Mitsubishi Outlander GS45X. Manual — part 1249

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <2.4L ENGINE>

11B-71

3. A connecting rod bearing has an identification mark at the

illustrated position.

.

>>F<< CONNECTING ROD CAP INSTALLATION

NOTE: The connecting rod resulting from the breaking process
has the high insertion force. The new connecting rod assembly
may possibly be difficult to remove the connecting rod.
If difficult to remove it, alternately strike the two bolt heads with
a plastic hammer while the connecting rod bolt is slightly loos-
ened, or strike the center of the cap shaft’s inside diameter
slightly and outward.
If the outside of the cap is directly struck, the lateral force is
added to the broken-out section. Thus, pay attention to the bro-
ken-out section that might be difficult to be separated or might
fall.
Clean the broken-out section before the installation to the
engine, using compression air.
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.

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 (0.016 inch)

.

AK700793AD

Identification
mark

AK503157

2

Cylinder No.

AE

Notch

Front mark

AK502752

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <2.4L ENGINE>

11B-72

>>G<< CONNECTING ROD CAP BOLT
INSTALLATION

1. Check in the following procedure before reusing the

connecting rod bolt.

(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: 0.1 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 (14 ft-lb).

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.

INSPECTION

M1113008502123

.

PISTON RINGS

1. Check clearance between piston rings and ring grooves. If

the limit is exceeded, replace piston rings or piston, or both.

Standard value:

Number 1 ring: 0.03

− 0.07 mm (0.001 − 0.003 inch)

Number 2 ring: 0.03

− 0.07 mm (0.001 − 0.003 inch)

Limit: 0.1 mm (0.004 inch)

AK604589AD

20.5 mm (0.81 in)

35 mm (1.38 in)

A

B

B

X

AK502749

90˚

Paint mark

AD

Paint mark

AK502751

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <2.4L ENGINE>

11B-73

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 free gauge. If the
end gap is excessive, replace piston rings.

Standard value:

Number 1 ring: 0.15

− 0.25 mm (0.006 − 0.011 inch)

Number 2 ring: 0.25

− 0.40 mm (0.010 − 0.016 inch)

Oil ring: 0.10

− 0.35 mm (0.004 − 0.014 inch)

Limit:

Number 1 ring: 0.8 mm (0.03 inch)
Number 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.

3. Carefully install the connecting rod cap and tighten bolts to

the specified tightening 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.

5. Measure the crushed plastigage width (area most widely

crushed) using a scale printed on the plastigage bag.

Standard value: 0.018

− 0.045 mm (0.0007 − 0.0018

inch)
Limit: 0.1 mm (0.04 inch)

AK503370AF

Please down ring
with piston

End gap

Piston ring

Front mark

AK503373 AD

Plastigage

AK503374AD

Plastigage

CRANKSHAFT AND CYLINDER BLOCK

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ENGINE OVERHAUL <2.4L ENGINE>

11B-74

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION

M1113008703238

AK502938AE

5

26.5 ± 2.0 N·m

→ +45˚

20 ± 1 ft-lb

6

7

11 ± 1 N·m
98 ± 8 in-lb

8

4

3

2

1

Apply engine oil to
all moving parts
before installation.

Removal steps

>>E<<

1. Crankshaft bearing cap bolt

>>E<<

2. Crankshaft bearing cap

>>D<<

3. Crankshaft bearing lower

<<A>>

4. Crankshaft

>>C<<

5. Crankshaft bearing upper

>>B<<

6. Thrust bearing

>>A<<

7. Crankshaft sensing ring
8. Cylinder block

Removal steps (Continued)