Mitsubishi Galant 9G. Manual — part 591
CYLINDER HEAD AND VALVES
TSB Revision
ENGINE OVERHAUL <2.4L ENGINE>
11B-36
>>B<< VALVE SPRING INSTALLATION
Install the valve spring with its identification color painted end
(larger pitch side) upward (toward the valve spring retainer).
Identification:
<Intake> Light blue
<Exhaust> Orange
.
>>C<< RETAINER LOCK INSTALLATION
CAUTION
Do not compress the valve spring excessively. It can dam-
age the stem seal.
1. Set special tool MD998735 as illustrated to compress the
valve spring. Install the retainer locks.
2. Relieve the spring tension. Check that the retainer locks are
seated correctly.
.
>>D<< CYLINDER HEAD BOLT INSTALLATION
1. When the removed cylinder head bolts are to be reused,
check that the shank length of each bolt meets the limit. If it
exceeds the limit, replace the bolts.
Limit: 99.4 mm (3.91 inches)
2. Apply engine oil to the thread of the bolts and to the
washers.
AK300717
PAINTED END
AD
AK300163
MD998735
AC
AK300591AE
SHANK LENGTH
CYLINDER HEAD AND VALVES
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ENGINE OVERHAUL <2.4L ENGINE>
11B-37
3. Using special tool MB991654 tighten the bolts to the
specified torque, using the tightening sequence shown.
Tightening torque: 78
± 2 N⋅m (58 ± 2 ft-lb)
4. Loosen all bolts fully in the reverse order of tightening.
5. Retighten the loosened bolts to the specified torque in the
tightening sequence shown.
Tightening torque: 20
± 2 N⋅m (15 ± 1 ft-lb)
6. Make a paint mark across each bolt head and cylinder head.
7. Tighten the cylinder head bolts 90 degrees in the specified
order.
CAUTION
• If the bolt is turned less than 90 degrees, proper fasten-
ing performance may not be achieved. Be careful to
turn each bolt exactly 90 degrees.
• If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening proce-
dure from step 1.
8. Tighten the bolts another 90 degrees in the same order as in
step 7, and check that the paint marks on the cylinder head
bolt are aligned with the paint marks on the cylinder head.
INSPECTION
M1113007000431
.
CYLINDER HEAD
1. Check the cylinder head gasket surface for flatness by using
a straight edge and feeler gauge.
Standard value: 0.03 mm (0.001 inch)
Limit: 0.2 mm (0.007 inch)
2. If it exceeds the limit, correct to meet specification.
Grinding limit: *0.2 mm (0.007 inch)
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
120 mm (4.7 inches)
.
AK300165
MB991654
AC
AK301394AC
4
2
5
7
10
6
1
3
9
8
TIMING BELT SIDE
AK300166
90˚
90˚
PAINT MARK
AC
AK300167
CYLINDER HEAD AND VALVES
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ENGINE OVERHAUL <2.4L ENGINE>
11B-38
VALVE
1. Check the valve seat contact. Valve seat contact should be
uniform at the center of the valve face. If incorrect, reface
using a valve refacer.
2. If the margin is below the limit, replace the valve.
Standard value:
<Intake> 1.0 mm (0.03 inch)
<Exhaust> 1.2 mm (0.04 inch)
Minimum limit:
<Intake> 0.5 mm (0.02 inch)
<Exhaust> 1.0 mm (0.03 inch)
3. Measure the valve's total length. If the measurement is less
than the limit, replace the valve.
Standard value:
<Intake> 111.33 mm (4.383 inches)
<Exhaust> 113.54 mm (4.470 inches)
Minimum limit:
<Intake> 110.83 mm (4.363 inches)
<Exhaust> 113.04 mm (4.450 inches)
.
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)
.
AK300593AD
MARGIN
CONTACT
(SHOULD BE AT
CENTER OF FACE)
AK103808AD
TOTAL LENGTH
AK300718AD
OUT OF SQUARE
FREE HEIGHT
AK300168
GUIDE INSIDE DIAMETER
STEM DIAMETER
VALVE
GUIDE
AC
CYLINDER HEAD AND VALVES
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ENGINE OVERHAUL <2.4L ENGINE>
11B-39
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.
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)
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)
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
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