Mitsubishi Galant. Manual — part 38

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-33

>>B<< VALVE SPRING INSTALLATION
Install the valve spring with its ID color painted end (larger pitch
side) upward (toward the valve spring retainer).

>>C<< RETAINER LOCK INSTALLATION

CAUTION

Do not compress the valve spring excessively. It can
damage the stem seal.
1. Set special tool MD998772 as illustrated to compress the

valve spring. Install the retainer locks.

2. Relieve the spring tension. Check that the retainer locks are

seated correctly.

>>D<< CYLINDER HEAD BOLT INSTALLATION
1. When the removed cylinder head bolts are to be reused,

check that the shank length of each bolt meets the limit. If it
exceeds the limit, replace the bolts.

Limit: 99.4 mm (3.91 inches)

2. Apply engine oil to the thread of the bolts and to the

washers.

3. Using special tool MB991654 tighten the bolts to the

specified torque 78 N

⋅

m (58 ft-lb), using the tightening

sequence shown.

4. Loosen all bolts fully in the reverse order of tightening.

5. Retighten the loosened bolts to 20 N

⋅

m (14 ft-lb) in the

tightening sequence shown.

AKX00454

SPRING
RETAINER

IDENTIFICATION
COLOR

STEM
SEAL

SPRING
SEAT

AB

AKX00520

MD998772

AB

AKX00467

SHANK LENGTH

AB

AKX00526

TIMING BELT SIDE

8

6

1

3

9

10

4

2

5

7

AB

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-34

6. Make a paint mark across each bolt head and cylinder head.

7. Tighten the cylinder head bolts 90 degree angle in the

specified order.

CAUTION

•

If the bolt is turned less than 90 degree angle, proper
fastening performance may not be achieved. Be careful
to turn each bolt exactly 90 degree angle.

•

If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening
procedure from step 1.

8. Tighten the bolts another 90 degree angle in the same order

as in step 7, and check that the paint marks on the cylinder
head bolt are aligned with the paint marks on the cylinder
head.

INSPECTION

M1113007000055

CYLINDER HEAD
1. Check the cylinder head gasket surface for flatness by using

a straight edge and feeler gauge.

Standard value: 0.05 mm (0.002 inch)

Limit: 0.2 mm (0.007 inch)

2. If it exceeds the limit, correct to meet specification.

Grinding limit: *0.2 mm (0.007 inch)
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
120 mm (4.7 inches)

VALVE
1. Check the valve seat contact. Valve seat contact should be

uniform at the center of the valve face. If incorrect, reface
using a valve refacer.

2. If the margin is below the limit, replace the valve.

Standard value:

Intake 1.0 mm (0.03 inch)
Exhaust 1.2 mm (0.04 inch)

Minimum limit:

Intake 0.5 mm (0.02 inch)
Exhaust 0.7 mm (0.03 inch)

3. Measure the valve's total length. If the measurement is less

than the limit, replace the valve.

Standard value:

Intake 112.30 mm (4.421 inches)
Exhaust 114.11 mm (4.493 inches)

Minimum limit:

Intake 111.80 mm (4.402 inches)
Exhaust 113.61 mm (4.473 inches)

AKX00449

90˚

PAINT MARK

AB

90˚

AKX00604

AKX00455

VALVE SEAT
CONTACT

MARGIN

AB

AKX00502

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-35

VALVE SPRING
1. Measure the free height of the spring. If it is less than the

limit, replace.

Standard value: 51.0 mm (2.00 inches)
Minimum limit: 50.0 mm (1.97 inches)

2. Measure the squareness of the spring. If it exceeds the limit,

replace.

Standard value: 2

°°°°

or less

Limit: 4

°°°°

VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If it exceeds the limit, replace the valve guide or valve, or
both.

Standard value:

Intake 0.02

−−−−

0.05 mm (0.0008

−−−−

0.0019 inch)

Exhaust 0.03

−−−−

0.07 mm (0.0012

−−−−

0.0027 inch)

Limit:

Intake 0.10 mm (0.003 inch)
Exhaust 0.15 mm (0.005 inch)

VALVE SEAT
Assemble the valve, then measure the valve stem projection
between the end of the valve stem and the spring seating
surface. If the measurement exceeds the specified limit,
replace the valve seat.

Standard value: 49.30 mm (1.941 inches)
Limit: 49.80 mm (1.960 inches)

VALVE SEAT RECONDITIONING PROCEDURE

1. Before correcting the valve seat, check for clearance

between the valve guide and valve and, if necessary,
replace the valve guide.

2. Using the seat grinder, correct to obtain the specified seat

width and angle.

3. After correcting the valve seat, lap the valve and valve seat

using lapping compound. Then, check the valve stem
projection.

AKX00441

OUT OF
SQUARE

FREE
HEIGHT

AB

AKX00565

VALVE
GUIDE

GUIDE ID

STEM OD

AB

AKX00536

VALVE STEM END

VALVE STEM
PROJECTION

SPRING SEATING
SURFACE

AB

AKX00569

43.5˚ - 44˚

0.9 - 1.3 mm
(0.04 - 0.05 in)

65˚

30˚

AB

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-36

VALVE SEAT REPLACEMENT PROCEDURE

1. Cut the valve seat from the inside to thin the wall thickness.

Then, remove the valve seat.

2. Rebore the valve seat hole in the cylinder head to a selected

oversize valve seat diameter.

Intake seat ring hole diameters

0.3 O.S. 34.30

−−−−

34.33 mm (1.3504

−−−−

1.3515 inches)

0.6 O.S. 34.60

−−−−

34.63 mm (1.3622

−−−−

1.3633 inches)

Exhaust seat ring hole diameters

0.3 O.S. 31.80

−−−−

31.83 mm (1.2520

−−−−

1.2531 inches)

0.6 O.S. 32.10

−−−−

32.13 mm (1.2638

−−−−

1.2649 inches)

3. Before fitting the valve seat, either heat the cylinder head up

to approximately 250

°

C (482

°

F) or cool the valve seat in

liquid nitrogen, to prevent the cylinder head bore from
galling.

4. Using a valve seat cutter, correct the valve seat to the

specified width and angle.
See "VALVE SEAT RECONDITIONING PROCEDURE" on
the previous page.

VALVE GUIDE REPLACEMENT PROCEDURE

1. Using a press, remove the valve guide toward the cylinder

block.

CAUTION

Do not install a valve guide of the same size again.
2. Rebore the valve guide hole of the cylinder head so that it

fits the press-fitted oversize valve guide.

Valve guide hole diameters

0.05 O.S. 11.05

−−−−

11.07 mm (0.4350

−−−−

0.4358 inch)

0.25 O.S. 11.25

−−−−

11.27 mm (0.4430

−−−−

0.4436 inch)

0.50 O.S. 11.50

−−−−

11.52 mm (0.4528

−−−−

0.4535 inch)

3. Press-fit the valve guide until it protrudes 14 mm (0.6 inch)

from the cylinder head top surface as shown in the
illustration.

NOTE: When press-fitting the valve guide, work from the
cylinder head top surface.

NOTE: Pay attention to the difference in length of the valve
guides. [Intake side: 45.5 mm (1.79 inch); exhaust side: 50.5
mm (1.99 inch)]

NOTE: After installing the valve guides, insert new valves in
them to check for smooth operation.

AKX00444

0.5 - 1.0 mm (0.02 - 0.03 in)

CUT AWAY

0.5 - 1.0 mm
(0.02 - 0.03 in)

AB

AKX00445

HEIGHT OF
SEAT RING

OVERSIZE ID

AB

AKX00571

REMOVAL

INSTALLATION

PRESS

PRESS

PUSHROD

PUSHROD

VALVE
GUIDE

VALVE
GUIDE

AB

AKX00597

14mm
(0.6 in)

AB