Mitsubishi Galant 9G. Manual — part 612
PISTON AND CONNECTING ROD
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ENGINE OVERHAUL <3.8L ENGINE>
11D-46
INSTALLATION SERVICE POINTS
.
>>A<< PISTON PIN INSTALLATION
1. When replacing the piston, note the cylinder bore size mark
on the cylinder block as illustrated, and select a piston
according to the following 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.
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 a tight
fit at room temperature. Therefore, be sure to heat the pis-
ton before inserting the piston pin. Use care since the pis-
ton 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.
CYLINDER BORE SIZE
MARK
PISTON SIZE MARK
I
A
II
None
III
C
AK200850
TIMING BELT SIDE
CHECK DIGIT
No.4
No.1
No.2
No.3
AD
LEFT BANK
RIGHT BANK
No.6
No.5
CRANKSHAFT
BORE SIZE
MARK
AKX01398
70˚C
(158˚F)
AB
AK201080
FRONT MARK 74
AB
FRONT MARK
PISTON AND CONNECTING ROD
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ENGINE OVERHAUL <3.8L ENGINE>
11D-47
6. Check that the piston moves smoothly.
.
>>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. It will break the side rail.
2. Install the upper side rail by hand.
To install the side rail, first fit one end of the rail into the
piston groove, then press the remaining portion into the
position. See illustration.
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 both
directions.
.
AKX00716
AK000196AB
SIDE RAIL
SIDE RAIL
SPACER
AKX00608
SIDE RAIL END
AB
PISTON AND CONNECTING ROD
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ENGINE OVERHAUL <3.8L ENGINE>
11D-48
>>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.
.
>>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.
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
AKX00634
NO.5
LOCATION OF IDENTIFICATION COLOR
NO.2
NO.4
NO.1
NO.3
NO.6
AB
PISTON AND CONNECTING ROD
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ENGINE OVERHAUL <3.8L ENGINE>
11D-49
2. From the above table, select a bearing whose size is
appropriate for the crankshaft pin outside the diameter.
For example, if the crankshaft pin outside diameter
Identification color is "yellow" and the connecting rod
Identification mark is "2," 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.
.
>>E<< PISTON AND CONNECTING ROD
INSTALLATION
1. Liberally coat the circumference of the piston, piston ring,
and oil ring with engine oil.
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.
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
AKX00620
UPPER
SIDE RAIL
NO.1
PISTON PIN
TIMING
BELT SIDE
LOWER
SIDE RAIL
NO.2 RING GAP
AND SPACER GAP
AB
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