Mitsubishi Galant (2004+). Manual - part 592

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-57

>>E<< PISTON AND CONNECTING ROD INSTALLATION
1. Apply engine oil to 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.

.

>>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 (0.015 inch)

.

AK301459

UPPER SIDE
RAIL

NO. 1

TIMING
BELT 
SIDE

LOWER
SIDE RAIL

NO. 2 RING GAP
AND SPACER GAP

AC

PISTON PIN

AK300192

AK300193

NOTCHES

CYLINDER
NUMBER

AC

AK300194

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-58

>>G<< CONNECTING ROD CAP NUT TIGHTENING 
1. The connecting rod bolts should be examined before reuse. 

If the bolt threads are damaged, the bolt should be replaced.
Hand-thread the nut to the full length of the bolt threads. If 
the nut does not run down smoothly, the bolt should be 
replaced.

2. Before installing each nut, apply engine oil to the threaded 

portion and bearing surface of the nut.

3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to the specified torque to 

install the cap properly.

Tightening torque: 20 

± 2 N⋅m (14 ± 1 ft-lb)

5. Make a paint mark on the head of each nut.
6. Make a paint mark on the bolt end at the position 90 to 94 

degrees from the paint mark made on the nut in the direction 
of tightening the nut.

CAUTION

• If the nut is turned less than 90 degrees, proper fasten-

ing performance may not be achieved. Be careful to 
tighten the nut exactly 90 degrees.

• If the nut is overtightened (exceeding 94 degrees), 

loosen the nut completely and then retighten it by 
repeating the tightening procedure from step 3.

7. Turn the nut 90 to 94 degrees and make sure that the paint 

marks on the nut and bolt are aligned.

INSPECTION

M1113008500503

.

PISTON
Replace the piston if scratches or seizure is evident on its sur-
faces (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.

.

AK301477AC

PAINT MARK

PAINT
MARK

90˚ to 94˚

NUT

BOLT

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-59

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)

3. Insert the piston ring into the cylinder bore. Force the ring 

down with a piston, the piston crown being in contact with 
the ring, to correctly position it at right angles to the cylinder 
wall. Then, measure the end gap with a feeler gauge. 
If the ring gap is excessive, replace the piston ring.

Standard value: 

Number 1: 0.15 

− 0.30 mm (0.006 − 0.012 inch)

Number 2: 0.28 

− 0.43 mm (0.011 − 0.017 inch)

Oil: 0.10 

− 0.40 mm (0.003 − 0.015 inch)

Limit:

Number 1, Number 2: 0.8 mm (0.03 inch)
Oil: 1.0 mm (0.03 inch)

.

CRANKSHAFT PIN OIL CLEARANCE <PLASTIC GAUGING 
MATERIAL METHOD>
1. Remove oil from the crankshaft pin and the connecting rod 

bearing.

2. Cut plastic gauging material to the same length as the width 

of the bearing and place it on the pin, parallel with its axis.

3. Install the connecting rod cap carefully and tighten the nuts 

to the specified torque.

4. Carefully remove the connecting rod cap.

5. Measure the width of the plastic gauging material at its 

widest part by using a scale printed on the plastic gauging 
material package.

Standard value: 0.02 

− 0.05 mm (0.0008 − 0.0019 inch)

Limit: 0.1 mm (0.003 inch)

AK300195

AK301481AC

PISTON RING PISTON RING GAP

PUSH IN BY 
PISTON

AK300196

PLASTIC GAUGING
MATERIAL

AC

AK300197

PLASTIC GAUGING
MATERIAL

AC

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-60

CRANKSHAFT AND  CYLINDER BLOCK

REMOVAL AND INSTALLATION

M1113008700660

CAUTION

Do not remove the block heater unless it is damaged, because it cannot be re-used once it is 
removed.

AK303218AC

2

3

4

5

6

7

8

10

9

11

12

13

14

15

17

11 ± 1 N·m
98 ± 8 in-lb

132 ± 5 N·m
98 ± 3 ft-lb

25 ± 2 N·m
18 ± 1 ft-lb

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

1

9.0 ± 1.0 N·m
80 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

→ + 90˚

25 ± 2 N·m
18 ± 1 ft-lb → 

+ 90˚

16

2.6 ± 0.2 N·m
23 ± 1 in-lb

REMOVAL STEPS

1.

DRIVE PLATE BOLT

2.

ADAPTER PLATE

3.

DRIVE PLATE

4.

CRANKSHAFT BUSHING

5.

REAR PLATE

6.

BELL HOUSING COVER

>>F<<

7.

OIL SEAL CASE

>>E<<

8.

OIL SEAL

>>D<<

9.

BEARING CAP BOLT (HEAD 17)

>>D<<

10.

BEARING CAP BOLT (HEAD 14)

>>D<<

11.

BEARING CAP

>>C<<

12.

CRANKSHAFT BEARING (LOWER)

13.

CRANKSHAFT

>>C<<

14.

CRANKSHAFT BEARING (UPPER)

>>B<<

15.

CRANKSHAFT THRUST BEARING

>>A<<

16.

BLOCK HEATER

17.

CYLINDER BLOCK

REMOVAL STEPS (Continued)