Mitsubishi Montero Sport (2004+). Manual - part 144

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-51

4. Check the end play. If it exceeds the limit value, replace the 

thrust bearing.

Standard value: 0.05 

− 0.25 mm (0.002 − 0.009 inch)

Limit: 0.3 mm (0.01 inch)

.

>>D<< CRANKSHAFT REAR OIL SEAL INSTALLATION
Using special tool MD998718, press-fit a new crankshaft rear 
oil seal into the oil seal case.

.

>>E<< OIL SEAL CASE INSTALLATION
1. Apply the sealant Mitsubishi Genuine Part number 

MD970389 or equivalent to the oil seal case.

2. Apply a small amount of engine oil to the entire 

circumference of the oil seal lip section, and place the oil 
seal case on the cylinder block.
NOTE: Install the oil seal case within 15 minutes after apply-
ing liquid gasket.
NOTE: Then wait at least one hour. Never start the engine 
or let engine oil or coolant touch the adhesion surface during 
that time.

AK302423

AKX00693

MD998718

OIL SEAL 
CASE

AB

AKX00741

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-52

INSPECTION

M1113008800441

.

CRANKSHAFT JOURNAL OIL CLEARANCE 
<PLASTIC GAUGING MATERIAL METHOD>
1. Remove oil from the crankshaft journal and crankshaft 

bearing inner surface.

2. Install the crankshaft.
3. Cut plastic gauging material 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.

Tightening torque: 74 

± 4 N⋅m (54 ± 3 ft-lb)

5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastic gauging material 

at its widest section by using a scale printed on the plastic 
gauging material bag.

.

CRANKSHAFT REAR OIL SEAL
1. Check the oil seal lip for wear and damage.
2. Check the 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 sure that the surface is free from 
gasket chips and other foreign matter.

Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 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):

227.9 

− 228.1 mm (8.972 − 8.980 inches)

AK302438AB

PLASTIC GAUGING
MATERIAL

AK302439

AKX00738

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL

11B-53

4. Check the cylinder walls for scratches and seizure. If defects 

are evident, correct (bored to an oversize) or replace.

5. Using a cylinder gauge, measure the cylinder bore and 

cylindricality. 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.

Standard value:

Cylinder Inside Diameter: 93.0 mm (3.661 inches)
Cylindricality: 0.01 mm (0.0003 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 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 Outside Diameter (OD), 

calculate the boring finish dimension.

Boring finish dimension = Piston OD + (clearance 
between piston OD and cylinder) 

− 0.02 mm (0.0008 

inch) (honing margin)

CAUTION

To prevent distortion that may result from temperature rise 
during honing, bore cylinders in the order of number 2, 
number 4, number 6, number 1, number 3 and number 5.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance 

between piston OD and cylinder).

Standard value:

Cylinder Inside Diameter: 93.0 mm (3.661 inches) 
Cylindricality: 0.01 mm (0.0003 inch)

6. Check the clearance between the piston and cylinder.

Clearance between piston and cylinder:

0.02 

− 0.04 mm (0.0008 − 0.0015 inch)

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

AKX00739AB

12 mm (0.47 in)

BOTTOM

CENTER

SIZE

IDENTIFICATION MARK

0.50 mm (0.020 in) Oversize 
diameter

0.50

1.00 mm (0.040 in) Oversize 
diameter

1.00

AKX00740

PISTON OUTSIDE
DIAMETER

THRUST 
DIRECTION

AB

BRACKET

TSB Revision

ENGINE OVERHAUL

11B-54

BRACKET

REMOVAL AND INSTALLATION

M1113009000040

AK000455

75 ± 10 N·m
55 ± 7 ft-lb
(M12 BOLT)

41 ± 8 N·m
30 ± 6 ft-lb
(M10 BOLT)

75 ± 10 N·m
55 ± 7 ft-lb
(M12 BOLT)

2

1

AB

22 ± 4 N·m
16 ± 3 ft-lb
(M8 BOLT)

41 ± 8 N·m
30 ± 6 ft-lb
(M10 BOLT)

REMOVAL STEPS

1. ENGINE SUPPORT BRACKET, RIGHT
2. ENGINE SUPPORT BRACKET, LEFT