Mitsubishi Colt Ralliart. Manual - part 611

 

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Mitsubishi Colt Ralliart. Manual - part 611

 

 

PISTON AND CONNECTING ROD

ENGINE OVERHAUL <4G1>

11D-44

REMOVAL SERVICE POINTS
<<A>> CONNECTING ROD CAP 
REMOVAL

AK402390

Cylinder 
number

AC

Mark the cylinder number on the side of the connect-
ing rod big end as a guide for reassembly.

<<B>> PISTON PIN REMOVAL

AK201840AC

Push rod

Base

Guide B

Guide C

Guide D

(MB991659)

Guide A: 17.9 mm

Guide A: 18.9 mm

Guide A: 20.9 mm

Guide A: 21.9 mm

1. The special tool Piston pin setting tool 

(MD998780) consists of the elements shown in 
the illustration.

2. When removing the piston pin, the special tool 

Guide D (MB991659) is also used.

AK202405AC

Base

Guide D

Front mark

Front mark

Push rod

P

View P

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

AK200851

Timing belt side

Cylinder 
bore 
size mark

No.4

No.1

No.2

No.3

AC

1. When replacing a piston, check the cylinder bore 

size mark stamped at the indicated location on the 
cylinder block and select an appropriate 
replacement piston using the following table.

Main

Index

Group

TOC

Cylinder bore size 
mark

Piston size mark

A

A

B

None

C

C

PISTON AND CONNECTING ROD

ENGINE OVERHAUL <4G1>

11D-45

NOTE: The piston size mark is located on the pis-
ton top surface.

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.

AK201193AE

L

Guide A

Guide B

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

reaches 2.25mm between "A" and "B."

AK202406 AC

Base

Guide A

Front mark

Front mark

Push rod

P

View P

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: 4,900 

 14,700 N

>>B<< OIL RING INSTALLATION

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

Install the upper side rail, then the lower side rail.
NOTE: New spacers and side rails are an identi-
fied by color marks as follows:

Size

Color mark

Standard

No mark

0.50 mm oversize

Blue

1.00 mm oversize

Yellow

AK201803AC

Side rail end

CAUTION

Use of ring expander to expand the side rail end 
gap can break the side rail, unlike other piston 
rings.
2. To install each side rail, first fit one end of the rail 

into the piston groove, then press the remaining 
portion progressively into position by finger as 
shown in the illustration.

3. Make sure that the installed side rails move 

smoothly in either direction.

AK103812AC

Upper
side
rail
closed
gap

Lower
side
rail
closed
gap

Spacer closed gap

4. Locate the side rail and spacer end gaps as 

shown in the illustration.

Main

Index

Group

TOC

PISTON AND CONNECTING ROD

ENGINE OVERHAUL <4G1>

11D-46

>>C<< PISTON RING NO. 2/PISTON RING 
NO. 1 INSTALLATION

AK201804AC

Piston ring 
expander

AK202807

No. 2

AB

No. 1

Size marks

Identification mark

Using a piston ring expander, install the piston rings 
with their identification marks facing up (toward the 
piston crown).

Identification marks:

No. 1 ring 1R
No. 2 ring 2R

NOTE: . Each of the available piston rings has a size 
mark as follows:

Size

Size mark

Standard

No mark

0.50 mm oversize

50

1.00 mm oversize

100

>>D<< PISTON AND CONNECTING ROD 
ASSEMBLY INSTALLATION

1. Apply engine oil generously to the piston's outside 

surface, piston rings, and oil ring.

AK202553

No. 1

No. 2

Side rail

Side rail

AB

2. Align the end gaps of the piston rings and oil ring 

(side rails and spacer) as shown in the illustration.

3. Insert the piston and connecting rod assembly 

from the top of cylinder with the front mark on the 
crown toward the timing belt side.

AK201805

4. Use a piston ring band to hold the piston rings 

compressed when inserting the piston and 
connecting rod assembly into the cylinder.

Main

Index

Group

TOC

PISTON AND CONNECTING ROD

ENGINE OVERHAUL <4G1>

11D-47

>>E<< CONNECTING ROD BEARING 
INSTALLATION

AK402143

P

No. 1

No. 2

No. 3

No. 4

P

AC

1. When replacing the connecting rod bearing, 

select a bearing of the size appropriate for the 
crankshaft pin diameter in accordance with the 
crankshaft pin and connecting rod bearing 
matching table shown below.

Bearing Selection Table
Crankshaft

Connecting 
rod 
Identification 
mark

Bearing 
identification 
mark

Identification 
mark

Pin 
diameter 
mm

A or I

41.994 

− 

42.000

A

0

None

1

C

2

B or II

41.988 

− 

41.994

A

1

None

2

C

3

C or III

41.982 

− 

41.988

A

2

None

3

C

4

AK305611AB

Front mark

2. The identification mark of the connecting rod is 

found in the position shown in the illustration.

AK304598

Connecting bearing

Identification
mark position

AB

3. Select bearings from the bearing selection table in 

accordance with the identification marks and color 
codes checked at steps 1 and 2 above.

 <Bearing selection example>

(1) If the measured outside diameter of crankshaft 

pin is 42.000 mm, the identification mark are 
"A" and I, respectively.

(2) Based on the above, if the identification of the 

connecting rod is "A," select the bearing 
marked in I.

Main

Index

Group

TOC

 

 

 

 

 

 

 

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