Mitsubishi Galant (2004+). Manual — part 612
SPECIFICATIONS
TSB Revision
ENGINE OVERHAUL <3.8L ENGINE>
11D-65
Intake oversize rework
dimensions of valve
seat hole mm (in)
0.3 oversize
diameter
37.80
− 37.83 (1.4881 − 1.4894) −
0.6 oversize
diameter
38.10
− 38.13 (1.5000 − 1.5012) −
Exhaust oversize rework
dimensions of valve
seat hole mm (in)
0.3 oversize
diameter
34.80
− 34.83 (1.3701 − 1.3713) −
0.6 oversize
diameter
35.10
− 35.13 (1.3819 − 1.3831) −
Oil pan and oil pump
Oil pump tip clearance mm (in)
0.06
− 0.18 (0.003 − 0.007)
−
Oil pump side clearance mm (in)
0.04
− 0.10 (0.002 − 0.003)
−
Oil pump body clearance mm (in)
0.10
− 0.18 (0.004 − 0.007)
0.35 (0.013)
Oil pressure at curb idle speed kPa (psi)
[oil temperature is 75 to 90
°C (167 to 194°F)]
80 (11.6) or more
−
Piston and connecting rod
Piston outside diameter mm (in)
95.0 (3.74)
−
Piston ring to ring
groove clearance mm
(in)
No.1
0.03
− 0.07 (0.0012 − 0.0027)
0.1 (0.003)
No.2
0.02
− 0.06 (0.0008 − 0.0023)
0.1 (0.003)
Piston ring end gap mm
(in)
No.1
0.25
− 0.45 (0.010 − 0.017)
0.8 (0.03)
No.2
0.35
− 0.50 (0.014 − 0.019)
0.8 (0.03)
Oil ring side rail
0.10
− 0.35 (0.003 − 0.014)
1.0 (0.03)
Piston pin outside diameter mm (in)
22.0 (0.87)
−
Crankshaft pin oil clearance mm (in)
0.02
− 0.05 (0.0008 − 0.0019)
0.1 (0.003)
Connecting rod big end side clearance mm
(in)
0.10
− 0.25 (0.003 − 0.009)
−
Crankshaft and drive plate
Crankshaft end play mm (in)
0.05
− 0.25 (0.002 − 0.009)
0.3 (0.01)
Crankshaft journal outside diameter mm (in)
64 (2.520)
−
Crankshaft pin outside diameter mm (in)
55 (2.165)
−
Crankshaft journal oil
clearance mm (in)
No.1, 4
0.02
− 0.03 (0.0008 − 0.0012)
0.1(0.003)
No.2, 3
0.03
− 0.04 (0.0012 − 0.0016)
0.1(0.003)
Piston to cylinder clearance mm (in)
0.02
− 0.04 (0.0008 − 0.0016)
−
Cylinder block flatness of gasket surface
mm (in)
0.05 (0.02)
0.1 (0.003)
Cylinder block grinding limit of gasket surface
mm (in) total resurfacing depth of both
cylinder head and cylinder block
−
0.2 (0.008)
ITEMS
STANDARD VALUE
LIMIT
SPECIFICATIONS
TSB Revision
ENGINE OVERHAUL <3.8L ENGINE>
11D-66
SEALANTS
M1113000500350
Cylinder block overall height mm (in)
[upper plane of cylinder block from crankshaft
center]
227.9
− 228.1 (8.972 − 8.980)
−
Cylinder bore inside diameter mm (in)
95.0 (3.74)
−
Cylindricity mm (in)
0.01 (0.0003)
−
ITEMS
STANDARD VALUE
LIMIT
ITEMS
SPECIFIED SEALANT
QUANTITY
Camshaft position sensor support
MITSUBISHI genuine part No. MD970389 or
equivalent
As required
Engine coolant temperature sensor
3M
AAD Part No. 8731 or equivalent
As required
Engine oil pressure switch
3M
AAD Part No. 8672 or equivalent
As required
Oil pump case
MITSUBISHI genuine part No. MD970389 or
equivalent
As required
Oil pan
MITSUBISHI genuine part No. MD970389 or
equivalent
As required
Oil seal case
MITSUBISHI genuine part No. MD970389 or
equivalent
As required
23A-1
GROUP 23A
AUTOMATIC
TRANSAXLE
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .
AUTOMATIC TRANSAXLE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLESHOOTING
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION TO A/T DIAGNOSIS . . . .
A/T DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC FUNCTION . . . . . . . . . . . . .
FAIL-SAFE/BACKUP FUNCTION. . . . . . . .
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER STALL TEST . . . .
HYDRAULIC PRESSURE TESTS . . . . . . .
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . .
LINE PRESSURE ADJUSTMENT . . . . . . .
DIAGNOSTIC TROUBLE CODE CHART . .
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLE CODE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . .
SYMPTOM PROCEDURES . . . . . . . . . . . .
DATA LIST REFERENCE TABLE. . . . . . . .
ACTUATOR TEST REFERENCE TABLE . .
INVECS-II CANCEL COMMAND. . . . . . . . .
PCM TERMINAL VOLTAGE REFERENCE
CHART FOR TRANSAXLE OPERATION . .
PCM TERMINAL RESISTANCE AND
CONTINUITY INSPECTION CHART . . . . .
INSPECTION PROCEDURE USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . .
A/T FAULTY OPERATION PREVENTION
MECHANISM DIAGNOSIS . . . . . . . . .
INTRODUCTION TO A/T KEY INTERLOCK
AND SHIFT LOCK MECHANISMS . . . . . . .
A/T KEY INTERLOCK AND SHIFT LOCK
MECHANISMS DIAGNOSTIC TROUBLESHOOTING
STRATEGY . . . . . . . . . . . . . . . . . . . . . . . . .
SYMPTOM CHART . . . . . . . . . . . . . . . . . . .
SYMPTOM PROCEDURES . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
•
Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
passenger (from rendering the SRS inoperative).
•
Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS air bag control unit, SRS warning light, front impact sensors, air bag module,
clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection
with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).
23A-2
ON-VEHICLE SERVICE. . . . . . . . . . .
A/T CONTROL COMPONENT LAYOUT . .
ESSENTIAL SERVICE . . . . . . . . . . . . . . . .
TRANSMISSION FLUID CHECK . . . . . . . .
TRANSMISSION FLUID CHANGE . . . . . . .
FLUSHING COOLERS AND TUBES . . . . .
OIL COOLER FLOW CHECK . . . . . . . . . . .
TRANSMISSION RANGE SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION RANGE SWITCH AND
CONTROL CABLE ADJUSTMENT. . . . . . .
AUTOMATIC TRANSAXLE CONTROL
COMPONENT CHECK . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION FLUID TEMPERATURE
SENSOR CHECK . . . . . . . . . . . . . . . . . . . .
TRANSMISSION RANGE SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPLIGHT SWITCH CHECK . . . . . . . . . .
A/T CONTROL RELAY CHECK . . . . . . . . .
SOLENOID VALVE CHECK . . . . . . . . . . . .
SELECTOR LEVER OPERATION CHECK
KEY INTERLOCK AND SHIFT LOCK
MECHANISM CHECK. . . . . . . . . . . . . . . . .
TRANSAXLE CONTROL
CABLE ADJUSTMENT . . . . . . . . . . . . . . . .
TRANSAXLE CONTROL* . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
A/T KEY INTERLOCK AND SHIFT
LOCK MECHANISMS* . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
TRANSAXLE ASSEMBLY . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
TRANSMISSION FLUID COOLER,
HOSE AND PIPE . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . .
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS . . . . . . . . . . .
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