Mitsubishi Galant (2004+). Manual — part 596

11D-1

GROUP 11D

ENGINE OVERHAUL

<3.8L ENGINE>

CONTENTS

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11D-2

GENERATOR AND DRIVE BELT . . .

11D-4

REMOVAL AND INSTALLATION . . . . . . . .

11D-4

INTAKE MANIFOLD PLENUM AND
THROTTLE BODY ASSEMBLY . . . .

11D-6

REMOVAL AND INSTALLATION . . . . . . . .

11D-6

IGNITION SYSTEM . . . . . . . . . . . . . .

11D-9

REMOVAL AND INSTALLATION . . . . . . . .

11D-9

TIMING BELT. . . . . . . . . . . . . . . . . . .

11D-11

REMOVAL AND INSTALLATION . . . . . . . .

11D-11

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

11D-16

INTAKE MANIFOLD AND FUEL
PARTS . . . . . . . . . . . . . . . . . . . . . . . .

11D-18

REMOVAL AND INSTALLATION . . . . . . . .

11D-18

WATER PUMP & WATER HOSE . . .

11D-20

REMOVAL AND INSTALLATION . . . . . . . .

11D-20

EXHAUST MANIFOLD. . . . . . . . . . . .

11D-22

REMOVAL AND INSTALLATION . . . . . . . .

11D-22

ROCKER ARMS AND CAMSHAFT . .

11D-24

REMOVAL AND INSTALLATION . . . . . . . .

11D-24

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11D-27

CYLINDER HEAD AND VALVES. . . .

11D-30

REMOVAL AND INSTALLATION . . . . . . . .

11D-30

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11D-34

OIL PAN AND OIL PUMP. . . . . . . . . .

11D-38

REMOVAL AND INSTALLATION . . . . . . . .

11D-38

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11D-44

PISTON AND CONNECTING ROD . .

11D-45

REMOVAL AND INSTALLATION . . . . . . . .

11D-45

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11D-52

CRANKSHAFT AND CYLINDER
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .

11D-54

REMOVAL AND INSTALLATION . . . . . . . .

11D-54

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

11D-58

SPECIFICATIONS . . . . . . . . . . . . . . .

11D-61

FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .

11D-61

GENERAL SPECIFICATIONS . . . . . . . . . .

11D-63

SERVICE SPECIFICATIONS . . . . . . . . . . .

11D-63

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . .

11D-66

SPECIAL TOOLS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-2

SPECIAL TOOLS

M1113000600603

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MD998781
Flywheel stopper

General service tool

Loosening and tightening
crankshaft bolts

MB990767
End yoke holder
Use with MD998715

MB990767-01

Holding camshaft sprocket when
loosening or torquing bolt.

MD998715
Pin

MIT308239

MD998769
Crankshaft spacer

General service tool

Rotation of crankshaft when
installing piston and timing belt

MD998767
Tensioner wrench

MD998752-01

Adjustment of timing belt tension

MD998443
Lash adjuster holder
(8)

MD998443-01

Supporting of the lash adjuster to
prevent it from falling when rocker
shaft assembly is removed or
installed

MD998713
Camshaft oil seal
installer

MD998713-01

Installation of camshaft oil seal

MB991559
Camshaft oil seal
installer adaptor

MB991559-01

Installation of camshaft oil seal
(left bank)
(use with MD998713)

MD998442
Air bleed wire

General service tool

Air bleeding of auto lash adjuster

D998781

B990767

D998767

D998443

D998713

B991559

SPECIAL TOOLS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-3

MD998051
Cylinder head bolt
wrench

General service tool

Loosening and tightening cylinder
head bolts

MD998735
Valve spring
compressor

MD998735-01

Compression of valve spring

MD998772
Valve spring
compressor

MLR-MD998772 or
General service tool

Compression of valve spring

MD998774
Valve stem seal
installer

MD998774-01

Installation of valve stem seal

MD998717
Crankshaft front oil
seal installer

MD998717-01

Installation of crankshaft front oil
seal

MD998054
Oil pressure switch
wrench

General service tool or
MD998054-01

Removal and installation of engine
oil pressure switch

MD998718
Crankshaft rear oil seal
installer

MD998718-01

Installation of crankshaft rear oil
seal

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

GENERATOR AND DRIVE BELT

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-4

GENERATOR AND DRIVE BELT

REMOVAL AND INSTALLATION

M1113001300230

Required Special Tool:

• MD998781: Flywheel Stopper

AK203969AB

5

185 ± 5 N·m
137 ± 3 ft-lb

24 ± 4 N·m
18 ± 3 ft-lb

14 ± 1 N·m
122 ± 9 in-lb

44 ± 10 N·m
33 ± 7 ft-lb

49 ± 9 N·m
37 ± 6 ft-lb

49 ± 9 N·m
37 ± 6 ft-lb

7

8

9

2

3

6

1

4

14

10

13

12

11

15

16

49 ± 9 N·m
37 ± 6 ft-lb

49 ± 9 N·m
37 ± 6 ft-lb

41 ± 8 N·m
30 ± 6 ft-lb

41 ± 8 N·m
30 ± 6 ft-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

REMOVAL STEPS

1. IDLER PULLEY
2. ADJUSTING BOLT
3. ADJUSTING STUD
4. TENSIONER BRACKET
5. POWER STEERING PUMP

BRACKET

6. POWER STEERING PUMP

BRACKET STAY

7. DRIVE BELT TENSIONER

<<A>> >>A<<

8. CRANKSHAFT BOLT
9. CRANKSHAFT PULLEY WASHER
10. DAMPER PULLEY
11. GENERATOR
12. GENERATOR BRACKET
13. OIL DIPSTICK
14. O-RING
15. OIL DIPSTICK GUIDE
16. O-RING

REMOVAL STEPS (Continued)