11B-62 ENGINE OVERHAUL (CRANKSHAFT AND CYLINDER BLOCK, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION ZX cauTion. ‘On the exible ywheel equipped engines, do not remove any of the bolts "A" of the Aywheel shown {in the illustration. The balance ofthe lexible flywheel is adjusted in an assembled condition, Remov- ing the bot, therefore, cam cause the flexible Aywheel to be out of balance giving and resulting in damage. Removal eps Removal tps (Contin) Fiyricel sltQUT 2D) 10.Adigter plate (A) Bal bearing UT -2WD) 1 Dive ple AD) Fiynieel UT “26D) 12 tere ing) Pye olQUT~AWD) 13.Rearplte Baltening QUT ~44D) 14. Bat booing cover Oil selene itl Adspier (MT ~4WD) Flexible ywbesl WT ~#WD) Cranks adiyes WT AWD) Drive plate bok (AT) 18 Bessing capENGINE OVERHAUL 11B-63 (CRANKSHAFT AND CYLINDER BLOCK, Removal steps (Contnwed) >> C<<19. Bering 4p No >> C20. Rearing cap Not >> Bs<21, Crankshaft bearing, lover 22. Cals >> Bo 28. Cranks bearing. upper >> Be<24, Cranks cst beating >> Acc 2S. Check vale >> Ace26.0ilje 27. Engine sopport bracket, sight 28. Enyne support bracket, et 28. Cylinder book dnt mat nd raion INSTALLATION SERVICE POINTS (Using tot 0 ark nd ela oer oe) >-Ac< OIL JET INSTALLATION “ Nop / a woe \ (1) Measure the casa jou diameter and conf is clasicaion fom the following table. a the ese ofa crauksba supplied s a service part identi its joras and painted at the postions shown jn colors and marks of | inthe illstration connec pee SH inno vote Check waive et ‘There ave to types of oles installed. ‘one for No.1 and 3 and the othe for NO.2 and 4 ‘Make sure that the correc one is installed with cor rect direction as shown, (2) The cylinder block bore diameter identification atk are stamped atthe position shown in the illustration from front to sear beainning at Nou. >> Be< CRANKSHAFT BEARING INSTALLATION 1 When the bearing needs replacing, selest proper bearing by the following procedure. vdentheaton Ferner cedare is unnecessary11B-64 ENGINE OVERHAUL (3) Select proper bearings from the below table b, Next, cick the cylinder block bearing bore iden- ‘oa the bass of the identification data ‘ification mark stamped on the eylinder block. Fit confirmed under Items (1) and (2), is "AY read the "Bearing identification mark’ col- ‘umn to find the identification mark ofthe bearing Example to beused this cas, itis "I" or "Gneea" 4, Ifthe measured value ofa crankshaft journal ‘outer diameter is 65.997 mum, the journal is clas- sified as "1" or "Yellow inthe table, In case the ‘crankshaft is also replaced by a spare part check the identification colors of the journals painted on the new crankshaft, ‘Combination of crankstaf journal diameter and cylinder block bearing bore Bearing diameter ‘entiation mark, Cranishat Jouraal Clasitiention Cinder block bearing Taenification color oF mark ‘OD. bore diameter ‘Using both ID (mark and color) or identification marke either ove T Fellow aoa = SENT Tor Gre 5 Tor eli T Tor None z None BOT ITE Tor Va ¥ Tor None T Tor Bie z he BOT =I Tor None 5 Tor Bie c TorRat Forvppet evo%e 2. Cranks bearing 5 Crankshaft hast beara installation (1) Install the bearings having an oil groove to the (1) Install the two thrust bearing in the aumber 3. cylinder block. bearing bore in the cylinder block. For easier NOTE: The No. 3 bearing integrated with thrust Jinstallatioa. apply engine oil to the bearings. bearing has no oll groove. ‘this will help hold them in position. (2) Tas the bearings hang no il srooce tthe (2) The dst bearings mus be installed wih their bearing cap. groove side toward the crankshaft web >>C<< BEARING CAP/ BEARING CAP BOLT INSTALLATIONENGINE OVERHAUL 11B-65 (CRANKSHAFT AND CYLINDER BLOCK Standard value: 0.08 0.28 mm Front mak >-D<< OIL SEAL INSTALLATI Y vnoonea7 1 4 Taso according othe front mask and cap No. 2. Apply engine il tothe threaded portion and seating face ofthe bol 3. Tighten the bearing cap bolts in the lustrated sequenceto 40 2 Nu * When the tightening angle is smaller than the specified tightening angle, the appropriate ‘cannot be secured. + When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure. 4, Using the special tool Angle gauge (MB991614), tighten the bearing cap Dolts in the illustrated sequence by a fiuther 38° 1039", ‘5. After installing the bearing caps, make sure that the crankshaft tums stioothly andthe end play is comet. If the end play exceeds the limit replace cxankshat bearings 1. Apply oil tool sea ips. 2, Using te special tool Oil seal installer (€M1D902147), Press and fit the ol seal into the oil seal case to have the dimension shown in the iluswation. >>E<< OIL SEAL CASE INSTALLATION 1 Remove completely old FIPG remaining onthe rear oil seal ease and cylinder block. 2, Apply a bead of FIPG tothe surface ofthe rear oil seal case as shown inthe drawing ‘Specified sea ‘Three bond 1217G or equivalent NOTE: Be sure to instal he case quickly while ‘the sealant is we (vith 15 minutes) 3. Install the ol seal into the eylinder block after applying an appropriate amount of engine ol to the entive eizcumference ofits lip potion 4. Install the rear oil seal case by tightening its bolts ten =1Nm NOTE: After installation, keep the sealed area away From the oil for approximately one hour‘Mitsubishi L200. Manual - part 48 B66 ENGINE OvERIACT INSPECTION onset /entex atve crores , i 7 cock Fanaa pron : Seisteset ees atte ‘The inspection procedure for this ol jet isthe same 5 for the conventional ole. (CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD) ‘The crankshaft ol learance can be measured easly by using a pst 1 Remove oil and grease and any other foreign ‘martes fiom crankshaft journal and bearing inner sutfice. 2 instal the cranks 3, Cut he plstigage othe same length asthe wit ‘of bearing and place it on joumal in parallel with its ais, 4. Gly place th crankshaft bearing cap over it sd ighten the bolts tothe specified torque. 5, Remove the Dots and gently remove the crankshaft beating cap. plastizage bag Standard value: 0.02, ~ 0.03 mm Limit: 0 min CYLINDER BLOCK 1. Using a sraahtedge and thickness gauge, check the bck tp surface for warpage. Makes that the surface is fee from gasket chips and other objets Standard value: 0.05 mim Limit: 0 min 2 the distontion is excessive, replace the evlinder block 3. Check cylinder walls for sratces and size If defects are event. replace the cylinder block ENGINE OVERHAUL 11B-67 ‘CRANKSHAFT AND CYLINDER BLOCK 4. Using cylinder snuge, measure the eylinder bore ad ejindscity. If worn badly, place te cylinder block. Measurement points are shoven in llustation. Standard value: Cylinder LD.91.10 | 9113 mm Cylindeity 0.02 mm