Mitsubishi Montero (1991+). Manual - part 8

   .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  ..  1.3110-1.3120 (33.300-33.325)

   .024" (.6 mm) Oversize  ..  1.3228-1.3238 (33.600-33.625)

         VALVES

         Disassemble cylinder head. Measure valve stem diameter, valve

margin and overall length. Replace valves if not within specification.

See appropriate VALVES & VALVE SPRINGS table under ENGINE

SPECIFICATIONS at end of article. Check valve for worn valve tip.

Measure valve margin after grinding valves.

         LASH ADJUSTERS

         Before installation, submerge lash adjuster in diesel fuel.

Using a small wire, hold down internal check valve. Pump plunger up

and down 4 or 5 times to bleed air from lash adjuster.

         CYLINDER BLOCK ASSEMBLY OVERHAUL

         CYLINDER BLOCK

        1) Inspect cylinder block for cracks, warpage, cylinder bore

taper and out-of-round. Replace or repair cylinder block if it is not

within specification. See CYLINDER BLOCK table under ENGINE

SPECIFICATIONS at end of article.

         2) Measure cylinder bore and piston skirt diameter. Piston

skirt diameter should be measured at 90-degree angle to piston pin.

Clearance between piston and cylinder bore must be within

specification. See appropriate PISTONS, PINS & RINGS table under

ENGINE SPECIFICATIONS at end of article.

         PISTON & ROD ASSEMBLY

         1) Remove cylinder heads, and remove oil pan. See CYLINDER

HEADS and OIL PAN under REMOVAL & INSTALLATION. Ensure cylinder ridge

is removed. Mark connecting rod and cap for cylinder identification.

         2) Note front mark on piston and connecting rod. See  Fig. 23.

Mark is positioned toward timing belt side of engine. Remove rod cap

and piston assembly.

         3) Ensure piston ring end gap and side clearance are within

specification. See appropriate PISTONS, PINS & RINGS table under

ENGINE SPECIFICATIONS at end of article. Install rings on piston with

ring code identification marks toward top of piston. On DOHC, top ring

is marked "T" and No. 2 ring is marked "T2". On SOHC, top ring is

marked "T1" and No. 2 ring is marked "2R". Lubricate piston, rings and

cylinder bore with engine oil.

         4) Properly space ring end gaps on piston. See  Fig. 23.

Install piston and rod into cylinder bore. Ensure piston is installed

with front mark toward timing belt side of engine.

NOTE:    Front mark "R" on piston indicates installation in

         cylinders No. 1, 3 or 5 while front mark "L" indicates

         installation in cylinders No. 2, 4 or 6. Ensure front mark

         on piston and connecting rod are toward timing belt side of

         engine. See Fig. 23.

         5) Check bearing clearance using Plastigage method. Tighten

rod cap nuts to specification. See appropriate TORQUE SPECIFICATIONS

table at end of article. Ensure rod moves freely on crankshaft. Check

connecting rod side play. Repair or replace connecting rod if not

within specification. See CONNECTING RODS table under ENGINE

SPECIFICATIONS at end of article.

Fig. 23:  Aligning Piston & Rings

Courtesy of Mitsubishi Motor Sales of America, Inc.

         FITTING PISTONS

         Measure cylinder bore and piston skirt diameter. Piston skirt

diameter should be measured at 90-degree angle to piston pin.

Clearance between piston and cylinder bore must be within

specification. See appropriate PISTONS, PINS & RINGS table under

ENGINE SPECIFICATIONS at end of article.

         PISTON PIN REPLACEMENT

         1) Note reference mark on top of piston and connecting rod.

See Fig. 23. Using press and Piston Pin Remover/Installer (MD998184

for SOHC or MD998765 for DOHC), remove pin.

         2) Inspect piston for cracks and damage. Check ring side

clearance. Replace piston if not within specification. See appropriate

PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

         3) Check connecting rod for bend and twist. Replace

connecting rod if twist exceeds .004" (.10 mm) or bend exceeds .002"

(.05 mm). Pressure required to install pin in rod is 1686-3934 lbs.

(7500-17,500 N).

         4) Position piston on connecting rod. Ensure reference marks

on top of piston and connecting rod are aligned. See  Fig. 23.

Lubricate all components with oil. To install, reverse removal

procedure. Ensure piston pin is centered in piston.

NOTE:    Install piston with reference mark aligned with connecting

         rod reference mark. See Fig. 23.

         CRANKSHAFT & MAIN BEARINGS

         1) Remove flywheel or drive plate. Remove

transaxle/transmission mounting plate and rear seal case. Remove oil

pump, oil pan and oil pick-up tube. Ensure connecting rods and main

bearing cap are marked for location.

         2) Remove connecting rod caps and bearings. Note direction of

arrow on main bearing cap. Remove main bearing cap. See  Fig. 24.

Ensure all components are placed in correct order. Remove crankshaft.

Remove main bearings from cylinder block. Mark bearings for location.

         3) Inspect crankshaft for cracks and damaged gear or threads.

Check crankshaft for taper and out-of-round. Replace or repair

crankshaft if it is not within specification. See CRANKSHAFT, MAIN &

CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS at end of

article.

         4) Install upper main bearings in cylinder block. Ensure oil

hole is aligned and bearing is properly seated. Lubricate bearings

with engine oil. Install thrust bearings on No. 3 main bearing journal

with oil grooves toward crankshaft thrust surface.

         5) Install crankshaft in block. Install thrust bearing on No.

3 main bearing cap with oil grooves toward crankshaft thrust surface.

Install main bearing cap with arrow toward front of engine.

         6) Check oil clearance using Plastigage method. Tighten bolts

to specification in proper sequence. See Fig. 24. See appropriate

TORQUE SPECIFICATIONS table at end of article. Remove main bearing

cap. Clearance must be within specification. See CRANKSHAFT, MAIN &

CONNECTING ROD BEARINGS table. If oil clearance exceeds specification,

replace bearings or crankshaft.

         7) Ensure crankshaft rotates freely with main bearing cap

installed. Check crankshaft end play. See CRANKSHAFT, MAIN &

CONNECTING ROD BEARINGS table.

         8) Install connecting rod caps and bearings. Ensure

components are installed in original location. Tighten rod nuts to

specification. See appropriate TORQUE SPECIFICATIONS table. Ensure

connecting rods move freely on crankshaft. To complete installation,

reverse removal procedure. Tighten bolts to specification.

Fig. 24:  Main Bearing Cap Bolt Tightening Sequence

Courtesy of Mitsubishi Motor Sales of America, Inc.

         CONNECTING ROD BEARINGS

         1) Mark bearing cap and connecting rod for location. Remove

connecting rod cap and bearing. Install replacement bearing.

         2) Ensure reference marks on rod cap and connecting rod are

aligned. Check bearing clearance using Plastigage method. Ensure

connecting rod moves freely on crankshaft. Check connecting rod side

play. See CONNECTING RODS table under ENGINE SPECIFICATIONS at end of

article.

         CRANKSHAFT END PLAY

         If end play is not within specification, inspect thrust

bearings and crankshaft. Replace thrust bearing or crankshaft to

obtain correct end play. See CRANKSHAFT, MAIN & CONNECTING ROD

BEARINGS table under ENGINE SPECIFICATIONS at end of article.

         ENGINE OILING

         ENGINE LUBRICATION SYSTEM

         Oil pressure is provided by a rotor-type pump driven by

crankshaft. Pressure relief valve is located in oil pump body.

         CRANKCASE CAPACITY

         Montero & Pick-up oil capacity is 5.0 qts. (4.7L). Add .5 qt.

(.4L) with filter replacement. Add .5 qt. (.4L) with oil cooler.

3000GT oil capacity is 4.2 qts. (4.0L). Add .5 qt. (.4L) with filter

replacement. Add .5 qt. (.4L) with oil cooler.