Mitsubishi Outlander GS45X. Manual - part 1228

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L ENGINE>

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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 lb)

9. Check that the piston moves smoothly.

.

>>B<< OIL RING INSTALLATION

1. Fit the oil ring spacer into the piston ring groove.

NOTE: The side rails and spacer may be installed in either 
direction.

AK600937

Push rod

P

Base

Guide A

Guide B

Front mark

View P

Front mark
(Oil jet hole)

AC

AK600920

AK600797

Spacer

AC

Upper side rail

Lower side rail

PISTON AND CONNECTING ROD

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CAUTION

Do not use any piston ring expander when installing the 
side rail. If will break the side rail.
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 NUMBER2 / PISTON RING 
NUMBER1 INSTALLATION 

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

1. If the connecting rod bearing is replaced, select based on 

the identification mark of crankshaft (illustrated) and the 
table shown below.

AK600921

AK600791

No. 2

No. 1

Identification mark

AC

Crankshaft pin 
identification mark

Bearing identification 
color

1

Black

2

Purple

3

Green

AK703237

No.1

No.2

No.3

No.4

No.5

No.6

AK703237AD

Crankshaft pin
identification mark

Crankshaft
No.5 jornal

Crankshaft journal (Lower)
identification mark

PISTON AND CONNECTING ROD

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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.

.

>>E<< PISTON AND CONNECTING ROD 
INSTALLATION

1. Liberally coat the circumference of the piston, piston ring, 

and oil ring with engine oil.

2. Arrange the piston ring and oil ring gaps (side rail and 

spacer) as shown in the illustration.

3. Rotate the crankshaft so that the crank pin is on the center 

of the cylinder bore.

4. Insert the piston and connecting rod assembly into the 

cylinder with the front mark on the piston crown pointing to 
the timing belt side.

5. Using a suitable piston ring compressor tool, install the 

piston and connecting rod assembly into the cylinder block.

.

AK600843

Identification color

AC

AK600922

Piston pin

AC

No. 1

Timing belt 
side

Lower
side rail

No. 2 ring gap
and spacer gap

Upper side rail

AK600923AC

Front mark

AK600924

PISTON AND CONNECTING ROD

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>>F<< CONNECTING ROD CAP INSTALLATION

1. Verifying the mark made during disassembly, install the 

bearing cap to the connecting rod. If the connecting rod is 
new with no index mark, make sure that the bearing locking 
notches are on the same side as shown.

2. Make sure that the connecting rod big end side clearance 

meets the specification.

Standard value: 0.10 

− 0.25 mm (0.004 − 0.009 inch)

Limit: 0.4 mm (0.02 inch)

.

>>G<< CONNECTING ROD BOLT INSTALLATION

1. Apply engine oil to the threaded portion and seating face of 

the bolt.

2. To correctly install the cap, loosely install the bolts with 

fingers.

3. Alternately, tighten the bolts in several steps to the specified 

torque of 20 

± 2 N⋅m (15 ± 1 ft-lb).

4. Make a paint mark on the head of each 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.

5. Put another paint mark on the bolt head at 90 degrees in the 

tightening direction from the first paint mark.

6. Tighten the bolt 90 degrees. The paint mark on the 

connecting rod should be aligned with the paint mark on the 
bolt.

AK600909

Notches

Cylinder number

AC

AK600925

AK600926

90˚

Paint mark

AC

Paint mark