Engine Overhaul (3.8L): Removal & Installation Mitsubishi Eclipse IV рестайлинг

>> A << BOOST SENSOR INSTALLATION CAUTION

>> B << THROTTLE BODY GASKET INSTALLATION

Install the throttle body gasket so that the tab is positioned as shown in illustration.

Scheme 295

>> C << EXHAUST GAS RECIRCULATION VALVE GASKET INSTALLATION

Install the exhaust gas recirculation valve gasket so that the tab is positioned as shown in illustration.

Scheme 296

>> D << EXHAUST GAS RECIRCULATION PIPE GASKET INSTALLATION

Install the exhaust gas recirculation pipe gasket so that the tab is positioned as shown in illustration.

Scheme 297

>> E << EXHAUST GAS RECIRCULATION PIPE INSTALLATION

Scheme 298

1. Tighten temporarily the flare nut of exhaust gas recirculation pipe and the nut as shown in illustration.
2. Tighten each the flare nuts of exhaust gas recirculation pipe and the nut to the specified torque. Tightening torque: 59 +/- 10 N. m (44 +/- 7 ft-lb) < FLARE NUT > 19 +/- 3 N. m (14 +/- 2 ft-lb) < NUT >
3. Tighten the bolt shown in illustration to the specified torque. Tightening torque: 19 +/- 3 N. m (14 +/- 2 ft-lb)

Scheme 299

Required Special Tools

1. MD998781: Flywheel Stopper

Scheme 300

1. Using special tool MD998781, hold the drive plate.
2. Loosen the camshaft position sensing cylinder bolt.

Scheme 301

1. Using special tool MD998781, hold the drive plate.
2. Tighten the camshaft position sensing cylinder bolt to the specified torque. Tightening torque: 22 +/- 4 N. m (16 +/- 3 ft-lb)

>> B << CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

Apply a 3 mm (0.12 inch) diameter bead of sealant Mitsubishi Genuine Part number MD970389 or equivalent to the camshaft position sensor support.

Scheme 302

Scheme 303

Required Special Tools

1. MB990767: End Yoke Holder
2. MD998715: Pins
3. MD998767: Tensioner Pulley Wrench
4. MD998769: Crankshaft Spacer

<< A >> TIMING BELT REMOVAL

Scheme 304

1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove the timing belt.

Scheme 305

1. While holding the camshaft sprocket with special tools MB990767 and MD998715, loosen the camshaft sprocket bolt.
2. Remove the camshaft sprocket.

Scheme 306

1. Fit the camshaft sprocket to the front end of the camshaft.
2. While holding the camshaft sprocket with special tools MB990767 and MD998715, tighten the camshaft sprocket bolt. Tightening torque: 88 +/- 10 N. m (65 +/- 7 ft-lb)

Scheme 307

Scheme 308

1. Clean the hole in the crankshaft sprocket.
2. Clean and degrease the mating surfaces of the crankshaft sprocket, sensing blade, and spacer. NOTE: Degreasing is necessary to prevent decrease in friction on the mating surfaces.
3. Align the location of pin and pin hole, and then apply equal force in the direction of the arrow. CAUTION: Do not bend the sensing blade when installing sprocket.
4. Install the crankshaft sprocket to the crankshaft.

>> C << AUTO-TENSIONER INSTALLATION

If the auto-tensioner rod is fully extended, reset it as follows

Scheme 309

1. Clamp the auto-tensioner in the vise with soft jaws.
2. Push in the rod little by little with the vise until set hole A in the rod is aligned with hole B in the cylinder.
3. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set holes. This auto-tensioner setting wire will be used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.

>> D << TIMING BELT INSTALLATION

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

1. Install special tool MD998769 and the crankshaft pulley washer, and then tighten the crankshaft bolt.
2. Align the timing mark on the crankshaft sprocket with the timing mark on the oil pump case, and then rotate the sprocket three teeth counterclockwise.
3. Align the timing mark on the left bank camshaft sprocket with the timing mark on the rocker cover.
4. Align the timing mark on the right bank camshaft sprocket with the timing mark on the rocker cover.
5. Align the timing mark on the crankshaft sprocket with the timing mark on the oil pump case.
6. Install the timing belt on each sprocket and pulley in the following sequence. Do not leave the belt slack between each sprocket and pulley. Crankshaft sprocket Idler pulley Left bank camshaft sprocket Water pump pulley Right bank camshaft sprocket Tensioner pulley
7. Install special tool MD998767 to the tensioner pulley. While pushing the pulley lightly against the belt using the special tool, tighten the flange bolt. Tightening torque: 48 +/- 6 N. m (35 +/- 4 ft-lb)
8. Check to see that the timing marks of all the sprockets are in alignment.
9. Rotate the crankshaft a quarter turn counterclockwise. Then rotate it back clockwise to verify that all the timing marks are aligned.
10. Loosen the flange bolt securing the tensioner pulley, and then mount special tool MD998767 and a torque wrench on the tensioner pulley.
11. Torque it to 4.4 N. m (39 in-lb) with the torque wrench.
12. While holding the tensioner pulley in position, tighten the flange bolt to the specified torque. Tightening torque: 48 +/- 6 N. m (35 +/- 4 ft-lb)
13. Rotate the crankshaft two turns clockwise and leave it alone for approximately five minutes.
14. Check to see whether the metal wire inserted when the auto-tensioner was installed can be removed without any resistance. If the metal wire can be removed without any resistance, it means that the belt has a proper tension. Therefore, remove the metal wire. In this condition, check that the rod protrusion of the auto-tensioner is within the standard value. Standard value: 4.8-6.0 mm (0.19-0.24 inch)
15. If the metal wire offers resistance when removed, repeat the previous steps 10 through 13 until proper belt tension is obtained.

>> E << ENGINE SUPPORT BRACKET, RIGHT INSTALLATION

The mounting bolts of the right engine support bracket must be tightened in the order shown in illustration.

Tightening torque: 45 +/- 5 N. m (34 +/- 3 ft-lb)

Bolt length

85 mm (33.5 inch) - Bolt 3

95 mm (37.4 inch) - Bolts 2 and 4

100 mm (39.4 inch) - Bolt 1

Scheme 318

>> B << INJECTOR INSTALLATION

Scheme 319

Scheme 320

1. Apply clean engine oil to the O-ring.
2. Insert the injector into the fuel rail.
3. Make sure the injector rotates smoothly. If not, remove the injector to check the O-ring for damage, and replace the O-ring if necessary. Then reinsert the injector and check that it rotates smoothly.
4. Confirm the protrusion of injector is at center. If not, rotate the injector for protrusion to be center.

Scheme 321

>> A << O-RING AND WATER INLET PIPE INSTALLATION

Scheme 322

1. Attach a new O-ring to each end of the water inlet pipe.
2. Wet the O-ring with water.
3. Insert the front end of the pipe into the water pump.

>> B << THERMOSTAT HOUSING GASKET INSTALLATION

Install the thermostat housing gasket so that the tab is positioned as shown in illustration.

Scheme 323

Scheme 324

1. Check that the rubber ring is free from damage and seated correctly in the thermostat flange.
2. Install the thermostat as shown in illustration. The jiggle valve must be at the top position.

>> B << OIL SEAL INSTALLATION

1. Apply engine oil to the lip area of the oil seal and the front end outside diameter of camshaft.
2. Using special tool MD998713, install the camshaft oil seal.

>> C << ENGINE OIL PRESSURE SWITCH INSTALLATION

Apply 3M(tm) AAD Part number 8672 or equivalent to the threads of the oil pressure switch.

Scheme 325

Scheme 326

1. Apply a small amount of engine oil to the O-ring and then install it to the engine oil control valve.
2. Install the engine oil control valve to the cylinder head.
3. Tighten the engine oil control valve to the specified torque of 11 +/- 1 N. m(98 +/- 8 in-lb).

>> E << OIL PIPE/EYE BOLT INSTALLATION

1. Install the oil pipe and eye bolt gasket lightly with eye bolt by hand.
2. Tighten eye bolt to 30 ± 3 N.m (22 ± 1 ft-lb).
3. Tighten the flange bolt to 11 ± 1 N.m (98 ± 8 in-lb).

Scheme 327

Required Special Tools

1. MD998442: Air Bleed Wire
2. MD998443: Lash Adjuster Holder
3. MD998713: Camshaft Oil Seal Installer

<< A >> ROCKER ARMS AND ROCKER ARM SHAFT REMOVAL

When the rocker arm is removed from the rocker shaft, tag them to show the installation location for the reinstallation of the rocker arm, the T-lever, the piston arm assembly and so on.

<< B >> ROCKER ARMS AND SHAFT REMOVAL

Set special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor.

Scheme 328

>> A << CAMSHAFT INSTALLATION

Scheme 329

Scheme 330

1. Apply engine oil to the camshaft journals and cams and then install the camshafts. NOTE: The camshaft with a longer overall length is for the left bank.
2. Check to see that the dowel pin of the camshaft is located at the position shown.

>> B << LASH ADJUSTER INSTALLATION

Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out. Fit special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor.

Scheme 331

>> C << ADJUSTING SCREW INSTALLATION

When installing the screw to the rocker arm temporarily, project it slightly 3mm (0.12 in) from the same face level of the rocker arm end as shown in illustration.

Scheme 332

Scheme 333

Scheme 334

1. Position the end with the larger chamfer at the right on the front bank, and at the left on the rear bank. NOTE: The side with the four bolt holes is on the intake side.
2. Position the side with the oil holes on the lower side (cylinder head side).
3. Check that notches in the each rocker shaft are facing the direction shown in illustration.
4. Install the rocker shaft cap as its identification mark is in the direction shown.
5. Tighten the mounting bolts to the specified torque. Tightening torque: Intake side: 31 +/- 3 N. m (23 +/- 2 ft-lb) Exhaust side: 13 +/- 1 N. m (115 +/- 9 in-lb)
6. Remove special tool MD998443.

Scheme 335

1. Apply engine oil to the lip area of the oil seal and the front end outside diameter of camshaft.
2. Using special tool MD998713, install the camshaft oil seal.

<< A >> CYLINDER HEAD BOLT REMOVAL

Use special tool MD998051 to loosen the cylinder head bolt.

Scheme 336

Scheme 337

Scheme 338

1. Using special tool MD998735 or MD998772, compress the spring.
2. Remove the retainer locks. NOTE: Tag removed valves, springs and other components, noting their cylinder numbers and locations to facilitate reassembly. Store these components safely.

Scheme 339

Scheme 340

1. Install the valve spring seat. CAUTION: Valve stem seals for intake valves and for exhaust valves are different. Be sure to install the correct ones. Valve stem seal identification color Intake: GRAY Exhaust: GRAY GREEN CAUTION: Always use the special tool to install the valve stem seal. Improperly installed valve stem seals may leak oil.
2. Using special tool MB991999, install a new stem seal to the valve guide.

>> B << VALVE SPRING INSTALLATION

Install the valve spring end with its identification color toward the spring retainer.

Scheme 341

>> C << RETAINER LOCK INSTALLATION

Using special tool MD998735 or MD998772, compress the valve spring and insert the retainer lock into position.

Note. The valve spring, if excessively compressed, causes the bottom end of retainer to damage the stem seal.

Scheme 342

Scheme 343

>> D << CYLINDER HEAD BOLT INSTALLATION

Scheme 344

1. Tighten the bolts in the illustrated sequence in two or three steps. Tightening torque: 108 +/- 5 N. m (80 +/- 4 ft-lb)
2. Back off the bolts once and tighten them again to the specified torque in step 1 .

Scheme 345

1. Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through G shown in illustration. Standard value: 0.03 mm (0.0012 inch) Limit: 0.2 mm (0.007 inch)
2. If the service limit is exceeded, correct to meet the specification. Grinding limit: *0.2 mm (0.007 inch)
3. *If the service limit is exceeded, correct to meet the specification. Cylinder head height (specification when new): 120 mm (4.7 inches)

Scheme 346

Scheme 347

1. Check the valve face for correct contact. If incorrect, reface using a valve refacer. The valve should make a uniform contact with the seat at the center of the valve face.
2. If the margin exceeds the service minimum limit, replace the valve. Standard value: < Intake > 1.0 mm (0.04 inch) < Exhaust > 1.2 mm (0.05 inch) Minimum limit: < Intake > 0.5 mm (0.02 inch) < Exhaust > 0.7 mm (0.03 inch)
3. Measure the valve's total length. If the measurement is less than specified, replace the valve. Standard value: < Intake > 109.33 mm (4.304 inches) < Exhaust > 113.50 mm (4.468 inches) Minimum limit: < Intake > 108.83 mm (4.285 inches) < Exhaust > 113.00 mm (4.449 inches)

Scheme 348

1. Measure the free height of the spring and, if it is smaller than the minimum limit, replace the spring. Standard value: < Intake > 56.19 mm (2.212 inch) < Exhaust > 53.30 mm (2.098 inch) Limit: < Intake > 55.19 mm (2.173 inch) < Exhaust > 52.30 mm (2.059 inch)
2. Measure the squareness of the spring and, if the limit is exceeded, replace the spring. Standard value: 2° or less Limit: 4°

VALVE SEAT REPLACEMENT PROCEDURE

Scheme 349

Scheme 350

1. Cut the valve seat from the inside to thin the wall thickness. Then, remove the valve seat.
2. Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Seat ring hole diameter: Intake valve 0.3 oversize 37.80-37.83 mm (1.4882-1.4894 inches) 0.6 oversize 38.10-38.13 mm (1.5000-1.5012 inches) Exhaust valve 0.3 oversize 34.80-34.83 mm (1.3701-1.3713 inches) 0.6 oversize 35.10-35.13 mm (1.3819-1.3831 inches)
3. Before fitting the valve seat, either heat the cylinder head up to approximately 250°C (482°F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the specified width and angle. Using a valve seat cutter, correct the valve seat to the specified width and angle. See " «VALVE SEAT RECONDITIONING PROCEDURE»(ref-308283-S26308807532009020200000) " on the previous page.

Scheme 351

1. Remove the snap ring from the exhaust valve guide.
2. Using a press, remove the valve guide toward the cylinder head gasket surface. CAUTION: Do not install a valve guide of the same size again.
3. Re-bore the valve guide hole of the cylinder head so that it fits the press-fitted oversize valve guide. Valve guide hole diameter: 0.05 oversize 11.05-11.07 mm (0.4350-0.4358 inch) 0.25 oversize 11.25-11.27 mm (0.4429-0.4437 inch) 0.50 oversize 11.50-11.52 mm (0.4528-0.4535 inch)
4. Install the new snap ring into the groove of exhaust valve guide.
5. Press-fit the valve guide until it protrudes 14 mm (0.55 inch) from the cylinder head top surface as shown in illustration.

Note. When press-fitting the valve guide, work from the cylinder head top surface.

Note. After installing the valve guides, insert new valves in them to check for sliding condition.

Scheme 352

Scheme 353

Required Special Tool

1. MD998012: Oil Pressure Switch Socket Wrench
2. MD998717: Crankshaft Front Oil Seal Installer

<< A >> OIL PAN, LOWER REMOVAL

1. Remove the lower oil pan mounting bolts. CAUTION: Do not use a scraper or special tool to remove the oil pan.
2. Remove the lower oil pan by tapping on its side with a plastic hammer (mallet) through a wooden plank held against it.

Scheme 354

Scheme 355

1. Remove the long bolts "A" shown in illustration first.
2. Remove all other bolts. CAUTION: Do not use a scraper or special tool to remove the oil pan.
3. Remove the oil pan.
4. Screw M10 bolts into the two bolt holes in the oil pan to break the joint and remove the oil pan.

<< C >> ENGINE OIL PRESSURE SWITCH REMOVAL

Using special tool MD998012, remove the engine oil pressure switch.

Scheme 356

<< D >> OUTER ROTOR/INNER ROTOR REMOVAL

Make alignment dots on the outer and inner rotors for ease of reassembly.

Scheme 357

>> A << INNER ROTOR/OUTER ROTOR INSTALLATION

Apply engine oil to the rotors. Then install the rotors, ensuring that the alignment dots made at disassembly are properly aligned.

Scheme 358

Scheme 359

1. Clean the gasket mating surfaces of oil pump case and cylinder block.
2. Apply a 3 mm (0.1 inch) diameter bead of sealant (Mitsubishi Genuine Part number MD970389 or equivalent) to the oil pump case. Apply sealant as indicated by the broken line in the illustration; the grooves must be traced and the bolt holes must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front of the cylinder block. NOTE: Be sure to install the oil pump case quickly while the sealant is wet (within 15 minutes).
4. Tighten the oil pump case mounting bolts to the specified torque. Tightening torque: 14 +/- 1 N. m (122 +/- 9 in-lb) NOTE: After installation, keep the sealed area away from oil and coolant for approximately one hour.

Scheme 360

Scheme 361

1. Install the guide of special tool MD998717 to the front end of the crankshaft.
2. Apply engine oil to the lip area of a new oil seal and push it in until it contacts the oil pump case.
3. Using special tool MD998717, press-fit the oil seal into the oil pump case.

Scheme 362

1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the O-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to the specified torque. Tightening torque: 14 +/- 2 N. m (122 +/- 17 in-lb)
4. If no torque wrench can be used for tightening, use the following procedure. Screw in the oil filter until its O-ring contacts the oil filter bracket. Tighten the oil filter 1 turn.

>> E << ENGINE OIL PRESSURE SWITCH INSTALLATION

Scheme 363

Scheme 364

1. Apply 3M(tm) AAD Part number 8672 or equivalent to the thread of engine oil pressure switch.
2. Tighten the engine oil pressure switch together with the oil filter bracket to the specified torque, using special tool MD998012. Tightening torque: 10 +/- 2 N. m (87 +/- 17 in-lb)

Scheme 365

Scheme 366

1. Clean both gasket surfaces of the upper oil pan and cylinder block.
2. Apply a 4 mm (0.2 inch) diameter bead of sealant (Mitsubishi Genuine Parts number MD970389 or equivalent) to the upper oil pan. Apply sealant as indicated by the broken line in the illustration; the grooves must be traced and the bolt holes must be surrounded with a bead of sealant. CAUTION: When installing the upper oil pan, be sure not to expel the sealant from the oil pan flange at portion A in the illustration.
3. Install the oil pan to the bottom of the cylinder block. NOTE: Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
4. Tighten the upper oil pan bolts in the sequence shown. Tightening torque: 9.0 +/- 3.0 N. m (80 +/- 26 in-lb) NOTE: After installation, keep the sealed area away from the oil and coolant for approximately one hour.

Scheme 367

Scheme 368

1. Clean both gasket surfaces of the upper and lower oil pans.
2. Apply a 4 mm (0.2 inch) diameter bead of sealant (Mitsubishi Genuine Parts number MD970389 or equivalent) to the lower oil pan. Apply sealant as indicated by the broken line in the illustration; the grooves must be traced and the bolt holes must be surrounded with a bead of sealant.
3. Install the lower oil pan to the upper oil pan. NOTE: Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
4. Tighten the lower oil pan bolts in the sequence shown. Tightening torque: 11 +/- 1 N. m (98+/- 8 in-lb) NOTE: After installation, keep the sealed area away from oil for approximately one hour.

>> H << DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction shown.

Scheme 369

Scheme 370

Scheme 371

Scheme 372

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)

Scheme 373

Scheme 374

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.

Scheme 375

1. Remove the snap rings. CAUTION CAUTION: The clearance between the piston and the piston pin is a tight fit at room temperature. Therefore, be sure to heat the piston before pulling out the piston pin. Use care since the piston is hot after heating.
2. Heat the piston to approximately 70°C (158°F) and pull out the piston pin.

Scheme 376

Scheme 377

Scheme 378

Scheme 379

1. When replacing the piston, note the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table. MARK REFERENCE CHART CYLINDER BORE SIZE MARK PISTON SIZE MARK I A II None III C 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. CAUTION: Apply an ample coat of engine oil to the periphery of the piston pin and the hole of the connecting rod small end. The clearance between the piston and the piston pin is a tight fit at room temperature. Therefore, be sure to heat the piston before inserting the piston pin. Use care since the piston is hot after heating.
3. Heat the piston to approximately 70°C (158°F).
4. With the front mark of the connecting rod and that of the piston located on the same side, insert the piston pin.
5. Set the snap ring into the other side of the piston pin hole.
6. Check that the piston moves smoothly.

Scheme 380

Scheme 381

1. Fit the oil ring spacer into the piston ring groove. NOTE: The side rails and spacer may be installed in either direction. CAUTION: Do not use any piston ring expander when installing the side rail. It will break the side rail.
2. Install the upper side rail by hand. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into the position. See illustration.
3. Install the lower side rail in the same procedure as described in step 2 .
4. Make sure that the side rails move smoothly in both directions.

Scheme 382

Scheme 383

1. To prevent wrong installation, check the identification mark of each piston ring. The identification mark is stamped near the ring gap. Identification mark Number 1 ring: 1T Number 2 ring: 2T NOTE: Size marks on piston rings are as follows. MARK REFERENCE CHART SIZE SIZE MARK Standard None 0.25 mm (0.010 in) oversize diameter 25 0.50 mm (0.020 in) oversize diameter 50
2. Using a piston ring expander, fit the number 2 piston ring into the number 2 groove of piston. NOTE: Install the piston rings with their identification mark facing up, to the piston crown side.
3. Install the number 1 piston ring in the same manner as step 2 .

Scheme 384

Scheme 385

Scheme 386

1. Measure the crankshaft pin 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 pins are painted/stamped at the positions shown in illustration. CRANKSHAFT SPECIFICATIONS CHART CRANKSHAFT PIN OUTSIDE DIAMETER CONNECTING ROD BEARING IDENTIFICATION COLOR SIZE mm (in) IDENTIFICATION MARK IDENTIFICATION COLOR Yellow 54.994-55.000 (2.1651-2.1654) 0 Pink 1 Red 2 Green None 54.988-54.994 (2.1649-2.1651) 0 Red 1 Green 2 Black White 54.982-54.988 (2.1646-2.1649) 0 Green 1 Black 2 Brown
2. From the above table, select a bearing whose size is appropriate for the crankshaft pin outside the diameter. For example, if the crankshaft pin outside diameter Identification color is "yellow" and the connecting rod Identification mark is "2," select a bearing whose Identification color is "green." If there is no identification color paint on the crankshaft, measure the pin outside diameter and select bearing appropriate for the measured value.
3. Install the selected bearing in the big end and in the cap of the connecting rod.

Scheme 387

Scheme 388

Scheme 389

1. Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in illustration.
3. Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.
4. Insert the piston and connecting rod assembly into the cylinder with the front mark on the piston crown pointing to the timing belt side.
5. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.

Scheme 390

Scheme 391

1. Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches are on the same side as shown in illustration.
2. Make sure that the connecting rod big end side clearance meets the specification. Standard value: 0.10-0.25 mm (0.004-0.009 inch) Limit: 0.4 mm (0.02 inch)

Scheme 392

1. The connecting rod bolts should be examined before reuse. If the bolt threads are damaged, the bolt should be replaced. Hand-thread the nut to the full length of the bolt threads. If the nut does not run down smoothly, the bolt should be replaced.
2. Before installation of each nut, apply engine oil to the threaded portion and bearing surface of the nut.
3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to a torque of 27 +/- 2 N. m (20 +/- 1 ft-lb) to install the cap properly.
5. Make a paint mark on the head of each nut. CAUTION: If the nut is turned less than 90 degrees, proper fastening performance may not be achieved. Be careful to tighten the nut exactly 90 degrees. If the nut is overtightened (exceeding 94 degrees), loosen the nut completely and then retighten it by repeating the tightening procedure from step 3 .
6. Make a paint mark on the bolt end at a position 90 to 94 degrees from the paint mark made on the nut in the direction of tightening the nut.
7. Turn the nut another 90 to 94 degrees and make sure that the paint marks on the nut and bolt are aligned.

REMOVAL AND INSTALLATION

Scheme 393

Required Special Tool

1. MD998718: Crankshaft Rear Oil Seal Installer

>> 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 N. m (21 +/- 1 ft-lb)

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

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 illustration.
2. The cylinder block bearing bore diameter identification marks are stamped at the position shown in illustration from left to right, beginning at No.1. CRANKSHAFT SPECIFICATIONS CHART CRANKSHAFT JOURNAL OUTSIDE DIAMETER CYLINDER BLOCK BEARING BORE CRANKSHAFT BEARING No. 1, 4 CRANKSHAFT BEARING No. 2, 3 IDENTIFICATION COLOR SIZE mm (in) IDENTIFICATION MARK IDENTIFICATION COLOR IDENTIFICATION COLOR Yellow 63.994-64.000 (2.5194-2.5197) I Pink Blue II Red Pink III Green Red None 63.988-63.994 (2.5192-2.5194) I Red Pink II Green Red III Black Green White 63.982-63.988 (2.5190-2.5192) I Green Red II Black Green III Brown Black
3. From the above 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" < No.1 & 4 > or "red" < No.2 & 3 >. 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 the groove toward the cylinder block.
5. Install the bearings having no groove to the bearing cap.

Scheme 399

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 weight side.

Scheme 400

Scheme 401

1. Attach the bearing cap on the cylinder block as shown in illustration.
2. Tighten the bearing cap bolts to specified torque in the sequence shown in illustration. Tightening torque: 74 +/- 4 N. m (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.

Scheme 402

Scheme 403

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 applying liquid gasket. Then wait at least one hour. Do not start the engine or let engine oil or coolant touch the sealant during that time.

Scheme 404

Scheme 405

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 N. m (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: 0.02-0.03 mm (0.0008-0.0012 inch) < No. 1 & 4 > 0.03-0.04 mm (0.0012-0.0016 inch) < No. 2 & 3 > Limit: 0.1 mm (0.003 inch)