Mitsubishi Montero (1991+). Manual - part 7

and No. 2. Install bearing caps with front mark arrow facing the same

direction as similar mark on cylinder head beside bearing journal.

Note bearing cap number and identification mark ("I" for intake

camshaft and "E" for exhaust). See Fig. 22.

         3) Install front and rear bearing caps. Tighten bearing cap

bolts to specification. See TORQUE SPECIFICATIONS (3000GT) table at

end of article. Coat camshaft oil seal area with oil. Using Seal

Installer (MD998761), install camshaft oil seal. Using Circular

Packing Installer (MD998761), install circular packing.

         4) Install crankshaft angle sensor adapter. To complete

installation, reverse removal procedure. Tighten bolts to

specification. See TORQUE SPECIFICATIONS table.

         REAR CRANKSHAFT OIL SEAL

         Removal

         Remove transaxle/transmission. See appropriate article in

TRANSMISSION SERVICING or CLUTCHES. Remove flywheel or drive plate.

Remove rear oil seal case. Pry seal from seal case.

         Installation

         To install, coat seal lip with oil. Using Seal Installer

(MD998718), install seal in seal case. Apply sealant to sealing

surface of seal case. Install seal case. Install flywheel or drive

plate. Tighten bolts to specification. See appropriate TORQUE

SPECIFICATIONS table at end of article. To complete installation,

reverse removal procedure.

         WATER PUMP

         Removal

         Drain cooling system. Remove timing belt and crankshaft

sprocket. See TIMING BELT under REMOVAL & INSTALLATION. Remove coolant

pipes to water pump (if required). Remove water pump bolts, noting

length and location for reassembly reference. Remove water pump.

         Installation

         To install, reverse removal procedure using new gasket and

"O" rings. Coat all "O" rings with water before installation. Install

water pump and gasket. Tighten bolts to specification. See appropriate

TORQUE SPECIFICATIONS table at end of article.

         OIL PAN

         Removal (Montero)

         1) Remove hood. Remove skid plate and lower covers. Raise and

support vehicle. Disconnect and remove exhaust pipe from exhaust

manifolds. Drain engine oil. Remove starter cover and starter. Remove

oil pressure sending unit connector. Remove front suspension

crossmember.

         2) Remove transmission stays. Remove ground cable and motor

mount heat shields. Attach engine hoist. Remove motor mount bolts.

Raise engine, and insert a 1" wood spacer between front insulator and

mounts. Lower engine onto wood blocks.

         3) Raise vehicle using a hoist. Remove oil pan bolts. Using

Seal Cutter (MD998727), separate oil pan from cylinder block. Remove

pan from vehicle.

         Removal (Pickup)

         1) Remove skid plate and lower covers. Raise and support

vehicle. Drain engine oil. Using Steering Linkage Puller (C-3894-A or

MB990635), disconnect relay rod from idler arm and steering box.

         2) Remove oil pan bolts. Using Seal Cutter (MD998727),

separate oil pan from cylinder block. Remove pan from vehicle.

         Removal (3000GT)

         1) Raise and support vehicle. Remove engine undercovers.

Drain engine oil. Disconnect O2 sensor connector. Remove front exhaust

pipe from manifolds. On All-Wheel Drive (AWD) models, drain transfer

assembly. Remove front air dam. Remove AWD drive shaft and transfer

assembly.

         2) On turbocharged models, remove oil return lines from oil

pan. On all models, remove starter. Remove crossmember and transaxle

stays. Remove bellhousing cover. Remove oil pan bolts. Using Seal

Cutter (MD998727), separate oil pan from cylinder block. Remove pan

from vehicle.

         Inspection (All Models)

         Clean sealant from oil pan mating surface on engine block and

oil pan. Check oil pan for cracks and damage. Check sealing surface

for damage and deformation. Inspect oil pick-up screen for damage.

         Installation (All Models)

         1) To install, reverse removal procedure. Apply sealant to

oil pan flange in a continuous .16" (4 mm) diameter bead. See  Fig. 22.

Install oil pan within 15 minutes of applying sealant.

         2) Tighten bolts to specification in proper sequence. See

appropriate TORQUE SPECIFICATIONS table at end of article. Wait at

least 30 minutes before adding oil and starting engine. On AWD models,

refill transfer assembly with GL-4 hypoid gear oil. On all models,

complete installation by reversing removal procedure.

Fig. 22:  Sealant Application & Oil Pan Bolt Tightening Sequence

Courtesy of Mitsubishi Motor Sales of America, Inc.

         OVERHAUL

         CYLINDER HEAD

         Check cylinder head height and warpage at gasket and manifold

surfaces. Resurface head if warpage exceeds specification. See

appropriate CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of

article. Replace cylinder head if it is not within specification after

resurfacing.

         VALVE SPRINGS

         Measure free length of valve springs. Check spring pressure

at specified height. Replace springs if not within specification. See

appropriate VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS

at end of article. Check valve spring for squareness. Replace spring

if out-of-square exceeds 4 degrees.

NOTE:    Install valve springs with enamel-coated side toward valve

         spring retainer.

         VALVE STEM OIL SEALS

         With valves removed, remove oil seals from cylinder head.

Coat new seals with oil. Using Valve Stem Oil Seal Installer (MD998377

for Montero, MD998729 for Pick-up or MD998763 for DOHC), install valve

stem oil seal.

         VALVE GUIDES

         1) Measure valve stem-to-guide clearance. Replace valve guide

if not within specification. See appropriate VALVES & VALVE SPRINGS

table under ENGINE SPECIFICATIONS at end of article.

         2) Using rod of Valve Guide Remover/Installer (MD998115) for

SOHC, drive out valve guide toward combustion chamber side of cylinder

head. Note length of valve guides. On DOHC, use press and

appropriately-sized rod to press valve guide toward combustion chamber

side of head.

         3) On all models, cylinder head must be bored to install

oversized valve guide once guide is removed. DO NOT install valve

guide of same dimension as old guide. Bore cylinder head to

specification for oversize valve guide. See appropriate OVERSIZE VALVE

GUIDE SPECIFICATIONS table.

         4) On SOHC, install proper length valve guide. Intake guide

is 1.73" (43.9 mm) long and exhaust guide is 1.89" (48.0 mm) long. On

all models, position cylinder head with combustion chamber downward.

         5) Using valve guide remover/installer, install valve guide.

Remover/installer sets valve guide height on SOHC. On DOHC, install

valve guide to .689" (17.5 mm), measured from cylinder head spring

seating area to top of valve guide. On all models, ensure valve slides

smoothly in valve guide. Recondition valve seat.

OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE (SOHC)

Oversize In. (mm)     Size Mark            Bore Size In. (mm)

.002 (.05)  ............  5  ...  .5138-.5145 (13.050-13.068)

.010 (.25)  ............  25  ..  .5217-.5224 (13.251-13.269)

.020 (.51)  ............  50  ..  .5315-.5322 (13.500-13.518)

OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE (DOHC)

Oversize In. (mm)     Size Mark            Bore Size In. (mm)

.002 (.05)  ............  5  ...  .4744-.4751 (12.050-12.068)

.010 (.25)  ............  25  ..  .4823-.4830 (12.251-12.269)

.020 (.51)  ............  50  ..  .4921-.4928 (12.500-12.518)

         VALVE SEAT (SOHC)

         1) Valve seat sinkage should be checked after valve and valve

seat have been reconditioned and lightly lapped. With valve assembly

installed, measure installed height of valve spring between spring

seat and retainer. Valve seat must be replaced if measurement exceeds

1.63" (41.4 mm).

         2) Grind seat wall thickness until seat can be removed.

Machine cylinder head to accommodate an oversize valve seat. See

OVERSIZE VALVE SEAT SPECIFICATIONS (SOHC) table. Heat cylinder head to

approximately 480



F (250



C), and install valve seat. Grind valve seat

using 45-degree stone. Use 30-degree and 60-degree stones to set seat

height.

OVERSIZE VALVE SEAT SPECIFICATIONS TABLE (SOHC)

Application                                         In. (mm)

Intake

  Bore Depth

   .012" (.3 mm) Oversize  ............  .311-.319 (7.9-8.1)

   .024" (.6 mm) Oversize  ............  .323-.331 (8.2-8.4)

  Bore Diameter

   .012" (.3 mm) Oversize  ..  1.7440-1.7451 (44.300-44.325)

   .024" (.6 mm) Oversize  ..  1.7559-1.7569 (44.600-44.625)

Exhaust

  Bore Depth

   .012" (.3 mm) Oversize  ............  .311-.319 (7.9-8.1)

   .024" (.6 mm) Oversize  ............  .323-.331 (8.2-8.4)

  Bore Diameter

   .012" (.3 mm) Oversize  ..  1.5079-1.5089 (38.300-38.325)

   .024" (.6 mm) Oversize  ..  1.5197-1.5207 (38.600-38.625)

         VALVE SEAT (DOHC)

         Grind seat wall thickness until seat can be removed. Machine

cylinder head to accommodate an oversize valve seat. See OVERSIZE

VALVE SEAT SPECIFICATIONS (DOHC) table. Chill cylinder head with

liquid nitrogen, and install valve seat. Grind valve seat using 45-

degree stone. Use 30-degree and 60-degree stones to adjust seat

height.

OVERSIZE VALVE SEAT SPECIFICATIONS TABLE (DOHC)

Application                                         In. (mm)

Intake

  Bore Depth

   .012" (.3 mm) Oversize  ............  .295-.303 (7.5-7.7)

   .024" (.6 mm) Oversize  ............  .307-.315 (7.8-8.0)

  Bore Diameter

   .012" (.3 mm) Oversize  ..  1.4291-1.4301 (36.300-36.325)

   .024" (.6 mm) Oversize  ..  1.4409-1.4419 (36.600-36.625)

Exhaust

  Bore Depth