Mitsubishi Outlander (2013+). Manual - part 275

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-54

Enter cylinder No. for reassembly on the side of the 
connecting rod big end.

<<B>> PISTON PIN REMOVAL

AK305415AB

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

Special tool Piston pin setting tool (MD998780) con-
sists of parts shown in the illustration. Use also spe-
cial tool Guide D (MB991659) to remove the piston 
pin.

AK603502

20

A

AC

Base

Guide D

Piston pin

Push rod

Front mark

Front mark

1. Insert the push rod into the piston pin from the 

front mark side of the piston top surface, and 
attach special tool Guide D (MB991659).

2. Set the piston and connecting rod assembly on 

the base so that the front mark of the piston faces 
upward.

3. Use a press to push the push rod and pull out the 

piston pin.

NOTE: After pulling out the piston pin, organize 
pistons, piston pins and connecting rods by cylin-
der No.

INSTALLATION SERVICE POINTS

>>A<< PISTON PIN INSTALLATION

J

2

J

3

J

4

J

5

J

1

AK503237

No.1

No.2

No.3

No.4

AC

1. When replacing a piston, check the cylinder bore 

size mark stamped on the illustrated position of 
the cylinder block and select a corresponding 
piston from the table below.

Cylinder bore size 
mark

Piston size mark

A

A

B

B or None

C

C

AK603503

20

A

AC

Piston mark size

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-55

NOTE: The piston size mark is indicated on the 
piston top face.

2. Insert the push rod into the piston pin and attach 

guide A.

3. Align the front mark of the piston with that of the 

connecting rod to assemble.

4. Apply engine oil to the circumference of the piston 

pin.

5. Insert the guide A side of the piston pin 

assembled in section 1 into the pin hole from the 
front mark side of the piston.

AK502517AC

L

Guide A

Guide B

6. Screw guide B into guide A and open clearance 

between guide A and guide B by 3 mm (make the 
base in line with flushed surface) to assemble.

7. Set the piston on special tool piston setting base 

so that its front mark faces upward.

8. Use a press to press fit the piston pin. If the press 

fit load is below the standard value, replace the 
piston pin (piston assembly) or connecting rod, or 
both.

Standard value: 7,500 

− 17,500 N

>>B<< OIL RING INSTALLATION

AK103812AC

Upper
side
rail
closed
gap

Lower
side
rail
closed
gap

Spacer closed gap

1. Assemble the spacer of the oil ring into the piston 

ring groove. Then, assemble the upper side rail, 
and after this assemble the lower side rail.

NOTE: Install the side rail and end gap of the 
spacer so that they are at the position as shown in 
the illustration.

AK304891

CAUTION

The side rail may be broken if its end gap is wid-
ened by a ring expander as in other piston rings.
2. When assembling the side rail, push it by fingers, 

after fitting one end of the side rail into the piston 
groove, for easy assembly.

3. After assembling the oil ring into the piston, make 

sure that the side rail turns smoothly to either 
direction.

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

AK304892AB

Piston ring
expander

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-56

Use a piston ring expander to assemble piston rings 
with their identification marks facing upward. Piston 
rings can be assembled by hand without using the 
piston ring expander.

AK502529

Identification mark

No.1

No.2

AF

Identification mark:

No. 1 ring: T1 or 1T
No. 2 ring: T2 or 2T

>>D<< PISTON CONNECTING ROD 
ASSEMBLY INSTALLATION

1. Apply a sufficient amount of engine oil to the 

circumference of the piston, piston rings and oil 
ring.

AK202730

No. 1

No. 2

Side rail

Side rail

AC

Piston pin

2. Arrange end gap positions of piston rings and oil 

ring (side rail and spacer) as shown in the 
illustration.

3. Insert the piston and connecting rod assembly 

from the top surface of the cylinder block with the 
front mark of the piston top face facing toward the 
timing belt side.

AK502730

CAUTION

Driving it in hard causes breakage of piston rings 
and damage to the crank pin.

4. Firmly tighten the piston ring with a ring band and 

insert the piston and connecting rod assembly.

>>E<< CONNECTING ROD BEARING 
INSTALLATION

AK502527AC

No.1

No.2

No.3

No.4

Pin identification mark position

1. When replacing a connecting rod bearing, select 

the bearing corresponding to the crankshaft pin 
outside diameter according to the crankshaft pin 
identification in the table below.

Crankshaft pin

Connecting rod 
bearing

Identification 
mark

Journal 
diameter mm

Identification 
mark

1

47.966 

− 47.972 1

2

47.960 

− 47.966 2

3

47.954 

− 47.960 3

2. An identification mark of a crankshaft is stamped 

at the illustrated position by No.

AK305607AF

Identification
number

2

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-57

3. A connecting rod bearing has an identification 

mark at the illustrated position.

>>F<< CONNECTING ROD CAP 
INSTALLATION 

NOTE: The connecting rod resulting from the break-
ing process has the high insertion force. The new 
connecting rod assembly may possibly be difficult to 
remove the connecting rod.
If difficult to remove it, alternately strike the two bolt 
heads with a plastic hammer while the connecting 
rod bolt is slightly loosened, or strike the centre of the 
cap shaft’s inside diameter slightly and outward.
If the outside of the cap is directly struck, the lateral 
force is added to the broken-out section. Thus, pay 
attention to the broken-out section that might be diffi-
cult to be separated or might fall.
Clean the broken-out section before the installation 
to the engine, using compression air.

AK503157

2

Cylinder No.

AD

Notch

Front mark

1. Assemble the bearing cap on the connecting rod 

by aligning it with the mark put during removal. If a 
new connecting rod without a mating mark is 
used, assemble so that the detent notch of the 
bearing is on the same side as illustrated.

AK502752

2. Make sure that clearance of the thrust of the 

connecting rod big end is appropriate.

Standard value: 0.10 

− 0.25 mm

Limit: 0.4 mm

>>G<< CONNECTING ROD CAP BOLT 
INSTALLATION

1. Check in the following procedure before reusing 

the connecting rod bolt.

AK604589AE

20.5 mm

35 mm

A

B

B

X

(1) Measure the outside diameter "A."
(2) Measure the smallest outside diameter "B" 

within the range "X" shown in the illustration.

(3) If the difference of outside diameter of thread 

exceeds the limit, replace the connecting rod 
bolt.

Limit: 0.1 mm

2. Apply engine oil to the threaded portion and seat 

surface of the bolt before installing it.

3. After installing each bolt and tightening it by 

fingers, tighten bolts alternately to properly 
assemble the cap.

4. Tighten the bolt in several steps until the torque 

reaches 5.0 N

⋅m.

5. Tighten the bolt in several steps until the torque 

reaches 20 N

⋅m.