Mitsubishi Montero (2004+). Manual - part 120

OIL PAN AND OIL PUMP

TSB Revision

ENGINE OVERHAUL

11B-39

>>D<< DRAIN PLUG GASKET INSTALLATION

CAUTION

If the gasket is installed in the wrong direction, oil leaks 
will occur.
Install the drain plug gasket as illustrated.

.

>>E<< OIL FILTER INSTALLATION
1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the O-ring of the oil filter.
3. Screw the oil filter on until the O-ring contacts the bracket. 

Then tighten 3/4 turn [14 

±1 N⋅m (124 ± 9 in-lb)]

.

>>F<< SEALANT APPLICATION TO ENGINE OIL 
PRESSURE GAUGE UNIT

CAUTION

Keep the end of threaded portion clear of sealant. Avoid an 
overtightening.
1. Apply 3M

 ATD Part number 8672 or equivalent to the 

engine oil pressure switch.

AKX00726

DRAIN PLUG

OIL PAN 
SIDE

GASKET

OIL PAN

AB

AKX00692

BRACKET 
SIDE

AB

AKX00688

OIL PAN AND OIL PUMP

TSB Revision

ENGINE OVERHAUL

11B-40

INSPECTION

M1113008200159

.

OIL PUMP
1. Check the tip clearance.

Standard value: 0.06 

− 0.18 mm (0.003 − 0.007 inch)

2. Check the side clearance.

Standard value: 0.04 

− 0.10 mm (0.002 − 0.003 inch)

3. Check the body clearance.

Standard value: 0.10 

− 0.18 mm (0.004 − 0.007 inch)

Limit: 0.35 mm (0.013 inch)

.

OIL COOLER BYPASS VALVE
1. Make sure that valve moves smoothly.
2. Ensure that the dimension L measures the standard value 

under normal temperature and humidity.

Standard value: 34.5 mm (1.358 inches)

3. The dimension must be the standard value when measured 

after the valve has been dipped in 97 to 103

°C (207 to 

217

°F) oil.

Standard value: 40.0 mm (1.575 inches) 

AKX00743

AKX00744

AKX00745

AK000032

L

VALVE

AB

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL

11B-41

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

M1113008400603

AK201085

1

2

3

4

5

6

7

8

9

10

11

12

13

14

27 ± 2 N·m
20 ± 1 ft-lb

   + 90˚

AB

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

REMOVAL STEPS

>>G<<

1. CONNECTING ROD CAP NUT

<<A>> >>F<<

2. CONNECTING ROD CAP

>>D<<

3. CONNECTING ROD BEARING, 

LOWER

>>E<<

4. PISTON AND CONNECTING ROD 

ASSEMBLY

>>D<<

5. CONNECTING ROD BEARING, 

UPPER

>>C<<

6. PISTON RING NO.1

>>C<<

7. PISTON RING NO.2

>>B<<

8. OIL RING
9. SNAP RING

<<B>> >>A<<

10. PISTON PIN
11. SNAP RING
12. PISTON
13. CONNECTING ROD
14. BOLT

REMOVAL STEPS (Continued)

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL

11B-42

REMOVAL SERVICE POINTS

.

<<A>> CONNECTING ROD CAP REMOVAL
1. Mark the cylinder number on the side of the connecting rod 

big end for correct reassembly.

2. Keep the removed connecting rods, caps, and bearings in 

order according to the cylinder number.

.

<<B>> PISTON PIN REMOVAL
1. Remove the snap rings.

CAUTION

The clearance between the piston and the piston pin is a 
tight fit at room temperature. Therefore, be sure the heat 
the piston before pulling out the piston pin. Use care sine 
the piston is hot after heating.
2. Heat the piston approximately 70

°C (158°F) and pull out the 

piston pin.

INSTALLATION SERVICE POINTS

.

>>A<< PISTON PIN INSTALLATION
1. When replacing the piston, note the cylinder bore size mark 

on the cylinder block as illustrated, and select a piston 
according to the flowing table.

NOTE: The piston size mark shows on the top of the piston.

2. Set the snap ring into one side of the piston pin hole.

AKX00734

CYLINDER
NUMBER

AB

AKX01397

70˚C

(158˚F)

AB

CYLINDER BORE 
SIZE MARK

PISTON CLASS PISTON SIZE 

MARK

I

A

A

II

B

None

III

C

C

AK200850

TIMING BELT SIDE

CHECK DIGIT

No.4

No.1

No.2

No.3

AD

LEFT BANK

RIGHT BANK

No.6

No.5

CRANKSHAFT 
BORE SIZE
MARK