Balance Shaft: Service and Repair
FRONT CASE, COUNTERBALANCE SHAFT AND OIL PANREMOVAL AND INSTALLATION
Removal Steps 1-22:
Removal Step 1-20:
REMOVAL SERVICE POINTS
A OIL PAN REMOVAL
1. Remove the all oil pan bolts.
2. Drive in the service tool between the cylinder block and oil pan.
NOTE: Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.
B FLANGE NUT REMOVAL (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (.32 in.)] into the plug hole to lock the counterbalance shaft.
3. Loosen the oil pump sprocket flange nut.
C PLUG REMOVAL
1. If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.
D FLANGE BOLT REMOVAL (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Referring to B (2), lock the counterbalance shaft.
2. Loosen the flange bolt.
D FLANGE NUT REMOVAL (ENGINE WITHOUT COUNTERBALANCE SHAFTS)
1. Clamp the oil pump shaft end in a vise.
2. Remove the oil pump sprocket nut.
E COUNTERBALANCE SHAFT FRONT BEARING REMOVAL (ENGINE WITH COUNTERBALANCE SHAFTS)
Using the special tool, remove the counterbalance shaft front bearing from the cylinder block.
NOTE: Be sure to remove the front bearing first. It it has not been removed, the Rear Bearing Puller cannot be used.
F LEFT COUNTERBALANCE SHAFT REAR BEARING REMOVAL (ENGINE WITH COUNTERBALANCE SHAFTS)
Using the special tool, remove the left counterbalance shaft rear bearing from the cylinder block.
G RIGHT COUNTERBALANCE SHAFT REAR BEARING REMOVAL (ENGINE WITH COUNTERBALANCE SHAFTS)
Using the special tool, remove the right counterbalance shaft rear bearing from the cylinder block.
INSPECTION
FRONT CASE
1. Check oil holes for clogging and clean if necessary
2. Check left counterbalance shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front case.
3. Check the front case for cracks and other damage. Replace cracked or damaged front case.
OIL SEAL
1. Check the oil seal lip for wear and damage. Replace oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace oil seal if necessary.
COUNTERBALANCE SHAFT (ENGINE WITH COUNTERBALANCE SHAFT)
1. Check oil holes for clogging.
2. Check journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace counterbalance shaft, bearing or front case assembly.
OIL PUMP
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover.
3. Check the side clearance
Standard value:
Drive gear : 0.08-0.14 mm (0.0031-0.0055 in.)
Driven gear : 0.06-0.12 mm (0.0024-0.0047 in.)
OIL COOLER BYPASS VALVE (ENGINE WITH AIR COOLING TYPE OIL COOLER)
1. Make sure that the valve moves smoothly.
2. Ensure that the dimension (L) measures the standard value under normal temperature and humidity.
Standard value (L): 34.5 mm (1.36 in.)
3. The dimension must be the standard value when measured after the valve has been dipped in 100 °C (212 °F) oil.
Standard value (L): 40 mm (1.57 in.) or more
INSTALLATION SERVICE POINTS
A COUNTERBALANCE SHAFT OIL SEAL INSTALLATION (ENGINE WITH COUNTERBALANCE SHAFTS)
B OIL PUMP OIL SEAL INSTALLATION
C CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Using the special toot install the crankshaft front oil seal into the front case.
D OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION
1. Apply engine oil amply to the gears and line up the alignment marks.
E FLANGE NUT INSTALLATION (ENGINE WITHOUT COUNTERBALANCE SHAFTS)
CAUTION: Before installing the flange nut, apply an appropriate amount of oil to the seating surface.
1. Clamp the oil pump shaft end in a vise
2. Tighten the oil pump sprocket nut to the specified torque.
F SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT
1. Coat the threads of the oil pressure gauge unit with sealant and install the unit using the special tool.
Specified sealant: 3M ATD Part No.8660 or equivalent
CAUTION:
1. Keep the end of threaded portion clear of sealant.
2. Avoid an overtightening.
G SEALANT APPLICATION TO OIL PRESSURE SWITCH
1. Coat the threads of the oil pressure switch with sealant and install the switch using the special tool.
Specified sealant: 3M ATD Part No.8660 or equivalent
CAUTION:
1. Keep the end of threaded portion clear of sealant.
2. Avoid an overtightening.
H RIGHT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Apply engine oil to the outer surface of the bearing.
2. Using special tools, install the right rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole of the cylinder block.
I LEFT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Install the special tool (Guide Plate) to the cylinder block.
2. Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block.
3. Using the special tool, install the rear bearing.
NOTE: The left rear bearing has no oil holes.
J COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Using the special tools, install the front banged.
K FRONT CASE INSTALLATION
1. Set the special tool on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
2. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).
3. Mount the oil filter bracket with oil filter bracket gasket. Then, install the four bolts with washers.
4. Tighten the bolts to the specification.
NOTE:
1. The bolt marked with *1 in the illustration differs in tightening torque.
2. The bolt marked with *2 in the illustration is for engine without counterbalance shafts only.
L FLANGE BOLT INSTALLATION (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Insert a Phillips screwdriver into the hole on the left side of the cylinder block to lock the counterbalance shaft.
2. Secure the oil pump driven gear on the left counterbalance shaft by tightening the flange boll to the specified torque.
M PLUG INSTALLATION
1. Install a new O-ring in the groove of the front case.
2. Using the special tool, install the plug and tighten to the specified torque.
N FLANGE NUT INSTALLATION (ENGINE WITH COUNTERBALANCE SHAFTS)
1. Referring to L (1), lock the counterbalance shaft.
2. Tighten the flange nut to the specified torque.
O OIL PAN INSTALLATION
1. Clean both mating surface of the oil pan and the cylinder block.
2. Apply a 4 mm (.16 in.) wide bead of sealant to the entire circumference of the oil pan flange.
Specified sealant: MITSUBISHI GENUINE PART No. MD970389 or equivalent
NOTE:
1. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
2. After installation, keep the sealed area away from the oil and coolant for approx. 1 hour.
3. Note that the bolts at the location shown are different in length from the others.