REMOVAL AND INSTALLATION

Removal steps 1. Drive plate bolt 2. Adapter plate 3. Drive plate 4. Crankshaft adapter 5. Flywheel bolt 6. Flywheel 7. Ball bearing 8. Rear plate >>G<< 9. Rear oil seal >>G<< 10. Rear oil seal case >>H<< 11. Front plate 12. Stiffener RH 13. Stiffener LH <<C>> >>F<< 14. Balance shaft rear bearing LH <<C>> >>F<< 15. Balance shaft rear bearing RH <<A>> >>E<< 16. Bolt <<A>> >>E<< 17. Main bearing cap bolt >>C<< 18. Lower main bearing >>D<< 19. Lower crankcase >>B<< 20. Lower thrust plate 21. Crankshaft <<B>> >>A<< 22. Crankshaft gear 23. Key >>B<< 24. Upper thrust plate >>C<< 25. Upper main bearing >>B<< 26. O-ring 27. Upper crankcase

1 - 16: Bolt 17 - 26: Main bearing cap bolt 1.Gradually loosen the bolts in the sequence of numbers 1 - 16 shown in the illustration. 2.Then, gradually loosen the main bearing cap bolts in the sequence of numbers 17 - 26 shown, and remove.

Using the special tool Crankshaft front oil seal installer (MH062469), remove the crankshaft gear in the following manner. caution Apply engine oil to the sling surface of plate and puller.

Using the special tool Balancer shaft bearing installer (MH062490), remove the rear bearing in the following manner. caution Apply engine oil to the sling surface of plate and puller.

1.Set the tools as shown by passing the remover, through the rear bearing while tilting it as shown. 2.Pull the puller to bring the washer into contact with the remover.

3.Secure the plate to the crankcase using bolt. caution The securing position of the plate is different between when removing the left-hand and right-hand rear bearing. Be sure to secure it in right places.

4.Tighten the nut further to remove the rear bearing.

1.Before installing, heat the crankshaft gear to approximately 100° with a piston heater or the like. caution Use care not to be burned. 2.Align the notch in the crankshaft gear with the key of the crankshaft then install the crankshaft gear onto the crankshaft by tapping on the end face lightly with a plastic hammer.

Install the upper and lower thrust plates to the crankshaft assembly at No.5 journal only. caution Install the upper and lower thrust plates with the oil groove A oriented out ward. If the oversize thrust plates are to be used, be sure to use the same size of upper thrust plate and lower thrust plate at one side. However, using the same size of upper (or lower) thrust bearings on both sides is not necessary.

The main bearings must have a proper plate thickness that matches the difference between the bearing mounting hole I.D. of the crankcase assembly and the journal O.D. of the crankshaft. Measure the bearing mounting hole I.D. of the crankcase assembly and the journal O.D. of the crankshaft. A: Measuring point (One point in vertical direction for crankcase) caution Tighten the main bearing cap bolts by specified procedure before measuring the bearing mounting hole I.D. of the crankcase assembly. caution For the service parts, the above dimensions can be identified by the identification colors or identification marks on the crankcase and crankshaft. B: Identification color position C: Identification mark position D: Identification mark position (rear right of the crankcase) Select an appropriate thickness of the main bearings from the following table. E: Identification color position (side) F: Lug G: Oil hole caution The main bearing must be installed in the specified direction. The main bearings for No.3 journal are different in thickness from the others. caution The upper main bearing for No.3 journal is different in shape from the others. Crankshaft Crankcase Main bearing Identification Journal O.D. mm Size mark I.D. mm Identification Journal No. Plate thickness mm Oil clearance mm 1(None) 67.970 - 67.978 A 72.010 - 72.019 Black No.1,2,4,5 1.992 - 1.996 0.040 - 0.065 No.3 1.972 - 1.976 0.080 - 0.105 B 72.000 - 72.010 Blue No.1,2,4,5 1.988 - 1.992 0.038 - 0.064 No.3 1.968 - 1.972 0.078 - 0.104 2(Blue) 67.961 - 67.970 A 72.010 - 72.019 Yellow No.1,2,4,5 1.996 - 2.000 0.040 - 0.066 No.3 1.976 - 1.980 0.080 - 0.106 B 72.000 - 72.010 Black No.1,2,4,5 1.992 - 1.996 0.038 - 0.065 No.3 1.972 - 1.976 0.078 - 0.105

caution Be sure that the surface to be coated with sealant is clean and free of slush and other foreign matters. When installing the lower crankcase, be sure that sealant does not smear the surroundings. After the lower crankcase is installed, wait for at least one hour before starting the engine. Remove and reinstall the lower crankcase with fresh bead of sealant whenever the main bearing cap bolts were loosened or removed after the installation. 3.After installing the lower crankcase, verify the following: Smooth rotation of the crankshaft assembly. End play of the crankshaft assembly within specified service limit.

4.If the end play exceeds the specified service limit, replace the thrust plates with oversize thrust plates. Thrust plate installation: (Available oversizes) +0.15 mm, +0.30 mm, +0.45 mm

1.Apply a thin coat of engine oil to the main bearing cap bolts, and tighten them to 20 N·m in the sequence of numbers 17 - 26 shown in the illustration. 2.Then, tighten the bolts 1/4 turn (90 deg.) in the sequence of numbers shown. 3.Give them an additional 1/4 turn (90 deg.) in the same way as above. 4.After the main bearing cap bolts are all tightened, tighten the bolts to the specified torque in the sequence of numbers 1 - 16 shown in the illustration.

Using the special tool Balancer shaft bearing puller (MH062717), install the rear bearing in the following manner. caution Apply engine oil to the sliding surfaces of the installer and plate.

1.Fit the rear bearing onto the installer from the non- chamfered side. At this time, align the oil hole with the alignment mark "-" on the installer. Align the oil hole of the left - hand bush with the "L" line of the installer and the oil hole of the right-hand bearing with the "R" line. caution Before installing the rear bearing onto the installer apply chassis grease to the inside surface of the bearing so that the oil hole dose not slip out of position.

2.Secure the plate to the crankcase using bolt as shown. caution Note that the securing position of the plate is different between the left-hand balance shaft bearing and the right-hand bearing. Prior to securing the plate check that the installer is correctly positioned with respect to the rear bearing. 3.Line up alignment mark "-" on the installer and the alignment mark "-" on the alignment mark plate. 4.Screw the nut onto the installer up to its alignment mark "-" to predetermine the press-fitting depth of the rear bearing. 5.Strike on the installer until the nut positively contacts the washer to press-fit the rear bearing into the crankcase. 6.Check that the oil hole of the rear bearing shaft bush is in alignment with the oil hole in the crankcase.

1.Apply a thin coat of engine oil to the lip A, and install the oil seal to the rear oil seal case. 2.Apply an even bead of sealant to the illustrated position of the rear oil seal. [Bead diameter: 3 ± 1 mm]. 3.Install the rear oil seal case to the crankcase assembly within three minutes after the application of sealant. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent caution Be sure that the surface to be coated with sealant is clean and free of slush and other foreign matters. When installing the rear oil seal case, use care that the surroundings are not smeared with sealant. After the rear oil seal case is installed, wait for at least one hour before starting the engine. Remove and reinstall the rear oil seal case with fresh bead of sealant whenever the bolt (holding the rear oil seal case) was loosened or removed after the installation.

1.Apply an even bead of sealant without break to the crankcase assembly where indicated in the illustration. [Bead diameter: 2 ± 1 mm]. 2.Install the front plate to the crankcase assembly within 15 minutes after the application of sealant. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent caution Be sure that the surface to be coated with sealant is clean and free of slush and other foreign matters. when installing the front plate, use care that the surroundings are not smeared with sealant. After the front plate is installed, wait for at least one hour before starting the engine. The bolt that holds the front plate is also used to secure the timing gear case. Attach the front plate with a temporary bolt until the timing gear case is installed.