Mitsubishi Lancer Evolution 7. Manual — part 170
ENGINE OVERHAUL -
Piston and Connecting Rod
11B-57
REMOVAL SERVICE POINTS
A
A" CONNECTING ROD CAP REMOVAL
Note the cylinder No. on the side of the connecting rod’s
large end for identification during reassembly.
A
B" PISTON PIN REMOVAL
The special tool’s piston pin setting tool (MD998780) is
configured of the parts shown in the left illustration.
1. Insert the special tool’s push rod in from the front mark
(arrow) side of the piston’s front face, and install guide
C.
2. Set the piston and connecting rod assembly onto the
special tool’s piston pin setting base so that the front
mark faces upward.
3. Push out the piston pin using a press.
NOTE
After removing the piston pin, group the piston, piston
pin and connecting rod for each cylinder No.
Cylinder No.
Push rod
Guide B
Guide A: 17.9 mm
Guide A: 18.9 mm
Guide A: 20.9 mm
Guide A: 21.9 mm
Base
Guide C
Push rod
Front mark
Guide C
Base
Front
mark
ENGINE OVERHAUL -
Piston and Connecting Rod
11B-58
INSTALLATION SERVICE POINTS
"
AA PISTON PIN INSTALLATION
1. Measure the length of the following parts.
A : Piston pin installation section
B : Between piston boss
C : Piston pin
D : Connecting rod
2. Calculate using the following expression.
L = ((A - C) - (B - D)) ÷ 2
3. Insert the special tool’s push rod into the piston pin, and
remove guide A.
4. Align the piston and connecting rod front marks, and
assemble.
5. Apply engine oil on the periphery of the piston pin.
6. Insert the guide A side of the piston pin assembled in
step 3 into the pin hole from the front mark side of the
piston.
7. Screw guide B into guide A, and assemble so that the
clearance is the value 3 mm more than the value (L)
obtained in step 2.
8. Set onto the special tool’s piston setting base so that
the front mark faces upward.
9. Press in the piston pin using a press. If the press in
load is less than the standard value, replace the piston
pin (piston assembly), connecting rod or both parts.
Standard value: 7,355 - 17,162 N
Connecting rod
Piston
Piston pin
B
A
D
C
3 mm + L
Guide B
Guide A
Push rod
Piston pin
Front mark
Front
mark
Guide A
Guide B
Base
ENGINE OVERHAUL -
Piston and Connecting Rod
11B-59
"
BA OIL RING INSTALLATION
1. Assemble the oil ring’s spacer into the piston ring groove.
Next, assemble the upper side rail, and then assemble
the lower side rail.
NOTE
(1) Install so that the side rail and spacer closed gaps
are at the position shown in the illustration.
(2) The following identification colours are applied on
the spacer and side rail (new parts) according to the
size.
Size
Identification colour
S.T.D.
None
0.50 mm O.S.
Blue
1.00 mm O.S.
Yellow
2. The side rail can be assembled easily by fitting one end
of the side rail into the piston groove and then pressing
on it with fingers as shown in the illustration.
Caution
The side rail’s closed gap could break if it is spread
open with a ring expander in the same manner as
the other piston rings.
3. After assembling into the piston, check that the side rail
rotates smoothly in either direction.
"
CA PISTON RING NO. 2/PISTON RING NO. 1
INSTALLATION
Using a piston ring expander, assemble the ring with the
identification mark facing upward.
Identification mark
No. 1 ring 1R
No. 2 ring 2R
NOTE
The following size marks are stamped on the piston ring
according to the size.
Size
Size mark
S.T.D.
(None)
0.50 mm O.S.
50
1.00 mm O.S.
100
Spacer closed gap
Upper
side
rail
closed
gap
Lower
side
rail
closed
gap
Side rail edge
Piston ring expander
Identification
mark: 2R
Size marks
No. 1
No. 2
Identification mark: 1R
ENGINE OVERHAUL -
Piston and Connecting Rod
11B-60
"
DA PISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION
1. Apply sufficient engine oil on the piston ring’s periphery,
piston ring and oil ring.
2. Align the piston ring and oil ring (side rail, spacer) closed
gap positions as shown in the illustration.
3. Insert the piston and connecting rod assembly from the
top of the cylinder so that the front mark (arrow) on the
piston’s front face faces the camshaft sprocket side.
4. Securely hold the piston ring with a ring band, and insert
the piston and connecting rod assembly.
Caution
(1) The piston ring could break if tapped in with force.
(2) Make sure not to contact the oil jet when tapping
in.
"
EA CONNECTING ROD BEARING INSTALLATION
When replacing the bearing, use the following procedure to
select and assemble the bearing.
1. Measure the diameter of the crankshaft pin, and confirm
the class shown below.
When using a spare part, each identification colour is
painted at the position shown in the illustration.
2. The identification marks of the connecting rod bearings
are attached at the position shown in the illustration.
Crankshaft pin section
Connect-
ing rod
bearing
Class
Product
identifica-
tioncolour
Spare
part iden-
tification
colour
Diameter mm
Identifica-
tion mark
1
None
Yellow
44.995 - 45.000
0
2
None
None
44.985 - 44.995
1
3
None
White
44.980 - 44.985
2
3. Select the bearing from the above table according to
the identification confirmed in steps 1 and 2.
Example of selecting bearing
If the measured outer diameter of the crankshaft pin is
44.996 mm, Class 1 applies, and the spare part
identification colour is yellow. Thus, select a bearing with
identification mark 0.
Side rail
No. 1 ring
Side rail
No. 2 ring spacer
Piston pin
No. 4
No. 2
No. 3
No. 1
Identification
mark
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