Mitsubishi Galant 9G. Manual — part 596

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-56

9. Check that the piston moves smoothly.

.

>>B<< OIL RING INSTALLATION

1. Fit the oil ring spacer into the piston ring groove.

CAUTION

Do not use a 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 position
by hand. See illustration.
NOTE: The side rails and spacer may be installed in either
direction.
NOTE: New spacers and side rails are colored for identifica-
tion of their sizes.

3. Install the lower side rail in the same manner as described in

step 2.

4. Make sure that the side rails move smoothly in both

directions.

.

>>C<< PISTON RING NUMBER 2/PISTON RING
NUMBER 1 INSTALLATION

1. Using the piston ring expander, fit number 2 into the number

2 groove of piston.
NOTE: Install piston rings with identification mark facing up,
to the piston crown side.

AK301796

SIZE

IDENTIFICATION
COLOR

Standard

None

0.50 mm (0.020 in)
oversize diameter

Red

AK300190

SIDE RAIL END

AC

AK300395AD

UPPER
SIDE RAIL

SPACER

LOWER
SIDE RAIL

AK300191

PISTON RING
EXPANDER

AC

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-57

2. Install the number 1 piston ring in the same manner as step

1.

Identification mark:

Number 1 ring: 1R
Number 2 ring: 2R

NOTE: Confirm the profile for No.1 and No.2 piston rings
carefully. Install them correctly by paying careful attention to
the direction of the top and bottom.
NOTE: The identification mark and the size mark are
stamped on the upper plane of the piston ring (piston top
side).

3. To prevent incorrect installation, check the identification

mark of each piston ring. The identification mark is stamped
near the ring gap.

.

>>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.

.

SIZE

SIZE MARK

Standard

None

0.50 mm (0.020 in)
oversize diameter

50

AK301452AC

No.1

No.2

CRANKSHAFT PIN OUTSIDE
DIAMETER

CONNECTING
ROD BEARING

IDENTIFICAT
ION MARK

SIZE mm (in)

IDENTIFICATI
ON MARK

I

44.995

− 45.000

(1.7715

− 1.7717)

1

II

44.985

− 44.995

(1.7711

− 1.7715)

2

III

44.980

− 44.985

(1.7709

− 1.7711)

3

AK202909

No. 3

No. 1

No. 2

No. 4

AD

IDENTIFICATION MARK OF CRANKSHAFT
PIN DIAMETER

AK300397

IDENTIFICATION
MARK POSITION

AE

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-58

>>E<< PISTON AND CONNECTING ROD
INSTALLATION

1. Apply engine oil to 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.

.

>>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 (0.004 − 0.009 inch)

Limit: 0.4 mm (0.015 inch)

.

AK301459

UPPER SIDE
RAIL

NO. 1

TIMING
BELT
SIDE

LOWER
SIDE RAIL

NO. 2 RING GAP
AND SPACER GAP

AC

PISTON PIN

AK300192

AK300193

NOTCHES

CYLINDER
NUMBER

AC

AK300194

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-59

>>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 (14 ± 1 ft-lb)

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 fasten-

ing 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

M1113008500503

.

PISTON

Replace the piston if scratches or seizure is evident on its sur-
faces (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.

AK301477AC

PAINT MARK

PAINT
MARK

NUT

BOLT

90˚ TO 94˚