Mitsubishi Galant. Manual - part 74

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L>

11D-45

INSTALLATION SERVICE POINTS

>>A<< PISTON PIN INSTALLATION
1. Thread the stop screw and jam nut assembly into the base.

Fit the correct piston support on top of the base. Insert the
press pin, threaded end up, into the hole in the piston
support until the press pin touches the stop screw.

2. Using the graduations on the press pin, adjust the stop

screw to the depth.

Depth: 60 mm (2.36 inches)

3. Place the base on the press support blocks.

4. Slide the piston pin over the threaded end of the press pin,

and thread the correct guide pin up against it.

5. Coat the piston pin with engine oil, and with the connecting

rod held in position, slide the guide pin through the piston
and connecting rod.

6. Press the piston pin through the connecting rod until the

guide pin contacts the stop screw.

CAUTION

Due to production tolerance variations, it is necessary to
visually inspect the piston pin depth after installation to
verify that the piston pin is centered. Adjust if necessary.
7. Remove the piston assembly from the base. Remove the

guide pin and press pin from the assembly.

AKX00732

PRESS
PIN

PISTON
SUPPORT

STOP
SCREW

PIN DEPTH SET
LOCATION

FLAT PISTON
SUPPORT

JAM
NUT

BASE

AKX00646

JAM NUT

PRESS
PIN

PISTON PIN

FRONT
MARK

CONNECTING
ROD GUIDE
PIN

BASE

STOP
SCREW

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L>

11D-46

8. 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.

NOTE: New spacers and side rails are colored for
identification of their sizes.

CAUTION

Do not use any piston ring expander when installing 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 either

direction.

AKX00716

SIZE

COLOR

Standard

None

0.50 mm (0.020 in) oversize

Blue

1.00 mm (0.040 in) oversize

Yellow

AK000196AB

SIDE RAIL

SPACER

AKX00608

SIDE RAIL END

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L>

11D-47

>>C<< PISTON RING NO.2/PISTON RING NO.1
INSTALLATION
1. 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: T
Number 2 ring: 2T

NOTE: Size marks on piston rings are as follows.

2. Using a piston ring expander, fit the number 2 piston ring

into the number 2 groove of piston.

NOTE: Install the piston rings with their identification mark
facing up, to the piston crown side.

3. Install the number 1 piston ring in the same manner as step

>>D<< PISTON AND CONNECTING ROD INSTALLATION
1. Apply engine oil on the circumference of the piston, piston

rings, and oil ring.

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. Use suitable thread protectors on the connecting rod bolts

before inserting the piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.

5. Insert the piston and connecting rod assembly into the

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

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

piston and connecting rod assembly into the cylinder block.

SIZE

SIZE MARK

Standard

None

0.50 mm (0.020 in) oversize

1.00 mm (0.040 in) oversize

100

AKX00689

NO.1

NO.2

IDENTIFICATION
MARK

SIZE MARK

IDENTIFICATION MARK

AKX00633

AKX00620

UPPER
SIDE RAIL

NO.1

PISTON PIN

TIMING
BELT SIDE

LOWER
SIDE RAIL

NO.2 RING GAP
AND SPACER GAP

AKX00721

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.0L>

11D-48

>>E<< CONNECTING ROD CAP INSTALLATION
1. Mate the correct bearing cap with the correct connecting rod

by checking with the alignment marks marked during
disassembly. If a new connecting rod is used which has no
alignment mark, position the notches for locking the bearing
on the same side.

2. Check if the thrust clearance in the connecting rod big end is

correct.

Standard value: 0.10

−−−−

0.25 mm (0.004

−−−−

0.009 inch)

Limit: 0.4 mm (0.02 inch)

INSPECTION

M1113008500042

PISTON
Replace the piston if scratches or seizure is evident on its
surfaces (especially the thrust surface). Replace the piston if it
is cracked.

PISTON PIN
1. Insert the piston pin into the piston pin hole with your thumb.

You should feel a slight resistance. Replace the piston pin if
it can be easily inserted or there is an excessive play.

2. The piston and piston pin must be replaced as an assembly.

PISTON RING
1. Check the piston ring for damage, excessive wear, and

breakage. Replace if defects are evident. If the piston has
been replaced, the piston rings must also be replaced.

2. Check for clearance between the piston ring and ring

groove. If it exceeds the limit, replace the ring or piston, or
both.

Standard value:

Number 1 0.03

−−−−

0.07 mm (0.0012

−−−−

0.0027 inch)

Number 2 0.02

−−−−

0.06 mm (0.0008

−−−−

0.0023 inch)

Limit: 0.1 mm (0.003 inch)

AKX00735

CYLINDER NO.

NOTCHES

AKX00736

AKX00612

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