Mitsubishi Montero Sport (2004+). Manual - part 142

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL

11B-43

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.

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 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: 1T
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<< CONNECTING ROD BEARING INSTALLATION
1. Measure the crankshaft pin diameter and confirm its

classification from the following table. In the case of a
crankshaft supplied as a service part, identification
colors/marks of its pins are painted/stamped at the positions
shown in the illustration.

AKX00608

SIDE RAIL END

SIZE

SIZE MARK

Standard

None

0.50 mm (0.020 in) oversize
diameter

1.00 mm (0.040 in) oversize
diameter

100

AKX00689

NO.1

NO.2

IDENTIFICATION
MARK

SIZE MARK

IDENTIFICATION MARK

AKX00633

AKX00634

NO.5

LOCATION OF IDENTIFICATION COLOR

NO.2

NO.4

NO.1

NO.3

NO.6

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL

11B-44

2. From the following table, select a bearing whose size is

appropriate for the crankshaft pin outside the diameter.
If the crankshaft pin outside diameter Identification color is
"yellow" and the connecting rod Identification mark is "2,"
For example, select a bearing whose Identification color is
"green."
If there is no Identification color paint on the crankshaft,
measure the pin outside diameter and select bearing
appropriate for the measured value.

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.

CRANKSHAFT PIN OUTSIDE DIAMETER

CONNECTING ROD

BEARING

IDENTIFICATION COLOR SIZE mm (in)

IDENTIFICATION MARK IDENTIFICATION

COLOR

Yellow

54.994

− 55.000

(2.1651

− 2.1654)

Pink

Red

Green

None

54.988

− 54.994

(2.1649

− 2.1651)

Red

Green

Black

White

54.982

− 54.988

(2.1646

− 2.1649)

Green

Black

Brown

AK000449

IDENTIFICATION MARK

AKX00635

IDENTIFICATION
COLOR

AKX00620

UPPER
SIDE RAIL

NO.1

PISTON PIN

TIMING
BELT SIDE

LOWER
SIDE RAIL

NO.2 RING GAP
AND SPACER GAP

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL

11B-45

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.

>>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 CAP NUT INSTALLATION
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.

AK302589 AB

FRONT MARK

AKX00721

AKX00735

CYLINDER NO.

NOTCHES

AK302437

PISTON AND CONNECTING ROD

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ENGINE OVERHAUL

11B-46

2. Before installation of 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 a torque of 27

± 2 N⋅m

(20

± 1 ft-lb) to install the cap properly.

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

6. Make a paint mark on the bolt end at the position 90 degrees

to 94 degrees from the paint mark made on the nut in the
direction of tightening the nut.

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

paint marks on the nut and bolt are aligned.

INSPECTION

M1113008500020

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 a thumb.

You should feel a slight resistance. Replace the piston pin if
it can be easily inserted or there is 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 and replace if defects are evident. If the piston has
been replaced with a new one, the piston rings must also be
replaced with new ones.

2. Check for clearance between the piston ring and ring

groove. If the limit is exceeded, 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)

AKX01401AB

90˚ to 94˚

PAINT

MARKS

NUT

BOLT

PAINT

MARKS

AKX00612

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