Mitsubishi Outlander XL. Manual - part 187

 

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Mitsubishi Outlander XL. Manual - part 187

 

 

>>E<< PISTON AND CONNECTING ROD INSTALLATION

ZK602453

Upper side rail

No. 1

Timing belt 
side

Lower
side rail

No. 2 ring gap
and spacer gap

Piston pin

AA00

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.

ZK602454

Front mark

AA00

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.

ZK602455AA00

5.

Using a suitable piston ring compressor tool, install the piston
and connecting rod assembly into the cylinder block.

 

>>F<< CONNECTING ROD CAP INSTALLATION

ZK602115

Cylinder number

0000

Notches

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.

ENGINE OVERHAUL

11B-67

PISTON AND CONNECTING ROD

ZK602456AA00

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 BOLT INSTALLATION

1.

Apply engine oil to the threaded portion and seating face of
the bolt.

2.

To correctly install the cap, loosely install the bolts with fingers.

3.

Alternately, tighten the bolts in several steps to the specified
torque of 20 ± 2 N·m (15 ± 1 ft-lb).

ZK602457

90°

Paint mark

Paint mark

AA00

4.

Make a paint mark on the head of each bolt.

｠

If the bolt is tightened less than the specified lower limit
of  90  degrees,  the  bolt  may  become  loose.  Be  sure  to
tighten correctly.

｠

If the bolt is tightened in excess of the specified upper
limit of 90 degrees, loosen the bolt completely and repeat
the entire procedures.

5.

Put another paint mark on the bolt head at 90 degrees in the
tightening direction from the first paint mark.

6.

Tighten the bolt 90 degrees. The paint mark on the connecting
rod should be aligned with the paint mark on the bolt.

PISTON RING INSPECTION

M11103000913USA0000010000

1.

Check  the  piston  ring  for  damage,  excessive  wear,  and
breakage.  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.

ZK602458AA00

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: 0.04 - 0.08 mm (0.0016 - 0.0031 inch)
Number 2: 0.03 - 0.07 mm (0.0012 - 0.0027 inch)

Limit: 0.1 mm (0.004 inch)

11B-68

ENGINE OVERHAUL

PISTON AND CONNECTING ROD

ZK602459AA00

Piston ring

Push in by piston

Piston ring gap

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: 0.18 - 0.33 mm (0.008 - 0.012 inch)
Number 2: 0.28 - 0.48 mm (0.012 - 0.018 inch)
Oil: 0.10 - 0.60 mm (0.004 - 0.023 inch)

Limit:

Number 1, Number 2: 0.8 mm (0.03 inch)
Oil: 1.0 mm (0.04 inch)

CRANKSHAFT PIN OIL CLEARANCE

<PLASTIGAGE METHOD>

M11103000914USA0000010000

The crankshaft oil clearance can be measured easily by using
plastigage method, as follows:

1.

Remove  oil  from  the  crankshaft  pin  and  the  bearing  inner
surface.

ZK6021120000

Plastigage

2.

Cut plastigage to the same length as the width of the bearing
and place it on the pin in 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.

ZK6021130000

5.

Measure  the  width  of  the  smashed  plastigage  at  its  widest
section by using a scale printed on the plastigage bag.

Standard  value:  0.012  -  0.039  mm  (0.0005  -  0.0015
inch)
Limit: 0.1 mm (0.004 inch)

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION

M11103000087USA0000010000

ENGINE OVERHAUL

11B-69

PISTON AND CONNECTING ROD

ZK600031AA01

1

2

3

4

6

8

9

10

11

12

13

14

15

16

18

23 ± 6 N·m
17 ± 4 ft-lb

17

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

5

10 ± 2 N·m
89 ± 17 in-lb

10 ± 2 N·m
89 ± 17 in-lb

76 ± 4 N·m
57 ± 2 ft-lb

12 ± 2 N·m
106 ± 17 in-lb

7

24 ± 2 N·m
18 ± 1 ft-lb

→

 

+90°

Apply engine oil to
all moving parts
before installation.

Removal steps

<<A>> >>H<< 1.

DRIVE PLATE BOLT

2.

ADAPTER PLATE

3.

DRIVE PLATE

4.

REAR PLATE

>>G<< 5.

CRANKSHAFT REAR OIL SEAL

>>F<<

6.

OIL SEAL CASE

>>E<< 7.

BEARING CAP BOLT

>>E<< 8.

BEARING CAP

>>D<< 9.

CRANKSHAFT BEARING, LOWER

10. CRANKSHAFT

Removal steps

>>C<< 11. THRUST BEARING
>>B<< 12. CRANKSHAFT BEARING, UPPER
>>A<< 13. CRANKSHAFT SENSING RING

14. KNOCK SENSOR
15. KNOCK SENSOR
16. BANK STIFFENER
17. BANK STIFFENER GASKET
18. CYLINDER BLOCK

 

11B-70

ENGINE OVERHAUL

CRANKSHAFT AND CYLINDER BLOCK

 

 

 

 

 

 

 

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