Mitsubishi Grandis. Manual — part 666

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-59

>>D<< CONNECTING ROD BEARING
INSTALLATION

1. Measure the crankshaft pin diameter and confirm

its classification from the following table. On a
crankshaft supplied as a service part,
identification marks of its pins are stamped at the
positions shown in the illustration.

2. If the crankshaft pin outside diameter identification

mark is "I," for example, select a bearing whose
identification mark is "1."
If there is no identification color paint on the
crankshaft, measure the pin outside diameter and
select a bearing appropriate for the measured
value.

3. Install the selected bearing in the big end and in

the cap of the connecting rod.

>>E<< PISTON AND CONNECTING ROD
INSTALLATION

1. Apply engine oil on the circumference of the

piston, piston rings, and oil ring.

2. Arrange the piston ring and oil ring gaps (side rail

and spacer) as shown in the illustration.

3. Rotate the crankshaft so that the crank pin is on

the center of the cylinder bore.

4. Use suitable thread protectors on the connecting

rod bolts before inserting the piston and
connecting rod assembly into the cylinder block.
Care must be taken not to nick the crank pin.

5. Insert the piston and connecting rod assembly

into the cylinder with the front mark on the piston
crown pointing to the timing belt side.

6. Using a suitable piston ring compressor tool,

install the piston and connecting rod assembly
into the cylinder block.

Crankshaft pin outside
diameter

Connecting
rod bearing

Identification
mark

Size mm

Identification
mark

I

44.995

− 45.000

1

II

44.985

− 44.995

2

III

44.980

− 44.985

3

AK304412

Locations of crankshaft pin diameter
marks

No. 3

No. 1

No. 2

No. 4

AB

AK304598

Connecting bearing

Identification
mark position

AB

AK202730

No. 1

No. 2

Side rail

Side rail

AB

AK300192

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-60

>>F<< CONNECTING ROD CAP
INSTALLATION

1. Verifying the mark made during disassembly,

install the bearing cap to the connecting rod. If the
connecting rod is new with no index mark, make
sure that the bearing locking notches are on the
same side as shown.

2. Make sure that the connecting rod big end side

clearance meets the specification.

Standard value: 0.10

− 0.25 mm

Limit: 0.4 mm

>>G<< CONNECTING ROD CAP NUT
TIGHTENING

1. The connecting rod bolts should be examined

before reuse. If the bolt threads are damaged, the
bolt should be replaced.
Hand-thread the nut to the full length of the bolt
threads. If the nut does not run down smoothly,
the bolt should be replaced.

2. Before installing each nut, apply engine oil to the

threaded portion and bearing surface of the nut.

3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to the specified

torque to install the cap properly.

Tightening torque: 20

± 2 N⋅m

5. Make a paint mark on the head of each nut.
6. Make a paint mark on the bolt end at the position

90 to 94 degrees from the paint mark made on the
nut in the direction of tightening the nut.

CAUTION

• If the nut is turned less than 90 degrees,

proper fastening performance may not be
achieved. Be careful to tighten the nut exactly
90 degrees.

• If the nut is overtightened (exceeding 94

degrees), loosen the nut completely and then
retighten it by repeating the tightening
procedure from step 3.

7. Turn the nut 90 to 94 degrees and make sure that

the paint marks on the nut and bolt are aligned.

INSPECTION

M1113008500547

PISTON

Replace the piston if scratches or seizure is evident
on its surfaces (especially the thrust surface).
Replace the piston if it is cracked.

PISTON PIN

1. Insert the piston pin into the piston pin hole with

your thumb. You should feel a slight resistance.
Replace the piston pin if it can be easily inserted
or there is an excessive play.

2. The piston and piston pin must be replaced as an

assembly.

PISTON RING

1. Check the piston ring for damage, excessive

wear, and breakage. Replace if defects are
evident. If the piston has been replaced, the
piston rings must also be replaced.

AK300193

Notches

Cylinder
number

AD

AK300194

AK301477AD

Paint mark

Paint
mark

90˚ to 94˚

Nut

Bolt

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-61

2. Check for clearance between the piston ring and

ring groove. If it exceeds the limit, replace the ring
or piston, or both.

Standard value:

Number 1: 0.03

− 0.07 mm

Number 2: 0.02

− 0.06 mm

Limit: 0.1 mm

3. Insert the piston ring into the cylinder bore. Force

the ring down with a piston, the piston crown
being in contact with the ring, to correctly position
it at right angles to the cylinder wall. Then,
measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston
ring.

Standard value:

Number 1: 0.15

− 0.30 mm

Number 2: 0.28

− 0.43 mm

Oil: 0.10

− 0.40 mm

Limit:

Number 1, Number 2: 0.8 mm

Oil: 1.0 mm

CRANKSHAFT PIN OIL CLEARANCE
<PLASTIC GAUGING MATERIAL
METHOD>

1. Remove oil from the crankshaft pin and the

connecting rod bearing.

2. Cut plastic gauging material to the same length as

the width of the bearing and place it on the pin,
parallel with its axis.

3. Install the connecting rod cap carefully and tighten

the nuts to the specified torque.

4. Carefully remove the connecting rod cap.

5. Measure the width of the plastic gauging material

at its widest part by using a scale printed on the
plastic gauging material package.

Standard value: 0.02

− 0.05 mm

Limit: 0.1 mm

AK300195

AK301481AD

Piston ring

Piston ring gap

Push in by
piston

AK300196

Plastic gauging
material

AD

AK300197

Plastic gauging
material

AD

CRANKSHAFT AND CYLINDER BLOCK

ENGINE OVERHAUL

11B-62

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION

M1113008700756

CAUTION

On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition.
Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting
in damage.

AK304605AB

6

7

8

9

10

11

12

14

13

15

16

17

18

19

20

11 ± 1 N·m

132 ± 5 N·m

25 ± 2 N·m

5

9.0 ± 1.0 N·m

11 ± 1 N·m

→ + 90˚

25 ± 2 N·m

→ + 90˚

1

3

A

4

2

132 ± 5 N·m

Apply engine oil to
all moving parts
before installation.

Removal steps

1. Flywheel bolt (M/T)
2. Adapter plate (M/T)
3. Flywheel (M/T)
4. Crankshaft bushing (M/T)
5. Drive plate bolt (A/T)
6. Adapter plate (A/T)
7. Drive plate (A/T)

8. Crankshaft bushing (A/T)
9. Rear plate
10.Bell housing cover

>>E<<

11.Oil seal case

>>D<<

12.Oil seal

>>C<<

13.Bearing cap bolt (Head 14)

>>C<<

14.Bearing cap bolt (Head 17)

>>C<<

15.Bearing cap

Removal steps (Continued)