Mitsubishi Galant 9G. Manual — part 616

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-62

GENERAL SPECIFICATIONS

M1113000200553

Oil filter bracket bolt M10

41

± 8 N⋅m (30 ± 6 ft-lb)

Oil filter bracket cover bolt

11

± 1 N⋅m (95 ± 9 in-lb)

Oil pan, lower bolt

11

± 1 N⋅m (95 ± 9 in-lb)

Oil pan, upper bolt

9.0

± 3.0 N⋅m (80 ± 26 in-lb)

Oil pump case bolt

14

± 1 N⋅m (122 ± 9 in-lb)

Oil pump cover bolt

10

± 2 N⋅m (87 ± 17 in-lb)

Oil screen bolt

19

± 3 N⋅m (14 ± 2 ft-lb)

Relief plug

44

± 5 N⋅m (33 ± 4 ft-lb)

Piston and connecting rod
Connecting rod cap nut

27

± 2 N⋅m (20 ± 1 ft-lb) + 90° to 94°

Crankshaft and cylinder block
Bearing cap bolt

74

± 4 N⋅m (54 ± 3 ft-lb)

Block heater bolt

2.6

± 0.2 N⋅m (23 ± 1 in-lb)

Flywheel or drive plate bolt

74

± 1 N⋅m (54 ± 1 ft-lb)

Knock sensor

23

± 2 N⋅m (17 ± 1 ft-lb)

Knock sensor bracket bolt

28

± 2 N⋅m (22 ± 1 ft-lb)

Oil seal case bolt

11

± 1 N⋅m (95 ± 9 in-lb)

Rear plate bolt

11

± 1 N⋅m (95 ± 9 in-lb)

ITEMS

SPECIFICATIONS

DESCRIPTIONS

SPECIFICATIONS

Type

60

° V, OHV, SOHC

Number of cylinders

6

Combustion chamber

Pentroof type

Total displacement cm

3

(cu in)

3,828 (233.6)

Cylinder bore mm (in)

95.0 (3.74)

Piston stroke mm (in)

90.0 (3.54)

Compression ratio

10.0

Valve timing

Intake valve

Opens (BTDC)

7

°

Closes (ABDC)

61

°

Exhaust valve

Opens (BBDC)

61

°

Closes (ATDC)

15

°

Lubrication system

Pressure feed, full-flow filtration

Oil pump type

Trochoid type

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-63

SERVICE SPECIFICATIONS

M1113000300516

ITEMS

STANDARD VALUE

LIMIT

Timing belt
Auto tensioner rod length mm (in)

4.8

− 6.0 (0.19 − 0.21)

−

Auto tensioner rod production length mm (in) 12 (0.5)

−

Auto tensioner rod pushed-in amount
[when pushed with a force of 98 to 196 N (22
to 44 lb)] mm (in)

1.0 (0.03) or less

−

Rocker arms and camshaft
Camshaft cam height
mm (in)

Intake

37.39 (1.472)

Minimum 36.89 (1.452)

Exhaust

37.71 (1.485)

Minimum 37.21 (1.465)

Camshaft journal outside diameter mm (in)

45 (1.8)

−

Cylinder head and valves
Cylinder head flatness of gasket surface mm
(in)

Less than 0.03 (0.001)

0.2 (0.007)

Cylinder head grinding limit of gasket surface
mm (in) Total resurfacing depth of cylinder
head and cylinder block

−

0.2 (0.007)

Cylinder head overall height mm (in)

120 (4.7)

−

Valve thickness of valve
head (margin) mm (in)

Intake

1.0 (0.04)

Minimum 0.5 (0.02)

Exhaust

1.2 (0.05)

Minimum 0.7 (0.03)

Valve overall height mm
(in)

Intake

110.30 (4.343)

Minimum 109.80 (4.323)

Exhaust

112.11 (4.414)

Minimum 111.61 (4.394)

Valve stem outside
diameter mm (in)

Intake

6.0 (0.24)

−

Exhaust

6.0 (0.24)

−

Valve thickness to valve
guide clearance mm (in)

Intake

0.02

− 0.05 (0.0008 − 0.0019)

0.10 (0.003)

Exhaust

0.04

− 0.06 (0.0016 − 0.0023)

0.15 (0.005)

Valve face angle mm (in)

43.5

° − 44°

−

Valve spring free length mm (in)

51.0 (2.01)

50.0 (1.97)

Valve spring load/installed height N (lb) /mm
(in)

267/44.2 (60.0/1.74)

−

Valve spring out-of-squareness

2

° or less

4

°

Valve seat valve contact width mm (in)

0.9

− 1.3 (0.04 − 0.05)

−

Valve guide inside diameter mm (in)

6.0 (0.24)

−

Valve guide projection from cylinder head
upper surface mm (in)

14 (0.6)

−

Valve stem projection
mm (in)

Intake

48.30 (1.902)

48.80 (1.921)

Exhaust

51.71 (2.036)

52.21 (2.056)

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-64

Oversize rework
dimensions of valve
guide hole mm (in)

0.05 oversize
diameter

11.05

− 11.07 (0.4351 − 0.4358) −

0.25 oversize
diameter

11.25

− 11.27 (0.4429 − 0.4437) −

0.50 oversize
diameter

11.50

− 11.52 (0.4528 − 0.4535) −

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)

−

ITEMS

STANDARD VALUE

LIMIT

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-65

SEALANTS

M1113000500350

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)

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