Mitsubishi Outlander GS45X. Manual - part 1227

OIL PAN AND OIL PUMP

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ENGINE OVERHAUL <3.0L ENGINE>

11D-61

>>J<< DRAIN PLUG GASKET INSTALLATION

CAUTION

If the gasket is installed in the wrong direction, oil leaks 
will occur.
Install the drain plug gasket as illustrated.

AK600891

Oil pan

AD

Oil pan
side

Gasket

Drain plug

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L ENGINE>

11D-62

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

M1113008403226

Required Special Tools:

• MD998780: Piston Pin Setting Tool

• MB991659: Guide D

AK600801

1

2

3

4

5

6

7

8

9

10

11

 

→ +90˚

20 ± 2 N·m
15 ± 1 ft-lb

Apply engine oil to
all moving parts
before installation.

AC

Removal steps 

>>G<<

1. Connecting rod bolt

<<A>> >>F<<

2. Connecting rod cap

>>D<<

3. Connecting rod bearing, lower

>>E<<

4. Piston and connecting rod assembly

>>D<<

5. Connecting rod bearing, upper

>>C<<

6. Piston ring Number1

>>C<<

7. Piston ring Number2

>>B<<

8. Oil ring

<<B>> >>A<<

9. Piston pin
10. Piston
11. Connecting rod

Removal steps (Continued)

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L ENGINE>

11D-63

REMOVAL SERVICE POINTS

.

<<A>> CONNECTING ROD CAP REMOVAL

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

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.

AK600908

Cylinder number

AC

AK600935

Guide A:
21.9 mm

Guide B

Guide C

Guide D

(MB991659)

Base

Push rod

Guide A:
20.9 mm

Guide A:
18.9 mm

Guide A:
17.9 mm

AC

MD998780

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L ENGINE>

11D-64

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 con-
necting rods per cylinder.

INSTALLATION SERVICE POINTS

.

>>A<< PISTON PIN INSTALLATION

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.

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.

6. Screw the guide B into A until the clearance "L" reaches 

3.75 mm (0.147 inch) between A and B.

AK600936

Base

Guide D
(MB991659)

Push rod

P

Front mark
(Oil jet hole)

Front mark

View P

AC

Cylinder bore size 
mark

Piston size mark

A

A

B

B

AK600835

Timing belt side

Right side

Cylinder
bore size

Crankshaft
bore size

No.5

No.6

No.4 No.2

No.1

No.3

AF

AK600938

Guide A

Guide B

Push rod

L

AC

Front mark