Mitsubishi Galant (2004+). Manual - part 607

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-45

3. Check the body clearance.

Standard value: 0.10 

− 0.18 mm (0.004 − 0.007 inch)

Limit: 0.35 mm (0.013 inch)

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

M1113008400636

AKX00745

AK201085

1

2

3

4

5

6

7

8

9

10

11

12

13

14

27 ± 2 N·m
20 ± 1 ft-lb

   + 90˚ TO  94˚

AC

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

REMOVAL STEPS

>>G<<

1. CONNECTING ROD CAP NUT

<<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

REMOVAL STEPS (Continued)

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.8L ENGINE>

11D-46

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. Remove the snap rings.

CAUTION

The clearance between the piston and the piston pin is a 
tight fit at room temperature. Therefore, be sure to heat the 
piston before pulling out the piston pin. Use care since the 
piston is hot after heating.
2. Heat the piston approximately 70

°C (158°F) and pull out the 

piston pin.

>>C<<

6. PISTON RING NO.1

>>C<<

7. PISTON RING NO.2

>>B<<

8. OIL RING
9. SNAP RING

<<B>> >>A<<

10. PISTON PIN
11. SNAP RING
12. PISTON
13. CONNECTING ROD
14. BOLT

REMOVAL STEPS (Continued)

AKX00734

CYLINDER
NUMBER

AB

AKX01397

70˚C

(158˚F)

AB

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-47

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 following table.

NOTE: The piston size mark shows on the top of the piston.

2. Set the snap ring into one side of the piston pin hole.

CAUTION

Apply ample coat of engine oil to the periphery of the pis-
ton pin and the hole of the connecting rod small end. The 
clearance between the piston and the piston pin is a tight 
fit at room temperature. Therefore, be sure to heat the pis-
ton before inserting the piston pin. Use care since the pis-
ton is hot after heating. 
3. Heat the piston to approximately 70

°C (158°F).

4. With the front mark of the connecting rod and that of the 

piston located on the same side, insert the piston pin.

5. Set the snap ring into the other side of the piston pin hole.

CYLINDER BORE SIZE 
MARK

PISTON SIZE MARK

I

A

II

None

III

C

AK200850

TIMING BELT SIDE

CHECK DIGIT

No.4

No.1

No.2

No.3

AD

LEFT BANK

RIGHT BANK

No.6

No.5

CRANKSHAFT 
BORE SIZE
MARK

AKX01398

70˚C

(158˚F)

AB

AK201080

FRONT MARK 74

AB

FRONT MARK

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL <3.8L ENGINE>

11D-48

6. 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.

CAUTION

Do not use any piston ring expander when installing the 
side rail. It will break the side rail.
2. Install the upper side rail by hand.

To install the side rail, first fit one end of the rail into the 
piston groove, then press the remaining portion into the 
position. 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.

.

AKX00716

AK000196AB

SIDE RAIL

SIDE RAIL

SPACER

AKX00608

SIDE RAIL END

AB