Mitsubishi Outlander GS45X. Manual - part 1248

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-67

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

side of the piston top surface, and attach special tool 
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, pis-
ton pins and connecting rods by cylinder Number

INSTALLATION SERVICE POINTS

.

>>A<< PISTON PIN INSTALLATION

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.

A

AK502516AD

Base

Guide D

Pinston pin

Push rod

Front mark

Front mark

Cylinder bore size 
mark

Piston size mark

A

A

B

None

C

C

J

2

J

3

J

4

J

5

J

1

AK503237

No.1

No.2

No.3

No.4

AD

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-68

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.

6. Screw guide B into guide A and open clearance between 

guide A and guide B by 3 mm (0.11 inch) (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 (1.686 − 3.934 lbf)

.

>>B<< OIL RING INSTALLATION

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.

A

24

AK503238AF

Piston mark size

AK502517AD

L

Guide A:
20.9 mm
(0.82 in)

Guide B

AK103812

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-69

CAUTION

The side rail may be broken if its end gap is widened 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 NUMBER. 2 / PISTON RING 
NUMBER. 1 INSTALLATION

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

Identification mark:

Number 1 ring: 1T
Number 2 ring: 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.

AK304891

AK304892AD

Piston ring
expander

AK502529

Identification mark

No.1

No.2

AE

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-70

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.

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

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.

2. An identification mark of a crankshaft is stamped at the 

illustrated position by Number

AK202730

No. 1

No. 2

Side rail

Side rail

AG

Piston pin

AK502730

Crankshaft pin

Connecting 
rod bearing

Identificatio
n mark

Journal diameter 
mm (in)

Identificatio
n mark

1

47.966 

− 47.972

(1.8884 

− 1.8886)

1

2

47.960 

− 47.966

(1.8882 

− 1.8884)

2

3

47.954 

− 47.960

(1.8880 

− 1.8881)

3

AK502527AD

No.1

No.2

No.3

No.4

Pin identification mark position