Mitsubishi Outlander Service Manual

Mitsubishi Outlander Service Manual

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ENGINE OVERHAUL
REWORK DIMENSIONS . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . .
SEALANTS . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
THROTTLE BODY . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
EXHAUST MANIFOLD. . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
WATER HOSE AND PIPE . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
GROUP 11B
CONTENTS
REMOVAL AND INSTALLATION . . . . . . . .
TIMING CHAIN . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
11B-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
11B-14
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11B-1
11B-21
11B-59

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Summary of Contents for Mitsubishi Outlander

  • Page 1: Table Of Contents

    11B-1 GROUP 11B ENGINE OVERHAUL CONTENTS GENERAL SPECIFICATIONS ..11B-2 OIL PAN AND TIMING CHAIN CASE 11B-21 REMOVAL AND INSTALLATION ..11B-21 SERVICE SPECIFICATIONS..11B-2 TIMING CHAIN .
  • Page 2: General Specifications

    ENGINE OVERHAUL 11B-2 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS M1113000203154 Item Specification Engine model 4B11 4B12 Type In-line DOHC Number of cylinders Combustion chamber Pentroof type Total displacement mL 1,998 2,360 Cylinder bore mm Piston stroke mm Compression ratio 10.5 Auto lash adjuster Non-equipped SERVICE SPECIFICATIONS M1113000303645...
  • Page 3: Rework Dimensions

    ENGINE OVERHAUL 11B-3 REWORK DIMENSIONS Item Standard value Limit 7,500 − 17,500 − Piston pin press-fit load N 0.03 − 0.07 Clearance between piston ring and No.1 ring groove mm 0.03 − 0.07 No.2 0.15 − 0.28 Piston ring end gap mm No.1<4B11>...
  • Page 4 ENGINE OVERHAUL 11B-4 TORQUE SPECIFICATIONS Item N⋅m 44 ± 10 Alternator bolt 10 ± 2 Ignition coil bolt 25 ± 5 Spark plug 44 ± 8 Accessory bracket bolt Throttle body 11 ± 1 Vacuum pipe assembly bolt 9.5 ± 2.5 Throttle body bolt 4.0 ±...
  • Page 5 ENGINE OVERHAUL 11B-5 TORQUE SPECIFICATIONS Item N⋅m 10 ± 2 Timing chain case bolt <M6> Timing chain case bolt <M8 × 10> 13 ± 1 Timing chain case bolt <M8 × 30> 24 ± 4 10 ± 2 Oil pan bolt <M6> 31 ±...
  • Page 6: Sealants

    Specified sealant Drive plate bolt ThreeBond 1324 or equivalent Oil pan ThreeBond 1227D, ThreeBond 1217G (MITSUBISHI MOTORS GENUINE Part No,1000A923), ThreeBond 1207F (MITSUBISHI MOTORS GENUINE Part No,MD970389), LOCTITE 5970, LOCTITE 5900 or equivalent Cylinder head cover (matching area of the...
  • Page 7: Special Tools

    ENGINE OVERHAUL 11B-7 SPECIAL TOOLS tion. Do not pour oil or water on applied locations or do not start the engine until sufficient time (approxi- mately one hour) passes. The application procedure of FIPG may differ depending on areas. Follow the procedure in the body of the manual to apply FIPG.
  • Page 8 ENGINE OVERHAUL 11B-8 SPECIAL TOOLS Tool Part No. Tool name Application MD998735 Valve spring Compression of valve spring compressor MB992089 Retainer holder C MB992085 Valve stem seal pliers Extraction of valve stem seal MD998737 Valve stem seal Installation of valve stem seal installer MD998780 Piston pin setting tool Extraction and press fit of piston...
  • Page 9 ENGINE OVERHAUL 11B-9 SPECIAL TOOLS Tool Part No. Tool name Application MB991346 Top cover wrench Removal and installation of oil pump sprocket(4B11) B991346...
  • Page 10: Alternator And Ignition System

    ENGINE OVERHAUL 11B-10 ALTERNATOR AND IGNITION SYSTEM ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION M1113001002718 10 ± 2 N·m 25 ± 5 N·m 22 ± 4 N·m 210 N·m 44 ± 8 N·m 44 ± 8 N·m 44 ± 10 N·m 44 ±...
  • Page 11: Spark Plug 25

    ENGINE OVERHAUL 11B-11 ALTERNATOR AND IGNITION SYSTEM REMOVAL SERVICE POINTS >>B<< CRANKSHAFT PULLEY / CRANKSHAFT PULLEY WASHER / <<A>> CRANKSHAFT PULLEY CENTRE CRANKSHAFT PULLEY CENTRE BOLT BOLT REMOVAL INSTALLATION MB991883 MB991883 AK502869 AC AK503335 AC 1. Use special tool Flywheel stopper (MB991883) to secure the drive plate.
  • Page 12 ENGINE OVERHAUL 11B-12 ALTERNATOR AND IGNITION SYSTEM >>C<< ALTERNATOR INSTALLATION 5. Apply an appropriate and minimum amount of engine oil to the threaded portion of the crankshaft and lower part of the flange. 6. With the chamfered side on the inside of the washer facing the bolt top, install the crankshaft pulley washer to the crankshaft pulley centre bolt.
  • Page 13: Throttle Body

    ENGINE OVERHAUL 11B-13 THROTTLE BODY THROTTLE BODY REMOVAL AND INSTALLATION M1113009800347 11 ± 1 N·m 9.5 ± 2.5 N·m 4.0 ± 1.0 N·m 4.0 ± 1.0 N·m AKC00007AB INSTALLATION SERVICE POINTS Removal steps 1. Vacuum pipe and hose >>A<< MANIFOLD ABSOLUTE PRES- 2.
  • Page 14: Inlet Manifold And Fuel System

    ENGINE OVERHAUL 11B-14 INLET MANIFOLD AND FUEL SYSTEM INLET MANIFOLD AND FUEL SYSTEM REMOVAL AND INSTALLATION M1113032501169 3.5 ± 1.5 20 ± 2 N·m 3.5 ± 1.5 20 ± 2 N·m 3.5 ± 1.5 20 ± 2 N·m 3.5 ± 1.5 20 ±...
  • Page 15 ENGINE OVERHAUL 11B-15 INLET MANIFOLD AND FUEL SYSTEM INSTALLATION SERVICE POINTS >>C<< INLET MANIFOLD INSTALLATION >>A<< OIL PRESSURE SWITCH INSTAL- CAUTION Temporarily tighten the inlet manifold because LATION there is a bolt tightening procedure for the inlet manifold, delivery pipe and injector protector. 1 mm Install the inlet manifold and temporarily tighten bolts.
  • Page 16 ENGINE OVERHAUL 11B-16 INLET MANIFOLD AND FUEL SYSTEM 3. Check that the injector rotates smoothly. If it does 5. Securely assemble the injector to the injector not rotate smoothly, the O-ring may be caught. groove and delivery pipe collar. Remove the injector and check the O-ring for damage.
  • Page 17: Exhaust Manifold

    ENGINE OVERHAUL 11B-17 EXHAUST MANIFOLD EXHAUST MANIFOLD REMOVAL AND INSTALLATION M1113011901247 44 ± 5 N·m 8.0 ± 2.0 N·m 8.0 ± 2.0 N·m 11 ± 1 N·m 11 ± 1 N·m 49 ± 5 N·m 41 ± 10 N·m 56 ± 8 N·m 41 ±...
  • Page 18 ENGINE OVERHAUL 11B-18 EXHAUST MANIFOLD REMOVAL SERVICE POINTS Tighten the oxygen sensor to the specified torque by using special tool oxygen sensor wrench <<A>> OXYGEN SENSOR REMOVAL (MB991953). Tightening torque: 44 ± 5 N⋅m Oxygen sensor >>C<< CRANK ANGLE SENSOR / O-RING INSTALLATION MB991953 CAUTION...
  • Page 19: Water Hose And Pipe

    ENGINE OVERHAUL 11B-19 WATER HOSE AND PIPE WATER HOSE AND PIPE REMOVAL AND INSTALLATION M1113032900722 24 ± 3 N·m 30 ± 9 N·m 24 ± 3 N·m 24 ± 3 N·m 28 ± 8 N·m 24 ± 3 N·m 24 ± 3 N·m 11 ±...
  • Page 20 ENGINE OVERHAUL 11B-20 WATER HOSE AND PIPE >>B<< THERMOSTAT INSTALLATION >>C<< COOLANT TEMPERATURE SENSOR INSTALLATION CAUTION Be careful not to give a shock, twist and the like to the resin mould with a tool during installation. Jiggle Valve AK304916 AB Install the thermostat with the jiggle-valve facing almost straight upwards.
  • Page 21: Oil Pan And Timing Chain Case

    ENGINE OVERHAUL 11B-21 OIL PAN AND TIMING CHAIN CASE OIL PAN AND TIMING CHAIN CASE REMOVAL AND INSTALLATION M1113026301520 3.0 ± 1.0 N·m 5.5 ± 0.5 N·m 2.5 ± 0.4 N·m 10 ± 2 N·m 13 ± 1 N·m 10 ± 2 N·m 48 ±...
  • Page 22 ENGINE OVERHAUL 11B-22 OIL PAN AND TIMING CHAIN CASE REMOVAL SERVICE POINTS 3. Lightly tap and slide special tool Oil pan FIPG cutter (MD998727) to remove the oil pan. <<A>> OIL FILTER REMOVAL <<C>> TIMING CHAIN CASE REMOVAL MB991396 Hammer AK502733AC Use special tool Oil filter wrench (MB991396) to remove the oil filter.
  • Page 23 ENGINE OVERHAUL 11B-23 OIL PAN AND TIMING CHAIN CASE Ø2.5 ± 0.5 mm 7.5 ± 0.5 mm 1 ± 0.5 mm Ø2.5 ± 0.5 mm C-C view A-A view 3 ± 0.5 mm Ø2.5 ± 0.5 mm 3 ± 0.5 mm 4.5 ±...
  • Page 24 ENGINE OVERHAUL 11B-24 OIL PAN AND TIMING CHAIN CASE CAUTION The front oil seal must not be a strong press fit. The strong press fit can possibly cause the oil leakage, damaging the front oil seal. 2. Use special tool Bush remover and installer base (MB991448) in order to press-fit the front oil seal into the timing chain case as shown in the illustration.
  • Page 25 ENGINE OVERHAUL 11B-25 OIL PAN AND TIMING CHAIN CASE 4. Tighten the cylinder head cover to the tightening torque of 3.0 ± 1.0 N⋅m in the order shown in the 4 mm illustration. 5. Then, tighten it to the specified torque of 5.5 ± 0.5 2 mm 2 mm N⋅m in the same order.
  • Page 26: Timing Chain

    ENGINE OVERHAUL 11B-26 TIMING CHAIN TIMING CHAIN REMOVAL AND INSTALLATION M1113026601253 Apply engine oil to all moving parts before installation. 59 ± 5 N·m 10 ± 2 N·m 59 ± 5 N·m 10 ± 2 N·m 10 ± 2 N·m AKB00096 REMOVAL SERVICE POINTS Removal steps...
  • Page 27 ENGINE OVERHAUL 11B-27 TIMING CHAIN INSTALLATION SERVICE POINTS 2. Push the tensioner lever by hand and push in the plunger of the timing chain tensioner until it hits >>A<< INLET V.V.T. SPROCKET BOLT the bottom. Then, insert a hard wire (piano wire or INSTALLATION the like) of φ1.5 or hexagonal bar wrench (1.5 mm) into the fixing hole of the plunger.
  • Page 28 ENGINE OVERHAUL 11B-28 TIMING CHAIN • Make sure that the knock pin of the exhaust cam- 1. Align the timing mark of the inlet V.V.T. sprocket shaft assembly is positioned facing straight and the exhaust camshaft sprocket. upward. 2. Align the crankshaft sprocket keys with illustrated •...
  • Page 29: Inspection

    ENGINE OVERHAUL 11B-29 TIMING CHAIN INSPECTION Timing mark Timing mark M1113026701216 link plate (blue) link plate (orange) INLET V.V.T. SPROCKET CAUTION Never overhaul the V.V.T. sprocket. Retard Tape port Advance port Inlet V.V.T. Exhaust sprocket camshaft timing mark sprocket timing mark Make a hole Retard Advance...
  • Page 30 ENGINE OVERHAUL 11B-30 TIMING CHAIN 5. Turn the inlet V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 12.5°<4B11>,approximately 20°<4B12>) NOTE: The stopper pin is locked in the most retarded angle position. 6.
  • Page 31 ENGINE OVERHAUL 11B-31 TIMING CHAIN NOTE: There are 47 kinds of valve tappets at 9. Select a valve tappet in the following procedure. intervals of 0.015 mm in the range between 3.000 (1) Measure thickness of a removed valve tappet. and 3.690 mm.
  • Page 32: Camshaft

    ENGINE OVERHAUL 11B-32 CAMSHAFT CAMSHAFT REMOVAL AND INSTALLATION M1113026900950 17 ± 3 N·m 12 ± 1 N·m 30 ± 2 N·m Apply engine oil to all moving parts before installation. 10 ± 2 N·m AKB00211 Removal steps (Continued) Removal steps >>B<<...
  • Page 33: Camshaft Bearing Cap Bolt 12

    ENGINE OVERHAUL 11B-33 CAMSHAFT REMOVAL SERVICE POINTS >>B<< CAMSHAFT / BEARING / THRUST CAMSHAFT BEARING CAP / CAMSHAFT <<A>> FRONT CAMSHAFT BEARING BEARING CAP / OIL FEEDING CAP / OIL FEEDING CAMSHAFT BEAR- CAMSHAFT BEARING CAP / FRONT ING CAP / CAMSHAFT BEARING CAP / CAMSHAFT BEARING CAP THRUST CAMSHAFT BEARING CAP INSTALLATION...
  • Page 34 ENGINE OVERHAUL 11B-34 CAMSHAFT Timing chain side Dowel pin AK503814 AK502390 4. Set the dowel pins of the camshaft at the 7. Tighten each front camshaft bearing cap mounting bolt to the temporarily torque of 17 ± 3 illustrated positions. N⋅m in the order of number shown (1).
  • Page 35: Inspection

    ENGINE OVERHAUL 11B-35 CAMSHAFT INSPECTION M1113027000961 CAMSHAFT Plastigage AK503391 6. Measure the Plastigage whose width is most compressed using the scale printed on the AK503020AC Plastigage bag. When the measured value Measure camshaft height (camshaft major axis). If deviates from the standard one, replace the the height exceeds the limit, replace the camshaft.
  • Page 36 ENGINE OVERHAUL 11B-36 CAMSHAFT Thickness Thickness Thickness Thickness Thickness Thickness stamp stamp stamp 3.000 3.000 mm 3.240 3.240 mm 3.480 3.480 mm 3.015 3.015 mm 3.255 3.255 mm 3.495 3.495 mm 3.030 3.030 mm 3.270 3.270 mm 3.510 3.510 mm 3.045 3.045 mm 3.285...
  • Page 37: Cylinder Head And Valves

    ENGINE OVERHAUL 11B-37 CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION M1113006903463 +90˚ +90˚ +90˚ +90˚ 35 ± 2 N·m 35 ± 2 N·m Apply engine oil to all moving parts before installation. AK703803 Removal steps (Continued) Removal steps <<A>>...
  • Page 38 ENGINE OVERHAUL 11B-38 CYLINDER HEAD AND VALVES REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS <<A>> RETAINER LOCK REMOVAL >>A<< VALVE STEM SEAL INSTALLA- TION MB992089 CAUTION • The valve stem seal must not be reused. • Do not damage the tappet wall during assem- bly.
  • Page 39 ENGINE OVERHAUL 11B-39 CYLINDER HEAD AND VALVES >>B<< RETAINER LOCK INSTALLATION MB992089 MD998735 AK502741AC Ø2 to Ø3 mm Use a special tool to compress the valve spring and to install the retainer lock. • Valve spring compressor (MD998735) • Retainer holder C (MB992089) >>C<<...
  • Page 40: Inspection

    ENGINE OVERHAUL 11B-40 CYLINDER HEAD AND VALVES NOTE: Bolts and washers are different parts for 2. Completely remove oil, scale, sealant, carbon, bolts on the timing chain side. etc. After cleaning oil passages, blow air to make sure that they are not clogged. Timing chain side AK502392 AK502740...
  • Page 41 ENGINE OVERHAUL 11B-41 CYLINDER HEAD AND VALVES VALVE GUIDE Valve guide Length AK305409AB Stem diameter Guide inside diameter AK300168 3. Measure overall length of the valve. Measure clearance between the valve guide and If the limit is exceeded, replace the valve. valve stem.
  • Page 42 ENGINE OVERHAUL 11B-42 CYLINDER HEAD AND VALVES Inlet valve seat bore diameter: 0.3 O.S.: 36.22 − 36.24 mm 1.16 – 1.46 mm 1.35 – 1.65 mm Exhaust valve seat bore diameter: 0.3 O.S.: 30.22 − 30.24 mm 30˚ 30˚ 3. Press fit the valve seat, taking care not to score the cylinder head bore at room temperature.
  • Page 43: Oil Pump Chain <4B11

    ENGINE OVERHAUL 11B-43 OIL PUMP CHAIN <4B11> OIL PUMP CHAIN <4B11> REMOVAL AND INSTALLATION M1113033700572 40 N·m 130 N·m 10 ± 2 N·m 24 ± 2 N·m 10 ± 2 N·m Apply engine oil to all moving parts before installation. 26 ±...
  • Page 44 ENGINE OVERHAUL 11B-44 OIL PUMP CHAIN <4B11> REMOVAL SERVICE POINTS 1. Pry the illustrated position with a screwdriver or tap the boss with a hammer. <<A>> DRIVE PLATE BOLT REMOVAL MB991883 AK502756 AK502869 AC 2. If the ladder frame does not come off, insert a 1.
  • Page 45 ENGINE OVERHAUL 11B-45 OIL PUMP CHAIN <4B11> >>B<< CRANKSHAFT SPROCKET INSTALLATION 8.5 mm 1 mm : Wipe clean with a rag. : Wipe clean with a rag and degrease. Crankshaft 3 mm Engine front Crankshaft sprocket AK603521AE 1. Wipe off the dirt on the crankshaft sprocket and the crankshaft using a rag, and then remove the 1.75 mm grease from the portion shown in the illustration.
  • Page 46 ENGINE OVERHAUL 11B-46 OIL PUMP CHAIN <4B11> >>D<< REAR OIL SEAL INSTALLATION 2. Use special tool Flywheel stopper (MB991883) to secure the drive plate. CAUTION Do not apply oil to the circumference of the oil seal and oil seal pressing hole on the cylinder block side to prevent teeth from pulling out.
  • Page 47: Balancer Chain <4B12

    ENGINE OVERHAUL 11B-47 BALANCER CHAIN <4B12> BALANCER CHAIN <4B12> REMOVAL AND INSTALLATION M1113032200358 40 N·m 130 N·m 10 ± 2 N·m 10 ± 2 N·m 10 ± 2 N·m 24 ± 2 N·m Apply engine oil to 20 N·m 44 N·m 0 N·m 20 N·m +135˚...
  • Page 48 ENGINE OVERHAUL 11B-48 BALANCER CHAIN <4B12> REMOVAL SERVICE POINTS <<A>> DRIVE PLATE BOLT REMOVAL MB991883 AK502754 CAUTION The balancer shaft module must not be disas- AK502869 AC sembled because of assembly warranty. 1. Use special tool Flywheel stopper (MB991883) to 3.
  • Page 49 ENGINE OVERHAUL 11B-49 BALANCER CHAIN <4B12> INSTALLATION SERVICE POINTS >>A<< LADDER FRAME INSTALLATION CAUTION Be sure to remove liquid gasket that has entered mounting holes. 1. Completely remove liquid gasket adhering to the cylinder block and ladder frame. CAUTION Sufficiently check that there is no residual oil on AKB00722AB the place where degreasing is performed.
  • Page 50: Balancer Shaft Module Bolt 20 → 44 → 0 → 20 → +135

    ENGINE OVERHAUL 11B-50 BALANCER CHAIN <4B12> 1. Wipe the dirt on the crankshaft sprocket and the 6. While slanting the balancer shaft module, align crankshaft using a rag, and then remove the the link plate (blue) of another balancer chain with grease from the portion shown in the illustration.
  • Page 51 ENGINE OVERHAUL 11B-51 BALANCER CHAIN <4B12> 9. After tightening them to the specified torque of 20 CAUTION N⋅m again, use special tool Angle gauge Install the chain tensioner precisely in place after (MB991614) to tighten them up to 135°. installing the tensioner lever and chain guide to 10.Pull out the hexagonal bar wrench from the prevent the plunger of the chain tensioner from balancer module sprocket.
  • Page 52 ENGINE OVERHAUL 11B-52 BALANCER CHAIN <4B12> AK600847AB AK603576 3. Apply engine oil to thread of crankshaft and bolt 5. Tighten drive plate bolts to temporary torque of 40 seat area of drive plate. N⋅m in the order shown to illustration. 4.
  • Page 53: Piston And Connecting Rod

    ENGINE OVERHAUL 11B-53 PISTON AND CONNECTING ROD PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION M1113008403903 Apply engine oil to all moving parts before installation. 5.0 N·m 20 N·m +90˚ AK603501 REMOVAL SERVICE POINTS Removal sequence >>G<< 1. Connecting rod cap bolt <<A>>...
  • Page 54 ENGINE OVERHAUL 11B-54 PISTON AND CONNECTING ROD Enter cylinder No. for reassembly on the side of the 1. Insert the push rod into the piston pin from the connecting rod big end. front mark side of the piston top surface, and attach special tool Guide D (MB991659).
  • Page 55 ENGINE OVERHAUL 11B-55 PISTON AND CONNECTING ROD >>B<< OIL RING INSTALLATION Piston mark size Upper Lower side side rail rail closed closed AK603503AC Spacer closed gap AK103812 AC NOTE: The piston size mark is indicated on the piston top face. 1.
  • Page 56 ENGINE OVERHAUL 11B-56 PISTON AND CONNECTING ROD Use a piston ring expander to assemble piston rings CAUTION with their identification marks facing upward. Piston Driving it in hard causes breakage of piston rings rings can be assembled by hand without using the and damage to the crank pin.
  • Page 57 ENGINE OVERHAUL 11B-57 PISTON AND CONNECTING ROD Identification number AK502752 AK305607AF 2. Make sure that clearance of the thrust of the 3. A connecting rod bearing has an identification connecting rod big end is appropriate. mark at the illustrated position. Standard value: 0.10 −...
  • Page 58: Inspection

    ENGINE OVERHAUL 11B-58 PISTON AND CONNECTING ROD Press down ring with piston 90˚ Front mark Paint mark Paint mark Piston ring End gap AK502749 AK503370AG 6. Put a paint mark on the bolt head as illustrated. 2. Put piston rings into the cylinder bore, press them 7.
  • Page 59: Crankshaft And Cylinder Block

    ENGINE OVERHAUL 11B-59 CRANKSHAFT AND CYLINDER BLOCK 5. Measure the crushed Plastigage width (area most widely crushed) using a scale printed on the Plastigage bag. Standard value: 0.018 − 0.045 mm Limit: 0.1 mm Plastigage AK503374AC CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION M1113008704286 11 ±...
  • Page 60 ENGINE OVERHAUL 11B-60 CRANKSHAFT AND CYLINDER BLOCK 2. Install the thrust bearing so that the grooved side Removal steps >>E<< is on the crankshaft weight side. 1. Crankshaft bearing cap bolt >>E<< 2. Crankshaft bearing cap >>D<< 3. Crankshaft bearing lower >>C<<...
  • Page 61 ENGINE OVERHAUL 11B-61 CRANKSHAFT AND CYLINDER BLOCK 3. Install the selected crankshaft bearing lower. >>D<< CRANKSHAFT BEARING LOWER >>E<< CRANKSHAFT BEARING CAP / INSTALLATION CRANKSHAFT BEARING CAP BOLT Journal identification mark position INSTALLATION No.1 No.2 No.3 AK502395 1. Install the crankshaft bearing cap with reference No.4 to the identification mark as illustrated.
  • Page 62: Inspection

    ENGINE OVERHAUL 11B-62 CRANKSHAFT AND CYLINDER BLOCK 4. Carefully install the bearing cap and tighten the CAUTION • When the tightening angle is smaller than the bolt according to the main point of installation >>B<<. specified tightening angle, the appropriate tightening capacity cannot be secured.
  • Page 63 ENGINE OVERHAUL 11B-63 CRANKSHAFT AND CYLINDER BLOCK Measuring points are as shown in the illustration. Standard value Cylinder bore: 86 mm <4B11> Cylinder bore: 88 mm <4B12> Cylindricity: 0.15 mm 12 mm AK503371 AC 4. Measure the bore and cylindricity of the cylinder using a cylinder gauge.

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