Mitsubishi Montero (2002-2004). Manual — part 452
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL
11B-41
REMOVAL SERVICE POINTS
.
<<A>> CONNECTING ROD CAP REMOVAL
1. Mark the cylinder number on the side of the connecting rod
big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in
order according to the cylinder number.
.
<<B>> PISTON PIN REMOVAL
1. Remove the snap rings.
CAUTION
The clearance between the piston and the piston pin is an
almost tight fit at room temperature. Therefore, be sure the
heat the piston before pulling out the piston pin. In addi-
tion, note that the piston is hot after heating.
2. Heat the piston approximately 70
°C (158°F) and pull out the
piston pin.
INSTALLATION SERVICE POINTS
.
>>A<< PISTON PIN INSTALLATION
1. When replacing the piston pin, read off the cylinder bore size
mark on the cylinder block as illustrated, and select a piston
according to the flowing table.
NOTE: The piston size mark shows on the top of the piston.
2. Set the snap ring into one side of the piston pin hole.
AKX00734
CYLINDER
NUMBER
AB
AKX01397
70˚C
(158˚F)
AB
CYLINDER BORE
SIZE MARK
PISTON CLASS PISTON SIZE
MARK
I
A
A
II
B
None
III
C
C
AK200850
TIMING BELT SIDE
CHECK DEGIT
No.4
No.1
No.2
No.3
AC
LEFT BANK
RIGHT BANK
No.6
No.5
CRANKSHAFT
BORE SIZE
MARK
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL
11B-42
CAUTION
Apply ample coat of engine oil to the periphery of the pis-
ton pin and the hole of the connecting rod small end. The
clearance between the piston and the piston pin is an
almost tight fit at room temperature. Therefore, be sure to
heat the piston before inserting the piston pin. In addition,
note that the piston is hot after heating.
3. Heat the piston to approximately 70
°C (158°F).
4. With the front mark of the connecting rod and that of the
piston located on the same side, insert the piston pin.
5. Set the snap ring into the other side of the piston pin hole.
6. Check that the piston moves smoothly.
.
AKX01398
70˚C
(158˚F)
AB
AK201080
FRONT MARK 74
AB
FRONT MARK
AKX00716
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL
11B-43
>>B<<OIL RING INSTALLATION
1. Fit the oil ring spacer into the piston ring groove.
NOTE: The side rails and spacer may be installed in either
direction.
CAUTION
Do not use any piston ring expander when installing the
side rail.
2. Install the upper side rail.
To install the side rail, first fit one end of the rail into the
piston groove, then press the remaining portion into the
position by finger. See illustration.
Use of a ring expander to expand the side rail end gap can
break the side rail, unlike other piston rings.
3. Install the lower side rail in the same procedure as described
in step (2).
4. Make sure that the side rails move smoothly in either
direction.
.
>>C<< PISTON RING NO.2/PISTON RING NO.1
INSTALLATION
1. To prevent wrong installation, check the identification mark
of each piston ring. The identification mark is stamped near
the ring gap:
Identification mark
Number 1 ring: 1T
Number 2 ring: 2T
NOTE: Size marks on piston rings are as follows.
2. Using a piston ring expander, fit the number 2 piston ring
into the number 2 groove of piston.
NOTE: Install the piston rings with their identification mark
facing up, to the piston crown side.
3. Install the number 1 piston ring in the same manner as step
2.
.
AK000196AB
SIDE RAIL
SIDE RAIL
SPACER
AKX00608
SIDE RAIL END
AB
SIZE
SIZE MARK
Standard
None
0.25 mm (0.010 in) oversize
diameter
25
0.50 mm (0.020 in) oversize
diameter
50
AKX00689
NO.1
NO.2
IDENTIFICATION
MARK
SIZE MARK
IDENTIFICATION MARK
AB
AKX00633
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL
11B-44
>>D<< CONNECTING ROD BEARING INSTALLATION
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/
marks of its pins are painted/stamped at the positions shown
in the illustration.
2. From the following table, select a bearing whose size is
appropriate for the crankshaft pin outside the diameter.
If the crankshaft pin outside diameter Identification color is
"yellow" and the connecting rod Identification mark is "2," for
example, select a bearing whose Identification color is
"green."
If there is no Identification color paint on the crankshaft,
measure the pin outside diameter and select bearing
appropriate for the measured value.
3. Install the selected bearing in the big end and in the cap of
the connecting rod.
.
AKX00634
NO.5
LOCATION OF IDENTIFICATION COLOR
NO.2
NO.4
NO.1
NO.3
NO.6
AB
CRANKSHAFT PIN OUTSIDE DIAMETER
CONNECTING ROD
BEARING
IDENTIFICATION COLOR SIZE mm (in)
IDENTIFICATION MARK IDENTIFICATION
COLOR
Yellow
54.994
− 55.000
(2.1651
− 2.1654)
0
Pink
1
Red
2
Green
None
54.988
− 54.994
(2.1649
− 2.1651)
0
Red
1
Green
2
Black
White
54.982
− 54.988
(2.1646
− 2.1649)
0
Green
1
Black
2
Brown
AK000449
IDENTIFICATION MARK
AB
AKX00635
IDENTIFICATION
COLOR
AB
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