Part 2
OIL PUMP AND OIL PAN
Removal
Follow removal steps outlined in illustration.
Removal Service Points
[A] Oil Pan Removal.
(1) Tap the special tool in deeply between the oil pan and the cylinder block.
(2) Hitting the special tool on the side, slide it along the oil pan to remove it.
[B] Outer Rotor / Inner Rotor Removal.
(1) Make alignment dots on the outer and inner rotors for reference in reassembly.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Inner Rotor / Outer Rotor Installation.
(1) Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly aligned.
]B[ Crankshaft Front Oil Seal Installation.
(1) Using the special tool, knock the oil seal into the oil pump case.
NOTE: Knock it as far as it goes.
]C[ Oil Pan Installation.
(1) Clean the gasket surfaces of the cylinder block and oil pan.
(2) Apply a 4 mm (0.157 inch) diameter bead of sealant to the oil pan. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
(3) Tighten oil pan bolts in the sequence shown.
(4) After installation, keep the sealed area away from the oil and coolant for approximately 1 hour.
CAUTION: When installing the oil pan, be sure not to expel the sealant form the oil pan flange at portion A in the illustration.
]D[ Drain Plug Gasket Installation.
(1) Install the drain plug gasket as illustrated.
]E[ 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 on until the O-ring contacts the bracket.
Then tighten 3/4 turn [14 Nm (10 ft. lbs.)]
]F[ Sealant Application To Oil Pressure Gauge Unit.
(1) Coat the threads of the gauge unit with sealant and install it using the special tools.
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 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 porttion clear of sealant.
2. Avoid and overtightening.
Inspection
Oil Pump
(1) Check the tip clearance.
Standard value: 0.06 - 0.18 mm (0.0024 - 0.0071 inch)
(2) Check the side clearance.
Standard value: 0.04 - 0.10 mm (0.0016 0 0.0039 inch)
(3) Check the body clearance.
Standard value:
0.10 - 0.18 mm (0.0040 - 0.0070 inch)
Limit:
0.35 mm (0.0138 inch)
Oil Cooler Bypass Valve
(1) Make sure that the valve moves smoothly.
(2) Ensure that the dimension L measures the standard value under normal temperature and humidity.
Dimension L: 34.5 mm (1.358 inch)
(3) The dimension must be the standard valve when measured after the valve has been dipped in 100° C (212° F) oil.
Dimension L: 40 mm (1.57 inch) or more.
PISTON AND CONNECTING ROD
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 the 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.
(4) Position the piston assembly on the piston support in the press. With the press pin up as shown in the illustration, 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 piston.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Piston Pin Installation.
(1) Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on the 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 graduations on the press pin, adjust the stop screw to the depth.
Depth: 62 mm
(3) Place the base on the 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 front the assembly.
IMPORTANT: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.
]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 spacers and side rails are colored for identification of their sizes.
(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.
Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings.
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:
(1) The ring end is provided with the identification mark.
Identification mark:
[SOHC]
No.1 ring 1R
No.2 ring 2R
[DOHC]
No.1 ring T
No.2 ring T2
(2) Install piston rings with identification mark facing up, to the piston crown side.
(3) Piston rings have one of the following size marks stamped according to their size.
]D[ Piston and Connecting Rod Installation.
(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 the illustration.
NOTE: The pistons for SOHC engine include those for right bank and left bank. They are identified by the marks as follows.
Identification mark R: For right bank
Identification mark L: For left bank
(3) Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.
(4) Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block.
Care must be taken not to nick the crank pin.
(5) Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
CAUTION: Install the piston with the front mark (arrow mark) on the top of the piston directed towards the engine front (timing belt side).
]E[ Connecting Rod Cap Installation.
(1) Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly. If a new connecting rod is used which has no alignment mark, position the notches for locking the bearing on the same side.
(2) Check if the thrust clearance in the connecting rod big end is correct.
Standard value:
0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit:
0.4 mm (0.016 inch)
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 clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both.
(3) Insert the piston ring into the cylinder bore. Force the ring down with a piston, the piston 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 gap is excessive, replace the piston ring.
Crankshaft Pin Oil Clearance (plastic Gauge Method)
The crankshaft oil clearance can be measured easily by using a plastic gauge as follows:
(1) Remove oil and grease and any other foreign material from the crankshaft pin and the bearing inner surface.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width of the bearing and place it on the pin in parallel with its axis.
(4) Gently place the crankshaft bearing cap over it and tighten the bolts to the specified torque.
(5) Remove the bolts and gently remove the crankshaft bearing cap.
(6) Measure the width of the smashed plastic gauge at its widest section by using a scale printed on the plastic gauge bag.
CRANKSHAFT, FLYWHEEL AND DRIVE PLATE
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Knock Sensor Bracket Installation.
(1) Check that the bracket is in intimate contact with the cylinder block boss and tighten to specified torque in the order shown.
]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 bearing supplied as a service part, its identification color is painted at the position 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 the engine, beginning at No 1.
[SOHC][DOHC]
(3) Select a proper bearing from the above table on the basis of the identification data confirmed under Items (1) and (2).
[Example (DOHC engine)]
1) If the measured value of a crankshaft journal outer diameter is 59.996 mm, the journal is classified as "1" in the table. (In case the crankshaft is also replaced by a spare part, check the identification color painted on the new crankshaft. If it 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 "1", read the Identification color for the spare bearing" column to find the identification color of the bearing to be used. In this case, it is "pink".
(4) Install the bearing halves with oil groove in the cylinder block side.
(5) Install the bearing halves without oil groove on the bearing cap side.
(6) Install the thrust bearings on both sides of the No.3 bearing with the grooves facing outward.
]C[ Bearing Cap / Bearing Bolt Installation.
(1) Attach the bearing cap on the cylinder block as shown in the illustration.
(2) Tighten the bearing cap bolts to the specified torque in the sequence shown in the illustration.
(3) Check that the crankshaft rotates smoothly.
(4) Check the end play. If it exceeds the limit value, replace the thrust bearing.
]D[ Crankshaft Rear Oil Seal Installation.
(1) Using the special tool, press-fit a new crankshaft rear oil seal into the oil seal case.
]E[ Oil Seal Case Installation.
(1) Apply specified sealant to the area shown in the illustration.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 or equivalent
(2) Apply a small amount of engine oil to the entire circumference of the oil seal lip section, and place the oil seal on the cylinder block.
NOTE:
(1) Install the oil seal case within 15 minutes after applying liquid gasket.
(2) Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time
Inspection
If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary.
(1) Measure the outside diameter of the journals and the inside diameter of the crankshaft bearings. If the difference between them (oil clearance) exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft.
Crankshaft Journal Oil Clearance Plastic Gauge Methods
The crankshaft oil clearance can be measured easily by using a plastic gauge, as follows:
(1) Remove oil and grease and any other foreign material from the crankshaft journal and bearing inner surface.
(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.
CAUTION: Do not attempt an undersize machining of the crankshaft with special surface treatment. This crankshaft can be identified by its dull gray appearance.
(4) Gently place the crankshaft bearing cap over it and tighten the bolts to the specified torque
(5) Remove the bolts and gently remove the crankshaft bearing cap.
(6) Measure the width of the smashed plastic gauge at its widest section by using a scale printed on the plastic gauge bag.
Crankshaft Rear Oil Seal
(1) Check the oil seal lip for wear and damage.
(2) Check rubber for deterioration or hardening.
(3) Check the oil seal case for cracks and damage.
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 cure that the surface is free from gasket chips and other foreign matter.
(3) If the distortion is excessive, correct within the allowable limit or replace.
(4) Check the 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 by boring the cylinders to an oversize and replace pistons and piston rings. Measure at the points shown in the illustration.
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 the outside diameter of the piston to be used. Measure it in the 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 inch) (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 in the order of No.2, No.4, No.6, No.1, No.3 and No.5.
(5) Hone to the final finish dimension (piston O.D. + clearance between piston O.D. and cylinder).
(6) Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
NOTE: When boring cylinders, finish all of six cylinders to the same oversize. Do not bore only one cylinder to an oversize.
Oil Jet Replacement Procedure
(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 removed oil jets.
(2) Using a pin punch having a diameter of 4 to 5 mm, drive in new oil jets from the crankshaft bearing section until they bottom.