Mitsubishi Galant (2004+). Manual — part 587

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-37

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

limit, replace.

Standard value:

<Intake> 54.8 mm (2.16 inches)
<Exhaust> 56.1 mm (2.21 inches)

Minimum limit:

<Intake> 53.8 mm (2.12 inches)
<Exhaust> 55.1 mm (2.17 inches)

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

replace.

Standard value: 2 degrees or less
Limit: 4 degrees

.

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

− 0.04 mm (0.0008 − 0.0016 inch)

<Exhaust> 0.04

− 0.06 mm (0.0016 − 0.0024 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 sur-
face. If the measurement exceeds the specified limit, replace
the valve seat.

Standard value:

<Intake> 48.33 mm (1.902 inches)
<Exhaust> 48.34 mm (1.903 inches)

Limit:

<Intake> 48.83 mm (1.922 inches)
<Exhaust> 48.84 mm (1.923 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.

AK300718AD

OUT OF SQUARE

FREE HEIGHT

AK300168

GUIDE INSIDE DIAMETER

STEM DIAMETER

VALVE
GUIDE

AC

AK300596

VALVE STEM
PROJECTION

SPRING
SEATING
SURFACE

AD

VALVE STEM
END

AK300385AD

INTAKE SIDE

EXHAUST SIDE

43.5˚ – 44˚

20˚

10˚

65˚

65˚

0.9 – 1.3 mm
(0.04 – 0.05 in)

0.9 – 1.3 mm
(0.04 – 0.05 in)

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-38

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 oversize:

35.30

− 35.33 mm (1.3898 − 1.3909 inches)

0.6 oversize:

35.60

− 35.63 mm (1.4016 − 1.4028 inches)

Exhaust seat ring hole diameters

0.3 oversize:

33.30

− 33.33 mm (1.3110 − 1.3122 inches)

0.6 oversize:

33.60

− 33.63 mm (1.3228 − 1.3240 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 oversize 11.05

− 11.07 mm (0.4350 − 0.4358 inch)

0.25 oversize 11.25

− 11.27 mm (0.4429 − 0.4437 inch)

0.50 oversize 11.50

− 11.52 mm (0.4528 − 0.4535 inch)

AK300719AD

CUT

0.5 – 1 mm
(0.02 – 0.04 in)

0.5 – 1 mm
(0.02 – 0.04 in)

AK300720AD

OVERSIZE HOLE
DIAMETER

VALVE SEAT
HEIGHT

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-39

3. Press-fit the valve guide until it protrudes 14.0 mm (0.55

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 inches); exhaust side:
50.5 mm (1.99 inches)]
NOTE: After installing the valve guides, insert new valves in
them to check for smooth operation.

AK301399AC

14.0 mm
(0.55 in)

OIL PAN AND OIL PUMP

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-40

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

M1113008100431

AK303217

8

9

10

11

12

13

15

16

17

18

19

20

21

22

23

24

25

26

29

27

28

36 ± 3 N·m
27 ± 1 ft-lb

10 ± 2 N·m
89 ± 17 in-lb

19 ± 3 N·m
14 ± 2 ft-lb

23 ± 3 N·m
17 ± 2 ft-lb

17 ± 1 N·m
12 ± 1 ft-lb

44 ± 5 N·m
33 ± 3 ft-lb

23 ± 3 N·m
17 ± 2 ft-lb

14

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

2

4

5

6

7

9.0 ± 2.0 N·m
80 ± 17 in-lb

22 ± 4 N·m
17 ± 2 ft-lb

9.0 ± 3.0 N·m
80 ± 26 in-lb

19 ± 3 N·m
14 ± 2 ft-lb

39 ± 5 N·m
29 ± 3 ft-lb

1

3

AB

REMOVAL STEPS

1. DRAIN PLUG

>>M<<

2. DRAIN PLUG GASKET

>>L<<

3. OIL FILTER

<<A>> >>K<<

4. OIL PAN
5. BAFFLE PLATE
6. OIL SCREEN
7. OIL SCREEN GASKET
8. RELIEF PLUG
9. GASKET
10.RELIEF SPRING
11.RELIEF PLUNGER

>>J<<

12.OIL FILTER BRACKET
13.OIL FILTER BRACKET GASKET

<<B>> >>I<<

14.PLUG
15.O-RING

<<C>> >>H<<

16.FLANGE BOLT
17.FRONT CASE

18.FRONT CASE GASKET
19.OIL PUMP COVER

>>G<<

20.OIL PUMP DRIVEN GEAR

>>G<<

21.OIL PUMP DRIVE GEAR

>>F<<

22.CRANKSHAFT FRONT OIL SEAL

>>E<<

23.OIL PUMP OIL SEAL

>>D<<

24.COUNTERBALANCE SHAFT OIL

SEAL

25.COUNTERBALANCE SHAFT, LEFT
26.COUNTERBALANCE SHAFT, RIGHT

<<D>> >>C<<

27.COUNTERBALANCE SHAFT, FRONT

BEARING

<<E>> >>B<<

28.COUNTERBALANCE SHAFT, REAR

BEARING, RIGHT

<<E>> >>A<<

29.COUNTERBALANCE SHAFT, REAR

BEARING, LEFT

REMOVAL STEPS (Continued)