Mitsubishi Evolution X. Manual — part 205
AK600791
No. 2
No. 1
Identification mark
AC
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL
11B-67
Identification mark
No. 1 ring: 1R
No. 2 ring: 2R
NOTE: Each of the available piston rings has a size mark as
follows:
Size
Size mark
Standard
No mark
0.25 mm (0.010 inch)
oversize
25
.
>>D<< PISTON CONNECTING ROD ASSEMBLY
INSTALLATION
1. Apply a sufficient amount of engine oil to the circumference
of the piston, piston rings and oil ring.
AK400403
No.1
Side rail
Side rail
AC
Piston pin
No.2
2. Arrange end gap positions of piston rings and oil ring (side
rail and spacer) as shown in the illustration.
3. Insert the piston and connecting rod assembly from the top
surface of the cylinder block with the front mark of the piston
top face facing toward the timing chain side.
AK502730
CAUTION
Driving it in hard causes breakage of piston rings and
damage to the crank pin.
4. Firmly tighten the piston ring with a ring band and insert the
piston and connecting rod assembly.
.
PISTON AND CONNECTING ROD
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ENGINE OVERHAUL
11B-68
>>E<< CONNECTING ROD BEARING
INSTALLATION
AK702193AD
No.1
No.2
No.3
No.4
Crankshaft pin identification stamp position
Crankshaft
front end
1. When replacing a connecting rod bearing, select the bearing
corresponding to the crankshaft pin outside diameter
according to the crankshaft pin identification in the table
below.
Crankshaft pin
Connecting
rod bearing
Identification
mark
Journal diameter
mm (in)
Identification
mark
1
51.966
− 51.972
(2.0459
− 2.0461)
1
2
51.960
− 51.966
(2.0457
− 2.0459)
2
3
51.954
− 51.960
(2.0454
− 2.0457)
3
2. An identification mark of a crankshaft is stamped at the
illustrated position by No.
AK700793AD
Identification
mark
3. A connecting rod bearings an identification mark at the
illustrated position.
.
>>F<< CONNECTING ROD CAP INSTALLATION
AK703289AD
Cylinder
number
Notch
1. Assemble the bearing cap on the connecting rod by aligning
it with the mark put during removal. If a new connecting rod
without a mating mark is used, assemble so that the detent
notch of the bearing is on the same side as illustrated.
AK703364
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL
11B-69
2. Make sure that clearance of the thrust of the connecting rod
big end is appropriate.
Standard value: 0.10
− 0.25 mm (0.004 − 0.010 inch)
Limit: 0.4 mm (0.02 inch)
.
>>G<< CONNECTING ROD CAP BOLT
INSTALLATION
1. Check in the following procedure before reusing the
connecting rod bolt.
AK604589AD
20.5 mm (0.81 in)
35 mm (1.38 in)
A
B
B
X
(1) Measure the outside diameter "A."
(2) Measure the smallest outside diameter "B" within the
range "X" shown in the illustration.
(3) If the difference of outside diameter of thread exceeds
the limit, replace the connecting rod bolt.
Limit: 0.10 mm (0.004 inch)
2. Apply engine oil to the threaded portion and seat surface of
the bolt before installing it.
3. After installing each bolt and tightening it by fingers, tighten
bolts alternately to properly assemble the cap.
4. Tighten the bolt in several steps until the torque reaches 5.0
N
⋅ m (44 in-lb).
5. Tighten the bolt in several steps until the torque reaches 20
N
⋅ m (15 ft-lb).
AK502749
90˚
Paint mark
AD
Paint mark
6. Put a paint mark on the bolt head as illustrated.
7. Put a paint mark on the connecting rod at 90
° position in the
tightening direction of the bolt with reference to the paint
mark position of the bolt.
CAUTION
• When the tightening angle is smaller than the specified
tightening angle, the appropriate tightening capacity
cannot be secured.
• When the tightening angle is larger than the specified
tightening angle, remove the bolt to start from the
beginning again according to the procedure.
8. Tighten the bolt 90
° , and make sure that the paint mark of
the connecting rod is aligned with that of the bolt.
PISTON AND CONNECTING ROD
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ENGINE OVERHAUL
11B-70
INSPECTION
M1113008501788
.
PISTON RINGS
AK502751
1. Check clearance between piston rings and ring grooves. If
the limit is exceeded, replace piston rings or piston, or both.
Standard value:
No. 1 ring: 0.02
− 0.06 mm (0.001 − 0.002 inch)
No. 2 ring: 0.02
− 0.06 mm (0.001 − 0.002 inch)
Limit: 0.10 mm (0.004 inch)
AK603466
Please down ring
with piston
End gap
Piston ring
AC
2. Put piston rings into the cylinder bore, press them against
the piston top face, and push them in. After achieving
squareness, measure the end gap with a thickness gauge. If
the end gap is excessive, replace piston rings.
Standard value:
No. 1 ring: 0.18
− 0.28 mm (0.007 − 0.011 inch)
No. 2 ring: 0.28
− 0.43 mm (0.011 − 0.017 inch)
Oil ring: 0.10
− 0.34 mm (0.004 − 0.013 inch)
Limit:
No. 1 ring: 0.8 mm (0.03 inch)
No. 2 ring: 0.8 mm (0.03 inch)
Oil ring: 1.0 mm (0.04 inch)
.
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIGAGE METHOD)
1. Wipe oil off the crankshaft pin and connecting rod bearing.
2. Place a plastigage in length equal to the bearing width on
the pin shaft straight in alignment with the shaft center.
AK703363AC
Plastigage
3. Carefully install the connecting rod cap and tighten bolts to
the specified torque of 5.0 N
⋅ m (44 in-lb) → 20 N⋅ m (15
ft-lb)
→ +90° .
4. Remove bolts and gently remove the connecting rod cap.
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