Mitsubishi Montero Sport (2004+). Manual - part 143

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL

11B-47

3. Insert the piston ring into the cylinder bore. Force the ring 

down with a piston, the piston crown being in contact with 
the ring, to correctly position it at right angles to the cylinder 
wall. Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.

Standard value:

Number 1: 0.30 

− 0.45 mm (0.012 − 0.017 inch)

Number 2: 0.45 

− 0.60 mm (0.018 − 0.023 inch)

Oil: 0.20 

− 0.60 mm (0.008 − 0.023 inch)

Limit:

Number 1, Number 2: 0.8 mm (0.03 inch)
Oil: 1.0 mm (0.03 inch)

.

CRANKSHAFT PIN OIL CLEARANCE 
<PLASTIC GAUGING MATERIAL METHOD>
The crankshaft oil clearance can be measured easily by using 
plastic gauging material, as follows:
1. Remove oil from the crankshaft pin and the bearing inner 

surface.

2. Cut plastic gauging material to the same length as the width 

of the bearing and place it on the pin in parallel with its axis.

3. Install the connecting rod cap carefully and tighten the nuts 

to the specified torque.

4. Carefully remove the connecting rod cap.

5. 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 

− 0.05 mm (0.0008 − 0.0019 inch)

Limit: 0.1 mm (0.003 inch)

AKX00719

PUSH IN BY
PISTON

PISTON
RING GAP

PISTON RING

AB

AKX00731AB

SCALE

AKX00609

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-48

CRANKSHAFT AND  CYLINDER BLOCK

REMOVAL AND INSTALLATION

M1113008700626

Required Special Tool:

• MD998718: Crankshaft Rear Oil Seal Installer

AK000450 AB

1

2

3

4

5

6

13

12

11

10

9

8

7

74 ± 4 N·m
54 ± 3 ft-lb

74 ± 2 N·m
54 ± 1 ft-lb

11 ± 1 N·m
97 ± 9 in-lb

11 ± 1 N·m
97 ± 9 in-lb

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

REMOVAL STEPS

1. ADAPTER PLATE
2. DRIVE PLATE BOLT
3. CRANKSHAFT ADAPTOR
4. REAR PLATE

>>E<<

5. OIL SEAL CASE 

>>D<<

6. CRANKSHAFT REAR OIL SEAL

>>C<<

7. BEARING CAP BOLT

>>C<<

8. BEARING CAP

>>A<<

9. CRANKSHAFT BEARING, LOWER
10. CRANKSHAFT

>>B<<

11. THRUST BEARING

>>A<<

12. CRANKSHAFT BEARING, UPPER
13. CYLINDER BLOCK

REMOVAL STEPS (Continued)

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-49

INSTALLATION SERVICE POINTS

.

>>A<< 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.

3. From the above table, select a bearing whose size is 

appropriate for the crankshaft journal outside diameter. 
If the crankshaft journal outside diameter Identification color 
is "yellow" and the cylinder block bearing bore Identification 
mark is "III," for example, select a bearing whose 
Identification color is "green."
If there is no Identification color paint on the crankshaft, 
measure the journal outside diameter and select a bearing 
appropriate for the measured valve.

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

White

63.982 

− 63.988

(2.5190 

− 2.5192)

I

Green

II

Black

III

Brown

AKX00621

IDENTIFICATION COLOR

AB

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-50

4. Install bearings with the groove toward the cylinder block.
5. Install the bearings having no groove to the bearing cap.

.

>>B<< 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.

.

>>C<< BEARING CAP/BEARING CAP 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 N⋅m (54 ± 3 ft-lb)

3. Check that the crankshaft rotates smoothly.

AKX00623

GROOVE

FOR UPPER

FOR LOWER

AB

AKX01393AB

GROOVE

THRUST
BEARING

AKX01395AB

FRONT MARK

BEARING CAP BOLT

NUMBERS ARE

TIGHTENING SEQUENCE

BEARING CAP

CRANKSHAFT

CYLINDER BLOCK