Mitsubishi Montero (2002-2004). Manual - part 454

 

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Mitsubishi Montero (2002-2004). Manual - part 454

 

 

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-49

INSTALLATION SERVICE POINTS

.

>>A<< KNOCK SENSOR BRACKET INSTALLATION
Check that the bracket is in proper contact with the cylinder 
block boss and tighten to the specified torque in the order 
shown.

Tightening torque: 28 

± 2 Nm (21 ± 1 ft-lb)

.

>>B<< CRANKSHAFT BEARING INSTALLATION
1. Measure the crankshaft journal diameter and confirm its 

classification from the following table. In the case of a 
crankshaft supplied as a service part, identification colors/
marks of its journals are painted/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.

AKX00649

TIMING BELT SIDE

AB

1

2

3

4

AKX01391

No.4 JOURNAL

No.1 JOURNAL

No.2 JOURNAL

No.3 JOURNAL

LOCATION OF IDENTIFCATION COLOR

AB

AKX00648

BEARING BORE 
DIAMETER 
IDENTIFICATION
MARK

CYLINDER INSIDE 
DIAMETER SIZE MARK

TIMING BELT SIDE

AB

No.4

No.2

No.3

No.1

CRANKSHAFT JOURNAL OUTSIDE 
DIAMETER

CYLINDER BLOCK 
BEARING BORE

CRANKSHAFT BEARING

IDENTIFICATION 
COLOR

SIZE   mm (in)

IDENTIFICATION MARK

IDENTIFICATION COLOR

Yellow

63.994 

− 64.000

(2.5194 

− 2.5197)

I

Pink

II

Red

III

Green

None

63.988 

− 63.994

(2.5192 

− 2.5194)

I

Red

II

Green

III

Black

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-50

3. From the following 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 a groove to 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

II

Black

III

Brown

CRANKSHAFT JOURNAL OUTSIDE 
DIAMETER

CYLINDER BLOCK 
BEARING BORE

CRANKSHAFT BEARING

IDENTIFICATION 
COLOR

SIZE   mm (in)

IDENTIFICATION MARK

IDENTIFICATION COLOR

AKX00621

IDENTIFICATION COLOR

AB

AKX00623

GROOVE

FOR UPPER

FOR LOWER

AB

AKX01393AB

GROOVE

THRUST
BEARING

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-51

>>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 Nm (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-52

>>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

M1113008800281

.

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-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

 

 

 

 

 

 

 

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