Mitsubishi Montero (1991+). Manual — part 7
and No. 2. Install bearing caps with front mark arrow facing the same
direction as similar mark on cylinder head beside bearing journal.
Note bearing cap number and identification mark ("I" for intake
camshaft and "E" for exhaust). See Fig. 22.
3) Install front and rear bearing caps. Tighten bearing cap
bolts to specification. See TORQUE SPECIFICATIONS (3000GT) table at
end of article. Coat camshaft oil seal area with oil. Using Seal
Installer (MD998761), install camshaft oil seal. Using Circular
Packing Installer (MD998761), install circular packing.
4) Install crankshaft angle sensor adapter. To complete
installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
REAR CRANKSHAFT OIL SEAL
Removal
Remove transaxle/transmission. See appropriate article in
TRANSMISSION SERVICING or CLUTCHES. Remove flywheel or drive plate.
Remove rear oil seal case. Pry seal from seal case.
Installation
To install, coat seal lip with oil. Using Seal Installer
(MD998718), install seal in seal case. Apply sealant to sealing
surface of seal case. Install seal case. Install flywheel or drive
plate. Tighten bolts to specification. See appropriate TORQUE
SPECIFICATIONS table at end of article. To complete installation,
reverse removal procedure.
WATER PUMP
Removal
Drain cooling system. Remove timing belt and crankshaft
sprocket. See TIMING BELT under REMOVAL & INSTALLATION. Remove coolant
pipes to water pump (if required). Remove water pump bolts, noting
length and location for reassembly reference. Remove water pump.
Installation
To install, reverse removal procedure using new gasket and
"O" rings. Coat all "O" rings with water before installation. Install
water pump and gasket. Tighten bolts to specification. See appropriate
TORQUE SPECIFICATIONS table at end of article.
OIL PAN
Removal (Montero)
1) Remove hood. Remove skid plate and lower covers. Raise and
support vehicle. Disconnect and remove exhaust pipe from exhaust
manifolds. Drain engine oil. Remove starter cover and starter. Remove
oil pressure sending unit connector. Remove front suspension
crossmember.
2) Remove transmission stays. Remove ground cable and motor
mount heat shields. Attach engine hoist. Remove motor mount bolts.
Raise engine, and insert a 1" wood spacer between front insulator and
mounts. Lower engine onto wood blocks.
3) Raise vehicle using a hoist. Remove oil pan bolts. Using
Seal Cutter (MD998727), separate oil pan from cylinder block. Remove
pan from vehicle.
Removal (Pickup)
1) Remove skid plate and lower covers. Raise and support
vehicle. Drain engine oil. Using Steering Linkage Puller (C-3894-A or
MB990635), disconnect relay rod from idler arm and steering box.
2) Remove oil pan bolts. Using Seal Cutter (MD998727),
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separate oil pan from cylinder block. Remove pan from vehicle.
Removal (3000GT)
1) Raise and support vehicle. Remove engine undercovers.
Drain engine oil. Disconnect O2 sensor connector. Remove front exhaust
pipe from manifolds. On All-Wheel Drive (AWD) models, drain transfer
assembly. Remove front air dam. Remove AWD drive shaft and transfer
assembly.
2) On turbocharged models, remove oil return lines from oil
pan. On all models, remove starter. Remove crossmember and transaxle
stays. Remove bellhousing cover. Remove oil pan bolts. Using Seal
Cutter (MD998727), separate oil pan from cylinder block. Remove pan
from vehicle.
Inspection (All Models)
Clean sealant from oil pan mating surface on engine block and
oil pan. Check oil pan for cracks and damage. Check sealing surface
for damage and deformation. Inspect oil pick-up screen for damage.
Installation (All Models)
1) To install, reverse removal procedure. Apply sealant to
oil pan flange in a continuous .16" (4 mm) diameter bead. See Fig. 22.
Install oil pan within 15 minutes of applying sealant.
2) Tighten bolts to specification in proper sequence. See
appropriate TORQUE SPECIFICATIONS table at end of article. Wait at
least 30 minutes before adding oil and starting engine. On AWD models,
refill transfer assembly with GL-4 hypoid gear oil. On all models,
complete installation by reversing removal procedure.
Fig. 22: Sealant Application & Oil Pan Bolt Tightening Sequence
Courtesy of Mitsubishi Motor Sales of America, Inc.
OVERHAUL
CYLINDER HEAD
Check cylinder head height and warpage at gasket and manifold
surfaces. Resurface head if warpage exceeds specification. See
appropriate CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of
article. Replace cylinder head if it is not within specification after
resurfacing.
VALVE SPRINGS
Measure free length of valve springs. Check spring pressure
at specified height. Replace springs if not within specification. See
appropriate VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS
at end of article. Check valve spring for squareness. Replace spring
if out-of-square exceeds 4 degrees.
NOTE: Install valve springs with enamel-coated side toward valve
spring retainer.
VALVE STEM OIL SEALS
With valves removed, remove oil seals from cylinder head.
Coat new seals with oil. Using Valve Stem Oil Seal Installer (MD998377
for Montero, MD998729 for Pick-up or MD998763 for DOHC), install valve
stem oil seal.
VALVE GUIDES
1) Measure valve stem-to-guide clearance. Replace valve guide
if not within specification. See appropriate VALVES & VALVE SPRINGS
table under ENGINE SPECIFICATIONS at end of article.
2) Using rod of Valve Guide Remover/Installer (MD998115) for
SOHC, drive out valve guide toward combustion chamber side of cylinder
head. Note length of valve guides. On DOHC, use press and
appropriately-sized rod to press valve guide toward combustion chamber
side of head.
3) On all models, cylinder head must be bored to install
oversized valve guide once guide is removed. DO NOT install valve
guide of same dimension as old guide. Bore cylinder head to
specification for oversize valve guide. See appropriate OVERSIZE VALVE
GUIDE SPECIFICATIONS table.
4) On SOHC, install proper length valve guide. Intake guide
is 1.73" (43.9 mm) long and exhaust guide is 1.89" (48.0 mm) long. On
all models, position cylinder head with combustion chamber downward.
5) Using valve guide remover/installer, install valve guide.
Remover/installer sets valve guide height on SOHC. On DOHC, install
valve guide to .689" (17.5 mm), measured from cylinder head spring
seating area to top of valve guide. On all models, ensure valve slides
smoothly in valve guide. Recondition valve seat.
OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE (SOHC)
Oversize In. (mm) Size Mark Bore Size In. (mm)
.002 (.05) . . . 5 ... .5138-.5145 (13.050-13.068)
.010 (.25) . . . 25 .. .5217-.5224 (13.251-13.269)
.020 (.51) . . . 50 .. .5315-.5322 (13.500-13.518)
OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE (DOHC)
Oversize In. (mm) Size Mark Bore Size In. (mm)
.002 (.05) . . . 5 ... .4744-.4751 (12.050-12.068)
.010 (.25) . . . 25 .. .4823-.4830 (12.251-12.269)
.020 (.51) . . . 50 .. .4921-.4928 (12.500-12.518)
VALVE SEAT (SOHC)
1) Valve seat sinkage should be checked after valve and valve
seat have been reconditioned and lightly lapped. With valve assembly
installed, measure installed height of valve spring between spring
seat and retainer. Valve seat must be replaced if measurement exceeds
1.63" (41.4 mm).
2) Grind seat wall thickness until seat can be removed.
Machine cylinder head to accommodate an oversize valve seat. See
OVERSIZE VALVE SEAT SPECIFICATIONS (SOHC) table. Heat cylinder head to
approximately 480
F (250
C), and install valve seat. Grind valve seat
using 45-degree stone. Use 30-degree and 60-degree stones to set seat
height.
OVERSIZE VALVE SEAT SPECIFICATIONS TABLE (SOHC)
Application In. (mm)
Intake
Bore Depth
.012" (.3 mm) Oversize . . . .311-.319 (7.9-8.1)
.024" (.6 mm) Oversize . . . .323-.331 (8.2-8.4)
Bore Diameter
.012" (.3 mm) Oversize .. 1.7440-1.7451 (44.300-44.325)
.024" (.6 mm) Oversize .. 1.7559-1.7569 (44.600-44.625)
Exhaust
Bore Depth
.012" (.3 mm) Oversize . . . .311-.319 (7.9-8.1)
.024" (.6 mm) Oversize . . . .323-.331 (8.2-8.4)
Bore Diameter
.012" (.3 mm) Oversize .. 1.5079-1.5089 (38.300-38.325)
.024" (.6 mm) Oversize .. 1.5197-1.5207 (38.600-38.625)
VALVE SEAT (DOHC)
Grind seat wall thickness until seat can be removed. Machine
cylinder head to accommodate an oversize valve seat. See OVERSIZE
VALVE SEAT SPECIFICATIONS (DOHC) table. Chill cylinder head with
liquid nitrogen, and install valve seat. Grind valve seat using 45-
degree stone. Use 30-degree and 60-degree stones to adjust seat
height.
OVERSIZE VALVE SEAT SPECIFICATIONS TABLE (DOHC)
Application In. (mm)
Intake
Bore Depth
.012" (.3 mm) Oversize . . . .295-.303 (7.5-7.7)
.024" (.6 mm) Oversize . . . .307-.315 (7.8-8.0)
Bore Diameter
.012" (.3 mm) Oversize .. 1.4291-1.4301 (36.300-36.325)
.024" (.6 mm) Oversize .. 1.4409-1.4419 (36.600-36.625)
Exhaust
Bore Depth
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