Mitsubishi Outlander GS45X. Manual — part 1248
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL <2.4L ENGINE>
11B-67
1. Insert the push rod into the piston pin from the front mark
side of the piston top surface, and attach special tool
MB991659.
2. Set the piston and connecting rod assembly on the base so
that the front mark of the piston faces upward.
3. Use a press to push the push rod and pull out the piston pin.
NOTE: After pulling out the piston pin, organize pistons, pis-
ton pins and connecting rods by cylinder Number
INSTALLATION SERVICE POINTS
.
>>A<< PISTON PIN INSTALLATION
1. When replacing a piston, check the cylinder bore size mark
stamped on the illustrated position of the cylinder block and
select a corresponding piston from the table below.
A
AK502516AD
Base
Guide D
Pinston pin
Push rod
Front mark
Front mark
Cylinder bore size
mark
Piston size mark
A
A
B
None
C
C
J
2
J
3
J
4
J
5
J
1
AK503237
No.1
No.2
No.3
No.4
AD
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL <2.4L ENGINE>
11B-68
NOTE: The piston size mark is indicated on the piston top
face.
2. Insert the push rod into the piston pin and attach guide A.
3. Align the front mark of the piston with that of the connecting
rod to assemble.
4. Apply engine oil to the circumference of the piston pin.
5. Insert the guide A side of the piston pin assembled in
section 1 into the pin hole from the front mark side of the
piston.
6. Screw guide B into guide A and open clearance between
guide A and guide B by 3 mm (0.11 inch) (make the base in
line with flushed surface) to assemble.
7. Set the piston on special tool piston setting base so that its
front mark faces upward.
8. Use a press to press fit the piston pin. If the press fit load is
below the standard value, replace the piston pin (piston
assembly) or connecting rod, or both.
Standard value: 7,500
− 17,500 N (1.686 − 3.934 lbf)
.
>>B<< OIL RING INSTALLATION
1. Assemble the spacer of the oil ring into the piston ring
groove. Then, assemble the upper side rail, and after this
assemble the lower side rail.
NOTE: Install the side rail and end gap of the spacer so that
they are at the position as shown in the illustration.
A
24
AK503238AF
Piston mark size
AK502517AD
L
Guide A:
20.9 mm
(0.82 in)
Guide B
AK103812
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL <2.4L ENGINE>
11B-69
CAUTION
The side rail may be broken if its end gap is widened by a
ring expander as in other piston rings.
2. When assembling the side rail, push it by fingers, after fitting
one end of the side rail into the piston groove, for easy
assembly.
3. After assembling the oil ring into the piston, make sure that
the side rail turns smoothly to either direction.
.
>>C<< PISTON RING NUMBER. 2 / PISTON RING
NUMBER. 1 INSTALLATION
Use a piston ring expander to assemble piston rings with their
identification marks facing upward. Piston rings can be assem-
bled by hand without using the piston ring expander.
Identification mark:
Number 1 ring: 1T
Number 2 ring: 2T
.
>>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.
AK304891
AK304892AD
Piston ring
expander
AK502529
Identification mark
No.1
No.2
AE
PISTON AND CONNECTING ROD
TSB Revision
ENGINE OVERHAUL <2.4L ENGINE>
11B-70
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 belt side.
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.
.
>>E<< CONNECTING ROD BEARING
INSTALLATION
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.
2. An identification mark of a crankshaft is stamped at the
illustrated position by Number
AK202730
No. 1
No. 2
Side rail
Side rail
AG
Piston pin
AK502730
Crankshaft pin
Connecting
rod bearing
Identificatio
n mark
Journal diameter
mm (in)
Identificatio
n mark
1
47.966
− 47.972
(1.8884
− 1.8886)
1
2
47.960
− 47.966
(1.8882
− 1.8884)
2
3
47.954
− 47.960
(1.8880
− 1.8881)
3
AK502527AD
No.1
No.2
No.3
No.4
Pin identification mark position
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