Crankshaft, Flywheel and Drive Plate

REMOVAL AND INSTALLATION

Removal Service Point
[A] Oil 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 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.








[No.1, No.2, No.4, No.5 journal]





[No.3 journal]

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.





6. Install the thrust bearings at the No.3 upper bearing with the grooved side toward the crank web.

]C[ 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 (A): Max. 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.
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.
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 is 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, 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 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 the oil and coolant for approximately 1 hour.

INSPECTION

Crankshaft Oil Clearance (Plastigage 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.





5. 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.





Piston Size Identification

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.