Mitsubishi L200. Manual — part 46

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-58

REMOVAL SERVICE POINTS

<<A>> CONNECTING ROD CAP REMOVAL

AK404150

Cylinder
number

AB

Mark the cylinder number on the side of the connect-
ing rod big end for correct reassembly.

<<B>> PISTON AND CONNECTING ROD
ASSEMBLY REMOVAL

AK402310 AC

MB992010

Crank pin

1. Not to damage the crank pin, attach a special tool

Bolt guide (MB992010), to the connecting rod
bolt.

2. Remove the piston and connecting rod assembly

from the cylinder block.

INSTALLATION SERVICE POINTS

>>A<< CONNECTING ROD / SNAP RING / PISTON
PIN / PISTON INSTALLATION

AK500593AB

Timing belt side

No.4

No.1

No.2

No.3

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
following table.

Cylinder bore size

Piston size mark

A

A

B

None

C

C

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.

AK801093

D5

Front mark

<Except Euro 5>

<Euro 5>

AD

Front mark

Front mark

3. With the front mark of the connecting rod and that

of the piston located on the same side, insert the
piston pin.
NOTE: It is difficult to fit the piston pin into the pis-
ton when they have a different temperature,
Therefore, fit the piston pin into the piston when
they have the same temperature.

4. Set the snap ring into the other side of the piston

pin hole.

5. Check that the piston moves smoothly.

>>B<< OIL RING INSTALLATION

AK500591

Expander coil

Oil ring

AB

Install the expander coil and oil ring in the piston ring
groove.

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-59

>>C<< PISTON RING NO. 1 / PISTON RING NO. 2
INSTALLATION

AK404152

AK202807

No. 2

AB

No. 1

Size marks

Identification mark

Use a piston ring expander to install the No.1 and
No.2 piston rings. The ring identification mark should
face upwards.

Identification marks

No. 1 ring: 1R
No. 2 ring: 2R

>>D<< PISTON AND CONNECTING ROD
ASSEMBLY INSTALLATION

AK202553

No. 1

No. 2

Side rail

Side rail

AC

Piston pin

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 crankshaft so that crank pin is on center of

cylinder bore.

AK402300AC

MB992010

Bolt

Connecting rod

4. Not to damage the crank pin, attach a special tool

Bolt guide (MB992010), to the connecting rod
bolt.

AK404153

5. Use suitable thread protectors on connecting rod

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

6. Using a suitable piston ring compressor tool,

install piston and connecting rod assembly into
cylinder block.

CAUTION

Insert with the front mark on the piston head
directed toward the engine front (timing belt
side).

>>E<< CONNECTING ROD CAP / CONNECTING
ROD CAP NUT INSTALLATION

AK404150

Cylinder
number

AB

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-60

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. The connecting rod cap bolts and nuts are

tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be
checked for elongation before installation.
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.

3. Apply engine oil to the threads and bearing

surface of each nut before installation.

4. Finger-tighten the nuts on the bolts, then tighten

the nuts alternately and repeatedly to install the
cap properly.

5. Tighten the nuts to a torque of 27

± 2 N⋅m.

AK500742

MB991614

AB

6. Using the special tool Angle gauge (MB991614),

tighten the connecting rod cap nut in the
illustrated sequence by a further 90

° to 94°.

CAUTION

• When the tightening angle is smaller than the

specified tightening angle, the appropriate
tightening capacity cannot be secured.

•

AK404156

When the tightening angle is larger than the
specified tightening angle, remove the bolt to
start from the beginning again according to
the procedure.

7. Make sure that connecting rod big end side

clearance meets the specification.

Standard value: 0.10

− 0.25 mm

Limit: 0.40 mm

INSPECTION

M1113008502651

PISTON RING

AK402966AB

Piston Thickness gauge

AK402967

Ring carrier

No.1 oil ring groove

AB

1. Check for side clearance. If the limit is exceeded,

replace the ring or piston, or both.
NOTE: In cases of keystone type, measure the
ring to groove clearance as shown.

Standard value:

No. 1: 0.07

− 0.10 mm

No. 2: 0.05

− 0.06 mm

Oil: 0.02

− 0.06 mm

Limit:

No. 1: 0.15 mm
No. 2: 0.15 mm
Oil: 0.10 mm

AK202788

Force ring down
with piston

End gap

Piston ring

AB

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-61

2. Insert the piston ring into 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 thickness gauge. If the end gap is excessive,
replace piston ring.

Item

Standard value
mm

Limit
mm

No.1

Except Euro5

0.30

− 0.45

0.8

Euro5

0.20

− 0.30

0.8

No.2

Except Euro5

0.30

− 0.45

0.8

Euro5

0.20

− 0.35

0.8

Oil

0.25

− 0.45

0.8

CRANKSHAFT PIN OIL CLEARANCE
(PLASTIGAGE METHOD)
1. Wipe off oil from the crankshaft pin and

connecting rod bearing.

AK404154AB

Plastigage

2. Cut a piece of plastigage whose length is

equivalent to 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 according to INSTALLATION SERVICE
POINTS >>E<<

P.11B-58

.

4. Remove the nuts, then remove the connecting rod

cap carefully.

AK404155

5. Measure the largest width of the crushed

plastigage using the ruler printed on the bag of the
plastigage.

Standard value: 0.02

− 0.05 mm

Limit: 0.1 mm