Part 2

]P[ 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 in until the O-ring contacts the bracket. Then tighten 3/4 turn [tightening torque: 17 Nm (12 ft. lbs).

NOTE: For MD135737, tighten one turn Tightening torque: 14 Nm (10 ft. lbs.] after the O-ring contacts the bracket.

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
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 inch)
Driven gear 0.06 - 0.12 mm (0.0024 - 0.0047 inch)

PISTONS AND CONNECTING RODS





Removal
Follow removal steps outlined in illustration.

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 stop screw from the base.






2. Select the correct piston support for your application. Fit the piston support onto the base. Place the base on press support blocks.
3. Insert the press pin through the piston pin hole. Select the correct connecting rod guide pin. Thread the guide pin onto the threaded portion of the press pin.

Figure 4:

4. Position the piston assembly on the piston support in the press. With the press pin up as shown in figure 4, insert the guide pin through the hole in the piston and through the hole in the piston support.
5. Press the piston pin out of the assembly.

Important: To avoid piston damage,
- The piston support must seat squarely against the piston.
- Verify that the piston pin will slide through the hole in the piston support.

6. Remove the piston pin from the press pin.

Installation
Installation in reverse order as removal.

Installation service points





]A[ Piston Pin Installation.
1. Thread the stop screw and lock: Put assembly into the base. Fit the correct piston support on top of the base. Insert the press, pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw.
2. Using the markings on the press pin, adjust the stop screw to the depth as shown below.





3. Place the base on press support blocks.
4. Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it.
5. Coat the piston pin with oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod.
6. Press the piston pin through the connecting rod until the guide pin contacts the stop screw.
7. Remove the piston assembly from the base. remove the guide pin and press pin from the assembly.

Important: Due to production tolerance variations, it is necessary to visually check the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.




8. Check that the piston moves smoothly.





]B[ Oil Ring Installation.
1. Fit the oil ring spacer into the piston ring groove.

NOTE:
1. The side rails and spacer may be installed in either direction.





2. New spacer and side rails are colored for identification





2. Install the upper side rail. to install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger.

CAUTION: Do not use piston ring expander when installing side rail.

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 either direction.





]C[ Piston ring No.2 / piston ring No.1 installation.
1. Using piston ring expander, fit No.2 and then No.1 piston ring into position.





NOTE: The ring end has an identification mark.





2. Install piston rings with identification mark facing up to the piston crown side.





3. Size marks on piston rings are as follows.





]D[ Piston and Connecting Rod Installation.
1. Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure.
3. Rotate crankshaft so that crank pin is on center of cylinder bore.

Identification mark: 63DTF

4. Rotate crankshaft so that the crank pin is on the center of the cylinder bore.
5. Use suitable thread protectors on the connecting rod bolts before inserting piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin.





6. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.





]E[ Connecting Rod Bearings Installation.
When the bearing needs replacing, select and install a pope bearing by the following procedure.
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 of its pins are painted at the positions shown in the illustration.





2. The connecting rod bearing identification mark is stamped at the position shown in the illustration.





3. Loosely tighten each nut to the bolt.

Example:
1. If the measured value of a crankshaft pin outer diameter is between 44.995 and 45.000 mm (1.7715 and 1.7717 inch), the pin is classified as "1" in the table. in case the crankshaft is also replaced by a spare part, check the identification colors of they pins painted on the new crankshaft. If the color is yellow, for example, the pin is classified as "1". In the above cases, select the connecting rod bearing having identification mark "1".





]F[ Connecting Rod Cap Installation.
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 come on the same side as shown.





2. Make sure that the connecting rod big end side clearance meets the specification.

Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit: 0.4 mm (0.016 inch)

]G[ Connecting Rod Cap Nut Installation.

NOTE: The connecting rod nut should be installed with the cylinder head or the spark plug removed.

1. Since the connecting rod bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined before reuse. If the bolt threads are "necked down", the bolt should be replaced.
Necking can be checked by running a nut with fingers 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 20 Nm (14.5 ft.lbs.) to install the cap properly.
5. Make a paint mark on the head of each nut.
6. Make a paint mark on the bolt end at the position 90° to 100° from the paint mark made on the nut in the direction of tightening the nut.
7. Give a 90° to 100° turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment.

CAUTION:
1. If the nut is turned less than 90°, proper fastening performance may not be expected. when tightening the nut, therefore, be careful to give a sufficient turn to it.
2. If the nut is over tightened (exceeding 100°), loosen the nut completely and then retighten it by repeating the tightening procedure from step (1).

Inspection

Piston
1. Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked.

Piston pin
1. Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play.





2. The piston and piston pin must be replaced as an assembly.

Piston ring
1. Check the piston ring for damage, excessive wear, and breakage and replace if defects are evident. if the piston has been replaced with a new one, the piston rings must also be replaced with new ones.





2. Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring, piston, or both.









3. Install the piston ring into the cylinder bore. Force it down with a piston, its 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 nap is excessive, replace the piston ring.

Limit:
No.1, No.2 ring: 0.8 mm (0.031 inch)
Oil ring: 1.0 mm (0.039 inch)





Crankshaft Pin Oil Clearance
(Plastigage method)
1. Remove oil from crankshaft pin and connecting rod bearing.
2. Cut the Plastigauge to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.





3. Install the connecting rod cap carefully and tighten the nuts to specified torque.
4. Carefully remove the connecting rod cap.
5. Measure the width of the Plastigauge at its widest part by using a scale printed on the Plastigauge package.

Standard value: 0.02 - 0.05 mm (0.0008 - 0.0020 inch)
Limit: 0.1 mm (0.004 inch)


CRANKSHAFT, FLYWHEEL AND DRIVE PLATE





Removal
Follow removal steps outlined in illustration.

Removal Service Point





[A] 0il Jet Removal.
Use an appropriate metal bar to press the oil jet out.

CAUTION:
1. Be careful not to damage the cylinder wall.
2. Never reuse the removed oil jet.


Installation
Installation in reverse order as removal.

Installation Service Points





]A[ Oil Jet Installation.
Use a pin punch of 4 - 5 mm (0.15 - 0.20 inch) diameter to press the oil jet in from the crank journal until the oil jet bottoms on.








]B[ 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 the front of engine, 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 (No. 1 journal)
1. If the measured value of a crankshaft journal outer diameter is between 56.994 - 57.000 mm (2.2439 - 2.2441 inch), 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 of the bearing to be used. In this case, it is "1" or green.

4. Install the bearings having an oil groove to the cylinder block.
5. Install the bearings having no oil groove to the bearing caps.





]C[ Bearing Cap / Bearing Cap Bolt Installation.
1. Install the bearing caps so that their arrows are directed to the timing belt side.
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 (A): Maximum 71.1 mm (2.79 inch)

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 sequence.

Torque Sequence:

5. Make a paint mark on the head of each bolt.
6. Make a paint 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.
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 is over tightened (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 cranked shaft turns smoothly and the end play is correct. If the end play exceeds the limit, replacer crankshaft bearings.

Standard value: 0.05 - 0.18 mm (0.0020 - 0 .0071 inch)
Limit: 0.25 mm (0.0098 inch)





]D[ Oil Seal Installation.





]E[ Sealant Application To Oil Seal Case.

Specified sealant: Mitsubishi Genuine Part N4D. 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 the oil and coolant for approximately 1 hour.

Inspection





Crankshaft Oil Clearance (Plastigauge Method)
1. Remove oil from the crankshaft journal and crankshaft bearing.
2. Install the crankshaft.
3. Cut the Plastigage to the same length as the width of bearing and place it on journal in parallel with its axis.





4. Install the crankshaft bearing cap carefully and tighten the bolts to specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package.

Standard value: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
Limit: 0.1 mm (0.004 inch)





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 inch)
Limit: 0.1 mm (0.004 inch)

3. If the distortion is excessive, correct within the allowable limit or replace.

Grinding limit: 0.2 mm (0.008 inch)
Includes/combined with cylinder head grinding.
Cylinder block height (when new): 283.9 - 284.1 mm (11.177 - 11.185 inch)

4. Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace. Using cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct cylinder to an oversize and replace piston and piston rings. Measure at the points shown in illustration.





Standard value:
Cylinder I.D.: 85.00 - 85.03 mm (3.3465 - 3.3476 inch)
Cylindricity: 0.01 mm (0.0004 inch)





Boring Cylinder
1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder.





NOTE: Size mark is stamped on piston top.

2. Measure outside diameter of piston to be used. Measure it in thrust direction as shown.
3. Based on measured piston O.D. calculate boring finish dimension.

Boring finish dimension = Piston O.D. + (clearance between piston O.D. and cylinder) 0.02 mm (0.0008 inch) (honing margin)

4. Bore all cylinders to 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 clearance between piston and cylinder.

Clearance between piston and cylinder: 0.03 - 0.05 mm (0.0012 - 0.0020 inch)

NOTE: When boring cylinders, finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize.