Mitsubishi Outlander XL. Manual — part 186
REMOVAL SERVICE POINTS
<<A>> CONNECTING ROD CAP REMOVAL
ZK602114
Cylinder number
0000
1.
Mark the cylinder number on the side of the connecting rod
big end for correct reassembly.
2.
Keep the removed connecting rods, caps, and bearings in
order according to the cylinder number.
<<B>> PISTON PIN REMOVAL
ZK602503AA00
Guide A:
21.9 mm (0.86 in)
Guide A:
20.9 mm (0.82 in)
Guide A:
18.9 mm (0.74 in)
Guide A:
17.9 mm (0.70 in)
Guide B
Guide C
Guide D
(MB991659)
Base
Push rod
MD998780
1.
The special tool MD998780 consists of the elements shown in
the illustration.
2.
When removing the piston pin, the special tool MB991659 is
also used.
ENGINE OVERHAUL
11B-63
PISTON AND CONNECTING ROD
ZK602504 AA00
Base
Guide D
(MB991659)
Front mark
Push rod
P
View P
Front mark
(Oil jet hole)
3.
Insert Push rod, into the piston from the front mark side, then
attach Guide D, to the push rod.
4.
Place the piston and connecting rod assembly on Base, with
the front mark facing up.
5.
Use a press to remove the piston pin.
NOTE:
Keep the disassembled pistons, piston pins and
connecting rods per cylinder.
INSTALLATION SERVICE POINTS
>>A<< PISTON PIN INSTALLATION
ZK600659
Crankshaft
bore size
0000
Timing belt side
No.6
No.5
No.1
No.2
No.3
Cylinder
bore size
Right side
No.4
1.
When replacing the piston, note the cylinder bore size mark on
the cylinder block as illustrated, and select a piston according
to the flowing table.
Cylinder bore size mark
Piston size mark
A
A
B
B
NOTE:
The piston size mark shows on the top of the piston.
2.
Insert the push rod into the piston pin and install the guide A.
3.
Align the front mark of the piston with that of the connecting
rod. Align the piston with the connecting rod.
4.
Apply engine oil to the outer circumference of the piston pin.
5.
Insert the piston pin guide A installed at step 2 into the pin hole
from the front mark of the piston.
ZK602506
Guide A
Guide B
Push rod
L
AA00
Front mark
6.
Screw the guide B into A until the clearance "L" reaches 3.75
mm (0.147 inch) between A and B.
11B-64
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
ZK602505AA00
View P
Front mark
(Oil jet hole)
Front mark
Push rod
P
Base
Guide A
Guide B
7.
Place the piston and connecting rod assembly onto Base, with
the front marks facing up.
8.
Install the piston pin using a press. If the required press force
is less than the standard value, replace the piston and piston
pin assembly or the connecting rod, or both.
Standard value: 5,000 - 15,000 N (1,124 - 3,372 pound)
ZK602450AA00
9.
Check that the piston moves smoothly.
>>B<< OIL RING INSTALLATION
ZK500351
Spacer
AA00
Lower side rail
Upper side rail
1.
Fit the oil ring spacer into the piston ring groove.
NOTE:
The side rails and spacer may be installed in
either direction.
Do not use any piston ring expander when installing the
side rail. If will break the side rail.
ENGINE OVERHAUL
11B-65
PISTON AND CONNECTING ROD
ZK602451AA00
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 the position by
finger. 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.
>>C<< PISTON RING NO.2 / PISTON RING NO.1
INSTALLATION
ZK500319
No. 2
No. 1
AA00
Identification mark
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
>>D<< CONNECTING ROD BEARING INSTALLATION
ZK600667
No.1
Crankshaft pin
identification mark
Model
name
2D code
No.2
No.3
No.4
No.5
No.6
Spare
0000
Crankshaft journal (Lower)
identification mark
Crankshaft
No.5 jornal
1.
If the connecting rod bearing is replaced, select based on the
identification mark of crankshaft (illustrated) and the table
shown below.
Crankshaft pin
Bearing
Identification mark
Identification color
1
Black
2
Purple
3
Green
ZK6006680000
Identification color
2.
Every connecting rod bearing is identified by the identification
color at the illustrated location.
3.
Install the selected bearing in the big end and in the cap of the
connecting rod.
11B-66
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
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