Assembly and installation of shatunno-piston group. Mitsubishi Outlander (since 2003 of release)
Repair and Mitsubishi Outlander service since 2003 of release.
1. Operation and car maintenance
2. Engine
2.1. The general procedures of check and prevention without removal of the power unit
2.2. Removal and engine installation assembled
2.2.1. Removal
2.2.2. Removal, check and installation of the oil pallet (2WD model)
2.2.3. Removal, check and installation of the oil pallet (4WD model)
2.2.4. Replacement of a belt of a drive of GRM and belt of a drive of the balansirny mechanism (4G64,4G69)
2.2.5. Replacement of a belt of a drive of GRM and belt of a drive of the balansirny mechanism (4G63)
2.2.6. Removal and installation of epiploons of camshafts (4G63)
2.2.7. Removal and installation of forward and back epiploons of a cranked shaft (4G63)
2.2.8. Removal and installation of a head of the block of cylinders (4G64, 4G69)
2.2.9. Removal and installation of a head of the block of cylinders (4G63)
2.2.10. Removal, check and installation of the distributive mechanism
2.2.11. Removal and dismantling of shatunno-piston group
2.2.12. Assembly and installation of shatunno-piston group
2.2.13. Block of cylinders, cranked shaft and flywheel
2.2.14. Block of cylinders
2.2.15. Assembly of components of the block of cylinders
2.3. System of cooling of the engine
2.4. Greasing system
2.5. System of the distributed injection of fuel (MPI) of engines of a series 4G6
3. Transmission
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
9. Appendix
10. Electric equipment schemes
 







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2.2.12. Assembly and installation of shatunno-piston group

Installation of a maslosjemny ring
Establish a dilator of a maslosjemny ring in a flute under a ring in the piston.

NOTE
Be convinced that gaps in locks of scrapers and a dilator are located, as is shown in drawing.

New details (a dilator and scrapers) have a color label according to the sizes (see the corresponding table).
Establish the top scraper of a maslosjemny ring. For installation of the top scraper, at first establish one end of a scraper in a piston flute, then get other part of a scraper a finger, as is shown in drawing.

ATTENTION
Do not use an ekspander of piston rings. Unlike other parts of piston rings the scraper of a maslosjemny ring can break at its expansion ekspandery.

Establish the bottom scraper of a maslosjemny ring in the same way, as well as top.
Check correctness of installation of the maslosjemny ring consisting of three details. At the correct installation of a maslosjemny ring, it should rotate smoothly in any direction.

Table of color labels of the sizes of maslosjemny rings

Installation of kompressionny rings No. 1 and No. 2
Ekspander for kompressionny rings establish kompressionny rings No. 1 and No. 2 identification marking up.

NOTE
Each kompressionny ring has the dimensional and identification labels, executed by punching on the ring ends. At installation arrange a ring so that the label was from above (see the table).

Selection of loose leaves of the shatunny bearing
At replacement of loose leaves of the shatunny bearing select them for the tables provided below according to dimensional group (symbolical or color labels) cranked shaft and dimensional group (symbolical or color labels) loose leaves of the shatunny bearing.
Nominal diameter of an opening of the bottom head of a rod: 48,000–48,015 mm.

The table for selection of loose leaves of shatunny bearings (engine 4G63-7)

The table for selection of loose leaves of shatunny bearings (engine 4G64)

The table for selection of loose leaves of shatunny bearings (engine 4G69)

ATTENTION
The label of dimensional group of a shatunny neck of a cranked shaft is put only on a detail, delivered as the spare part.

Piston and rod installation assembled
Grease with a thin layer of engine oil of a surface of the piston and piston rings.
Arrange locks of kompressionny rings and a maslosjemny ring (a dilator and scrapers), as is shown in drawing.
Turn a cranked shaft so that the shatunny neck of a shaft rose in the middle of a cylinder opening.
Use suitable protectors for carving elements of bolts of rods before piston installation with a rod assembled in a cylinder opening. It will allow to avoid damages of a working zone of necks of a cranked shaft.
By means of the special adaptation for compression of rings, establish the piston with a rod assembled in an opening of the cylinder of the block.

ATTENTION
The piston with a rod should be assembled established in the block of cylinders so that the label on the piston was directed to a forward part of the engine (flint of a drive of GRM).

Installation of a cover of a rod and check of an axial gap of the bottom head of a rod
Combine the corresponding covers with the corresponding rods, in view of the put labels (cylinder number) and a method of fixing of loose leaves (grooves for loose leaves). If the new rod without adjusting labels is established, arrange grooves for fixing of loose leaves on a rod and a cover on the one hand.
By means of flat щупа measure an axial gap of the bottom head of a rod.
Nominal axial gap: 0,10–0,25 mm.
Maximum permissible axial gap: 0,40 mm.

Inhaling of nuts of fastening of a cover of a rod
The bolt and nut of fastening of a cover of a rod are tightened on «a fluidity limit». Before installation of a bolt be convinced that the carving of a bolt/nut is not deformed. Existence of deformation of connection a bolt nut is checked by a nut nakruchivaniye on a bolt manually till the end of a carving. If the nut wells up on a bolt manually with difficulty, the carving of a bolt is deformed, and it is necessary to replace a bolt.
Before installation of a nut grease with a thin layer of engine oil carving parts of a nut and a bolt.
Screw nuts on the corresponding bolts manually. Then tighten each nut individually to be convinced that a cover of a rod of the village it is correct.
Alternately tighten nuts of fastening of covers the specified moment of an inhaling.
Inhaling moment: 20 ±2 N · m.
Tighten nuts of fastening of covers on a corner 90–94 °.

ATTENTION
If the nut довернута on a corner less than 90 °, an inhaling of nuts of fastening of covers is insufficient.
If a nut довернута on a corner more than 94 °, unscrew a nut and repeat inhaling procedure.



2.2.11. Removal and dismantling of shatunno-piston group

2.2.13. Block of cylinders, cranked shaft and flywheel