap nut

27 

± 2 N⋅m (20 ± 1 ft-lb) + 90° to 94°

Crankshaft and cylinder block

Bearing cap bolt

74 

± 4 N⋅m (54 ± 3 ft-lb)

Drive plate bolt A/T

74 

± 1 N⋅m (54 ± 1 ft-lb)

Flywheel bolts M/T

132 

± 5 N⋅m(97± 3 ft-lb

ITEMS

SPECIFICATIONS