Mitsubishi Galant 9G. Manual — part 615

CRANKSHAFT AND CYLINDER BLOCK

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ENGINE OVERHAUL <3.8L ENGINE>

11D-58

3. Cut plastic gauging material to the same length as the width

of the bearing and place it on the journal in parallel with its
axis.

4. Install the crankshaft bearing cap carefully and tighten the

bolts to the specified torque.

Tightening torque: 74

± 4 N⋅m (54 ± 3 ft-lb)

5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastic gauging material

at its widest section by using a scale printed on the plastic
gauging material bag.

Standard value:

0.02

− 0.03 mm (0.0008 − 0.0012 inch) <No.1, 4>

0.03

− 0.04 mm (0.0012 − 0.0016 inch) <No.2, 3>

Limit: 0.1 mm (0.003 inch)

.

CRANKSHAFT REAR OIL SEAL

1. Check the oil seal lip for wear and damage.
2. Check the rubber for deterioration or hardening.
3. Check the oil seal case for cracks and damage.

.

CYLINDER BLOCK

1. Visually check for scratches, rust, and corrosion. Use a flaw

detecting agent for the check. If defects are evident, correct
or replace.

2. Using a straightedge and feeler gauge, check the block top

surface for warpage. Make sure that the surface is free from
gasket chips and other foreign matter.

Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 inch)

3. If the distortion is excessive, correct within the allowable

limit or replace.

Grinding limit: *0.2 mm (0.008 inch)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):

227.9

− 228.1 mm (8.972 − 8.980 inches)

AK101043AB

PLASTIC
GAUGING
MATERIAL

AK201526

AKX00738

CRANKSHAFT AND CYLINDER BLOCK

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ENGINE OVERHAUL <3.8L ENGINE>

11D-59

4. Check the cylinder walls for scratches and seizure. If defects

are evident, correct (bored to an oversize) or replace.

5. Using a cylinder gauge, measure the cylinder bore and

cylindricality. If worn badly, correct by boring the cylinders to
an oversize and replace pistons and piston rings. Measure
at the points shown in the illustration.

Standard value:

Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)

.

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 of the piston to be used.

Measure it in the thrust direction as shown.

3. Based on the measured piston Outside Diameter (OD),

calculate the boring finish dimension.

Boring finish dimension = Piston OD + (clearance
between piston OD and cylinder)

− 0.02 mm (0.0008

inch) (honing margin)

CAUTION

To prevent distortion that may result from temperature rise
during honing, bore cylinders in the order of number 2,
number 4, number 6, number 1, number 3 and number 5.
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).

Standard value:

Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)

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 six cylinders to the
same oversize. Do not bore only one cylinder to an oversize.

AKX00739AB

12 mm (0.47 in)

BOTTOM

CENTER

SIZE

IDENTIFICATION MARK

0.25 mm (0.010 in) Oversize
diameter

0.25

0.50 mm (0.020 in) Oversize
diameter

0.50

AKX00740

PISTON OUTSIDE
DIAMETER

THRUST
DIRECTION

AB

SPECIFICATIONS

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ENGINE OVERHAUL <3.8L ENGINE>

11D-60

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1113023400688

ITEMS

SPECIFICATIONS

Generator and drive belt
Adjusting bolt

5.0

± 1.0 N⋅m (44 ± 9 in-lb)

Crankshaft bolt

185

± 5 N⋅m (137 ± 3 ft-lb)

Drive belt tensioner nut

49

± 9 N⋅m (37 ± 6 ft-lb)

Generator bolt

49

± 9 N⋅m (37 ± 6 ft-lb)

Generator bracket bolt

49

± 9 N⋅m (37 ± 6 ft-lb)

Idler pulley nut

49

± 9 N⋅m (37 ± 6 ft-lb)

Oil dipstick guide bolt

14

± 1 N⋅m (122 ± 9 in-lb)

Power steering pump bracket bolt

41

± 8 N⋅m (30 ± 6 ft-lb)

Power steering pump bracket stay bolt M8

24

± 4 N⋅m (18 ± 3 ft-lb)

Power steering pump bracket stay bolt M10

44

± 10 N⋅m (33 ± 7 ft-lb)

Tensioner bracket bolt (Flange bolt)

49

± 9 N⋅m (37 ± 6 ft-lb)

Tensioner bracket bolt (Bolt, washer assembly)

41

± 8 N⋅m (30 ± 6 ft-lb)

Intake manifold plenum and throttle body
Boost sensor bolt

5.0

± 1.0 N⋅m (44 ± 9 in-lb)

Exhaust gas recirculation pipe bolt

19

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust gas recirculation pipe nut

19

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust gas recirculation pipe flare nut

59

± 10 N⋅m (43 ± 7 ft-lb)

Exhaust gas recirculation valve bolt

24

± 3 N⋅m (18 ± 2 ft-lb)

Intake manifold plenum bolt

28

± 4 N⋅m (21 ± 3 ft-lb)

Intake manifold plenum stay bolt M8

18

± 2 N⋅m (13 ± 1 ft-lb)

Intake manifold plenum stay bolt M10

36

± 6 N⋅m (27 ± 4 ft-lb)

Solenoid valve bolt

9.0

± 1.0 N⋅m (80 ± 9 in-lb)

Throttle body bolt

28

± 4 N⋅m (21 ± 3 ft-lb)

Throttle body stay bolt

18

± 2 N⋅m (13 ± 1 ft-lb)

Vacuum pipe and hose bolt

9.0

± 1.0 N⋅m (80 ± 9 in-lb)

Ignition system
Ignition coil bolt

10

± 2 N⋅m (87 ± 17 in-lb)

Spark plugs

25

± 5 N⋅m (18 ± 4 ft-lb)

Camshaft position sensor bolt

11

± 1 N⋅m (95 ± 9 in-lb)

Camshaft position sensor support bolt

14

± 1 N⋅m (122 ± 9 in-lb)

Camshaft position sensing cylinder bolt

22

± 4 N⋅m (16 ± 3 ft-lb)

Timing belt
Adjusting bolt

5.0

± 1.0 N⋅m (44 ± 9 in-lb)

Auto-tensioner bolt

23

± 3 N⋅m (18 ± 2 ft-lb)

Bracket bolt

24

± 3 N⋅m (18 ± 2 ft-lb)

Camshaft sprocket bolt

88

± 10 N⋅m (65 ± 7 ft-lb)

Crankshaft position sensor bolt

8.5

± 0.5 N⋅m (76 ± 4 in-lb)

SPECIFICATIONS

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ENGINE OVERHAUL <3.8L ENGINE>

11D-61

Engine support bracket bolt

45

± 5 N⋅m (34 ± 4 ft-lb)

Idler pulley bolt

44

± 5 N⋅m (33 ± 4 ft-lb)

Tensioner pulley bolt

48

± 6 N⋅m (35 ± 4 ft-lb)

Tensioner arm bolt

44

± 10 N⋅m (33 ± 7 ft-lb)

Timing belt front cover bolt M6

11

± 1 N⋅m (95 ± 9 in-lb)

Timing belt front cover bolt M8, M10

14

± 1 N⋅m (122 ± 9 in-lb)

Timing belt rear cover bolt

14

± 1 N⋅m (122 ± 9 in-lb)

Intake manifold and fuel parts
Injector and fuel rail bolt

12

± 1 N⋅m (104 ± 9 in-lb)

Intake manifold nut

20

− 23 N⋅m (15 − 17 ft-lb)

Water pump and water pipes
Engine coolant temperature sensor

29

± 10 N⋅m (22 ± 7 ft-lb)

Thermostat housing bolt M6

11

± 1 N⋅m (95 ± 9 in-lb)

Thermostat housing bolt M8

19

± 1 N⋅m (14 ± 1 ft-lb)

Water inlet fitting bolt

19

± 1 N⋅m (14 ± 1 ft-lb)

Water pump bolt M8

24

± 3 N⋅ (17 ± 2 ft-lb)

Water pump bolt M10

42

± 8 N⋅m (31 ± 6 ft-lb)

Exhaust manifold
Connector bracket bolt

11

± 1 N⋅m (95 ± 9 in-lb)

Engine hanger bolt

35

± 6 N⋅m (26 ± 4 ft-lb)

Exhaust manifold nut

44

± 5 N⋅m (33 ± 4 ft-lb)

Exhaust manifold stay bolt M8

19

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust manifold stay bolt M10

44

± 8 N⋅m (33 ± 5 ft-lb)

Exhaust manifold stay bolt M12

75

± 10 N⋅m (56 ± 7 ft-lb)

Heat protector bolt

14

± 1 N⋅m (122 ± 9 in-lb)

Heated oxygen sensor

44

± 5 N⋅m (33 ± 4 ft-lb)

Rocker arms and camshaft
Thrust case bolt

13

± 2 N⋅m (115 ± 17 in-lb)

Positive crankcase ventilation valve

10

± 2 N⋅m (87 ± 17 in-lb)

Rocker arms and shaft bolt

31

± 3 N⋅m (23 ± 2 ft-lb)

Rocker cover bolt

3.5

± 0.5 N⋅m (31 ± 4 in-lb)

Cylinder head and valve
Cylinder head bolt

108

± 5 N⋅m (80 ± 4 ft-lb) → 0 N⋅m (0 in-lb)

→ 108 ± 5 N⋅m (80 ± 4 ft-lb)

Oil pan and oil pump
Baffle plate bolt

9.0

± 2.0 N⋅m (80 ± 17 in-lb)

Cover bolt

10.8

± 0.9 N⋅m (96 ± 7 in-lb)

Drain plug

39

± 5 N⋅m (29 ± 4 ft-lb)

Engine oil pressure switch

10

± 2 N⋅m (87 ± 17 in-lb)

Oil filter bracket bolt M8

23

± 3 N⋅m (18 ± 2 ft-lb)

ITEMS

SPECIFICATIONS