Crankshaft, Flywheel, and Drive Plate
CRANKSHAFT, FLYWHEEL AND DRIVE PLATEREMOVAL AND INSTALLATION
Removal Steps 1-25:
REMOVAL SERVICE POINT
A OIL JET REMOVAL
1. Drive out the oil jets using a metal rod of a suitable length.
Caution:
1. Use special care not to damage the cylinder wall.
2. Never reuse the removed oil lets.
INSPECTION
CRANKSHAFT OIL CLEARANCE [PLASTIC GAUGE METHOD]
1. Remove oil from the crankshaft journals and crankshaft bearings.
2. Install the crankshaft.
3. Cut the plastic gauge 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.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package.
Standard value: 0.02-0.05 mm (0.0008-0.0020 in.)
Limit: 0.1 mm (0.004 in.)
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.0020 in.)
Limit: 0.1 mm (0.004 in.)
3. If the distortion is excessive, correct within the allowable limit or replace.
Grinding limit: 0.2 mm (0.008 in.)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
283.9 - 284.1 mm <4G63>
(11.177 - 11.185.in)
289.9 - 290.1 mm <4G64>
(11.413 - 11.421 in.)
4. Check cylinder walls for scratches and seizure. If defects are evident, correct (rebore to an oversize) or replace.
5. Using a cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in illustration.
Standard value:
Cylinder l.D.
85.0 mm (3.35 in.) <4G63>
86.5 mm (3.41 in.) <4G64>
Cylindricity : 0.001 mm (0.0004 in.)
BORING CYLINDER
1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder.
Piston size identification
NOTE: Size mark is stamped on the piston top.
2. Measure outside diameter of piston to be used. Measure it in thrust direction as shown.
3. Based on the measured piston O.D. calculate the boring finish dimension.
Boring finish dimension = Piston O.D. + (clearance between piston O.D. and cylinder) - 0.02 mm (0.0008 in.) (honing margin)
4. Bore all cylinders to the calculated boring finish dimension.
CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 2 to No.4 to No.1 to No.3.
5. Hone to final finish dimension (piston O.D. + clearance between piston O.D. and cylinder).
6. Check the clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02-0.04 mm (0.0008-0.0016 in.) [Non-turbo]
0.03-0.05 mm (0.0012-0.0020 in.) [Turbo]
NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.
INSTALLATION SERVICE POINTS
A OIL JET INSTALLATION
Using a pin punch having a diameter of 4 to 5 mm (.15 - .20 in.), drive in new oil jets from the crankshaft journal section until they bottom.
A CRANKSHAFT BEARING INSTALLATION
When the bearing needs replacing, select and install a proper bearing by the following procedure.
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 of its journals are painted 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 engine front, beginning at No. 1.
3. Select a proper bearing from the above table on the basis of the identification data confirmed under Items (1) and (2).
(Example)
1. If the measured value of a crankshaft journal outer diameter is between 56.994 - 57.000 mm (2.2439 - 2.2441 in.), the journal is classified as "1" in the table. In case the crankshaft is also replaced by a spare part, check the identification colors of the journals painted on the new crankshaft. If the color is yellow, for example, the journal is classified as "1".
2. Next, check the cylinder block bearing hole identification mark stamped on the cylinder block. If it is "0", read the "Bearing identification mark" column to find the identification mark bearing to be used. In this case, it is "1".
4. Install the bearing having an oil groove to the cylinder block.
5. Install the bearing having an oil groove to the bearing caps.
B BEARING CAP/BEARING CAP BOLT INSTALLATION
1. Install the bearing caps so that their arrows are directed to the timing belt side.
2. Before installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt.
Limit: Max. 71.1 mm (2.79 in.)
3. Apply engine oil to the threaded portion and bearing surface of the bolt.
4. Tighten the bolts to 25 Nm (18 ft.lbs.) in the specified tightening sequences.
5. Make a point mark on the head of each bolt.
6. Make a point mark on the bearing cap at the position 90° to 100° from the paint mark made on the bolt in the direction of tightening the bolt.
7. According to the specified tightening sequence, give a 90° to 100° turn to each bolt and make sure that the paint mark on the bolt and that on the cap are in alignment.
Caution:
1. If the bolt is turned less than 90°, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it.
2. If the bolt has been overtightened (exceeding 100°), loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).
8. After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace crankshaft bearings.
Standard value: 0.05 - 0.18 mm (0.0020 - 0.0017 in.)
Limit: 0.25 mm (0.0098 in.)
C OIL SEAL INSTALLATION
D SEALANT APPLICATION TO OIL SEAL CASE
Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent.
NOTE:
1. Be sure to install the case quickly while the sealant is wet (within 15 minutes).
2. After installation, keep the sealed area away from oil and coolant for approx. 1 hour.