Mitsubishi Lancer Evolution VI. Manual — part 22
ENGINE –
Piston and Connecting Rod
11-63
"
C
A
PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
(1) Using piston ring expander, fit No. 2 and then No. 1 piston
ring into position.
NOTE
1.
The ring end is provided with identification mark.
Item
Identification mark
No. 1 ring
1R
No. 2 ring
2R
2.
Install piston rings with identification mark facing up,
to the piston crown side.
3.
Size marks on position rings are as follows.
Size
Size mark
Standard
None
0.50 mm oversize
50
1.00 mm oversize
100
"
D
A
PISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate the crankshaft so that crank pin is on the center
of cylinder bore.
(4) Use suitable thread protectors on the connecting rod bolts
before inserting piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.
(5) Using a suitable piston ring compressor tool, install the
piston and connecting rod assembly into the cylinder block.
"
E
A
CONNECTING ROD BEARINGS INSTALLATION
When the bearing needs replacing, select and install a proper
bearing by the following procedure.
(1) Measure the crankshaft pin diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors
of its pins are painted at the positions shown in the
illustration.
9EN0524
Identification mark
Identification mark
Side mark
No. 1
No. 2
Timing belt side
ENGINE –
Piston and Connecting Rod
11-64
(2) The connecting rod bearing identification mark is stamped
at the position shown in the illustration.
Crankshaft pin
Connecting rod bearing
Classi-
fication
Identifica-
tion mark
Identifi-
cation
color
O. D. mm
Identi-
fication
mark
Thickness mm
Produc-
tion part
Service
part
1
None
Yellow
44.995 – 45.000
0
1.483 – 1.487
2
None
None
44.985 – 44.995
1
1.487 – 1.491
3
None
White
44.980 – 44.985
2
1.491 – 1.495
Connecting rod I.D.: 48.000 – 48.015 mm
(3) Select a proper bearing from the above table on the basic
of the identification data confirmed under items (1) and
(2).
[Example]
If the measured value of a crankshaft pin outer diameter
is 44.996 mm, the pin is classified as “1” in the table.
In case the crankshaft is also replaced by a spare part,
check the identification colors of the pins painted on the
new crankshaft. If the color is yellow, for example, the
pin is classified as “1”. In the above cases, select the
connection rod bearing having identification mark “0”.
"
F
A
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 come 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
Identification mark
ENGINE –
Piston and Connecting Rod
11-65
"
G
A
CONNECTING ROD CAP NUT INSTALLATION
Caution
If the cylinder head has been installed before installing
the connecting rod cap nut, be sure to remove the spark
plugs.
(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not
run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine oil to the
thread portion and bearing surface of the nut.
(3) Install each nut to the bolt and tighten it with fingers.
Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.
(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
°
from the paint mark made on the nut in the direction
of tightening the nut.
(7) Give a 90
°
to 94
°
turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1.
If the nut is turned less than 90
°
, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2.
If the nut is overtightened (exceeding 94
°
), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
INSPECTION
PISTON RING
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check for the clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring or
piston, or both.
Standard value:
No. 1 ring
0.04 – 0.075 mm
No. 2 ring
0.02 – 0.06 mm
Limit: 0.1 mm
6AE0298
90
°
to 94
°
Paint mark
Paint
mark
Nut
Bolt
ENGINE –
Piston and Connecting Rod
11-66
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its 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:
No. 1 ring
0.25 – 0.35 mm
No. 2 ring
0.40 – 0.55 mm
Oil ring
0.10 – 0.40 mm
Limit:
No. 1, No. 2 ring 0.8 mm
Oil ring 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIC GAUGE METHOD)
(1) Remove oil from the crankshaft pin and connecting rod
bearing.
(2) Cut the Plastigage to the same length as the width of
the bearing and place it on the crankshaft pin in parallel
with its axis.
(3) Install the connecting rod cap carefully and tighten the
nuts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.03 – 0.05 mm
Limit: 0.1 mm
Plastigage
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