Mitsubishi Galant. Manual — part 45
SPECIFICATIONS
TSB Revision
ENGINE OVERHAUL <2.4L>
11B-61
BORING CYLINDER
1. Oversize pistons to be used should be determined on the
basis of the largest bore cylinder.
Piston size identification
NOTE: Size mark is stamped on the piston top.
2. Measure the outside diameter (OD) of the piston to be used.
Measure it in thrust direction as shown.
3. Based on the measured piston OD, calculate the boring
finish dimension.
Boring finish dimension = Piston OD +
(clearance between piston OD and cylinder)
−−−−
0.02 mm (.0008 inch) (honing margin)
CAUTION
To prevent distortion that may result from temperature rise
during honing, bore cylinders, working from number 2 to
number 4 to number 1 to number 3.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance
between piston OD and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.02
−−−−
0.04 mm (0.0008
−−−−
0.0015 inch)
NOTE: When boring cylinders, finish all of four cylinders to
the same oversize. Do not bore only one cylinder to an
oversize.
SPECIFIC ATIO NS
FASTENER TIGHTENING SPECIFICATIONS
M1113023400097
SIZE
IDENTIFICATION MARK
0.50 mm (0.02 in) oversize
diameter
50
1.00 mm (0.04 in) oversize
diameter
100
AKX00458
THRUST
DIRECTION
PISTON OD
AB
ITEMS
SPECIFICATIONS
Generator and drive belt
Adjusting bolt
5 N
⋅
m (43 in-lb)
Adjusting nut lock bolt
23 N
⋅
m (17 ft-lb)
Camshaft position sensing cylinder bolt
22 N
⋅
m (16 ft-lb)
Camshaft position sensor bolt
8.8 N
⋅
m (78 in-lb)
Camshaft position sensor support bolt
14 N
⋅
m (122 in-lb)
Crankshaft pulley bolt
25 N
⋅
m (18 ft-lb)
Generator brace bolt
24 N
⋅
m (17 ft-lb)
Generator pivot bolt nut
44 N
⋅
m (33 ft-lb)
SPECIFICATIONS
TSB Revision
ENGINE OVERHAUL <2.4L>
11B-62
Ignition coil bolt
10 N
⋅
m (87 in-lb)
Ignition failure sensor
10 N
⋅
m (87 in-lb)
Spark plugs
25 N
⋅
m (18 ft-lb)
Water pump pulley bolt
8.8 N
⋅
m (78 in-lb)
Timing belt
Auto tensioner bolt
24 N
⋅
m (17 ft-lb)
Camshaft sprocket bolt
88 N
⋅
m (65 ft-lb)
Counterbalance shaft sprocket bolt
45 N
⋅
m (33 ft-lb)
Crankshaft bolt
118 N
⋅
m (87 ft-lb)
Crankshaft position sensor bolt
8.8 N
⋅
m (78 in-lb)
Engine support bracket bolt and nut
49 N
⋅
m (36 ft-lb)
Idler pulley bolt
44 N
⋅
m (33 ft-lb)
Oil pump sprocket nut
35 N
⋅
m (26 ft-lb)
Power steering pump bolt
49 N
⋅
m (36 ft-lb)
Tensioner arm bolt
22 N
⋅
m (16 ft-lb)
Tensioner B bolt
19 N
⋅
m (14 ft-lb)
Tensioner pulley bolt
48 N
⋅
m (35 ft-lb)
Timing belt cover flange bolt M6
11 N
⋅
m (95 in-lb)
Timing belt cover flange bolt M8
14 N
⋅
m (122 in-lb)
Timing belt cover washer assembled bolt M6
8.8 N
⋅
m (78 in-lb)
Fuel and emission control parts
EGR valve bolt
19 N
⋅
m (14 ft-lb)
Fuel pressure regulator bolt
8.8 N
⋅
m (78 in-lb)
Injectors and fuel rail
12 N
⋅
m (104 in-lb)
Throttle body bolt
19 N
⋅
m (14 ft-lb)
Throttle body stay bolt
19 N
⋅
m (14 ft-lb)
Water pump and intake manifold
Engine coolant temperature gauge unit
11 N
⋅
m (95 in-lb)
Engine coolant temperature sensor
29 N
⋅
m (22 ft-lb)
Engine hanger
19 N
⋅
m (14 ft-lb)
Intake manifold plenum bolt and nut
20 N
⋅
m (14 ft-lb)
Intake manifold plenum stay M8
21 N
⋅
m (15 ft-lb)
Intake manifold plenum stay M10
30 N
⋅
m (22 ft-lb)
Manifold differential pressure sensor
4.9 N
⋅
m (43 in-lb)
Oil dipstick guide bolt
14 N
⋅
m (122 in-lb)
Thermostat housing bolt
24 N
⋅
m (17 ft-lb)
Water inlet fitting bolt
13 N
⋅
m (113 in-lb)
Water inlet pipe bolt
13 N
⋅
m (113 in-lb)
Water pump bolt
14 N
⋅
m (122 in-lb)
Exhaust manifold
ITEMS
SPECIFICATIONS
SPECIFICATIONS
TSB Revision
ENGINE OVERHAUL <2.4L>
11B-63
GENERAL SPECIFICATIONS
M1113000200100
Exhaust manifold bracket bolt
35 N
⋅
m (26 ft-lb)
Exhaust manifold cover bolt
14 N
⋅
m (122 in-lb)
Bracket
35 N
⋅
m (26 ft-lb)
Exhaust manifold nut M8
29 N
⋅
m (22 ft-lb)
Exhaust manifold nut M10
49 N
⋅
m (36 ft-lb)
Oxygen sensor
44 N
⋅
m (32 ft-lb)
Water outlet fitting bolt
13 N
⋅
m (113 in-lb)
Rocker arms and camshaft
Rocker cover bolt
3.5 N
⋅
m (30 in-lb)
Rocker arm shaft bolt
31 N
⋅
m (23 ft-lb)
Cylinder head and valve
Cylinder head bolt [Tighten to 78 N
⋅
m (58 ft-lb) and then completely
before tightening to final torque specification]
25 N
⋅
m (14 ft-lb) + 90
°
+ 90
°
Front case, counterbalance shaft and oil pan
Drain plug
39 N
⋅
m (29 ft-lb)
Flange bolt
36 N
⋅
m (27 ft-lb)
Front case bolt
24 N
⋅
m (17 ft-lb)
Oil filter part number MD36093514 N
⋅
m (122 in-lb)
Oil filter other than MITSUBISHI genuine filter
17 N
⋅
m (13 ft-lb)
Oil filter bracket bolt
19 N
⋅
m (14 ft-lb)
Oil pan bolt
6.9 N
⋅
m (61 in-lb)
Oil pressure switch
11 N
⋅
m (95 in-lb)
Oil pump cover bolt
17 N
⋅
m (12 ft-lb)
Oil pump cover screw
9.8 N
⋅
m (87 in-lb)
Oil screen bolt
19 N
⋅
m (14 ft-lb)
Plug
24 N
⋅
m (17 ft-lb)
Relief plug
44 N
⋅
m (33 ft-lb)
Piston and connecting rod
Connecting rod cap nut
20 N
⋅
m (14 ft-lb) + 90
°τ
o 94
°
Crankshaft and cylinder block
Bearing cap bolt
25 N
⋅
m (18 ft-lb) + 90
°
Bell housing cover
8.8 N
⋅
m (78 in-lb)
Drive plate bolt
132 N
⋅
m (98 ft-lb)
Oil seal case bolt
11 N
⋅
m (95 in-lb)
Rear plate bolt
11 N
⋅
m (95
•
9 in-lb)
ITEMS
SPECIFICATIONS
DESCRIPTIONS
SPECIFICATIONS
Type
In-line OHV, SOHC
Number of cylinders
4
Combustion chamber
Pentroof type
SPECIFICATIONS
TSB Revision
ENGINE OVERHAUL <2.4L>
11B-64
SERVICE SPECIFICATIONS
M1113000300107
Total displacement dm
3
(cu in)
2,350 (143.4)
Cylinder bore (in)
86.5 (3.41)
Piston stroke mm (in)
100.0 (3.94)
Compression ratio
9.5
Valve timing
Intake valve
Opens (BTDC)
16
°
Closes (ABDC)
53
°
Exhaust valve
Opens (BBDC)
50
°
Closes (ATDC)
16
°
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Involute gear type
DESCRIPTIONS
SPECIFICATIONS
ITEM
STANDARD
VALUE
LIMIT
Timing belt
Auto-tensioner rod projection length mm (in)
12 (0.5)
-
Auto-tensioner rod pushed-in amount [When pushed with a
force of 98
−
196 N (22
−
44 lb)] mm (in)
1.0 (0.03) or less
-
Rocker arms and camshaft
Camshaft cam height mm (in)
Intake
37.39 (1.472)
Minimum 36.89
(1.452)
Exhaust
36.83 (1.450)
Minimum 36.33
(1.430)
Camshaft journal outside diameter mm (in)
45 (1.8)
-
Cylinder head and valves
Cylinder head flatness of gasket surface mm (in)
Less than 0.05
(0.002)
0.2 (0.007)
Cylinder head grinding limit of gasket surface mm (in) (Total
resurfacing depth of cylinder head and cylinder block)
-
0.2 (0.007)
Cylinder head overall height mm (in)
120 (4.7)
-
Cylinder head bolt shank length mm (in)
-
99.4 (3.91)
Valve thickness of valve head
(margin)
Intake
1.0 (0.03)
Minimum 0.5 (0.02)
Exhaust
1.2 (0.04)
Minimum 0.7 (0.03)
Valve overall height mm (in)
Intake
112.30 (4.421)
Minimum 111.80
(4.402)
Exhaust
114.11 (4.493)
Minimum 113.61
(4.473)
Valve stem outside diameter mm
(in)
Intake
6.0 (0.24)
-
Exhaust
5.9 (0.23)
-
Valve thickness to valve guide
clearance mm (in)
Intake
0.02
−
0.05
(0.0008
−
0.0019)
0.10 (0.003)
Exhaust
0.03
−
0.07
(0.0012
−
0.0027)
0.15 (0.005)
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