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Mitsubishi Galant. Manual - part 45

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-61

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 (OD) of the piston to be used.

Measure it in thrust direction as shown.

3. Based on the measured piston OD, calculate the boring

finish dimension.

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

−−−−

0.02 mm (.0008 inch) (honing margin)

CAUTION

To prevent distortion that may result from temperature rise
during honing, bore cylinders, working from number 2 to
number 4 to number 1 to number 3.
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).

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

SPECIFIC ATIO NS

FASTENER TIGHTENING SPECIFICATIONS

M1113023400097

SIZE

IDENTIFICATION MARK

0.50 mm (0.02 in) oversize
diameter

1.00 mm (0.04 in) oversize
diameter

100

AKX00458

THRUST
DIRECTION

PISTON OD

ITEMS

SPECIFICATIONS

Generator and drive belt

Adjusting bolt

5 N

⋅

m (43 in-lb)

Adjusting nut lock bolt

23 N

⋅

m (17 ft-lb)

Camshaft position sensing cylinder bolt

22 N

⋅

m (16 ft-lb)

Camshaft position sensor bolt

8.8 N

⋅

m (78 in-lb)

Camshaft position sensor support bolt

14 N

⋅

m (122 in-lb)

Crankshaft pulley bolt

25 N

⋅

m (18 ft-lb)

Generator brace bolt

24 N

⋅

m (17 ft-lb)

Generator pivot bolt nut

44 N

⋅

m (33 ft-lb)

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-62

Ignition coil bolt

10 N

⋅

m (87 in-lb)

Ignition failure sensor

10 N

⋅

m (87 in-lb)

Spark plugs

25 N

⋅

m (18 ft-lb)

Water pump pulley bolt

8.8 N

⋅

m (78 in-lb)

Timing belt

Auto tensioner bolt

24 N

⋅

m (17 ft-lb)

Camshaft sprocket bolt

88 N

⋅

m (65 ft-lb)

Counterbalance shaft sprocket bolt

45 N

⋅

m (33 ft-lb)

Crankshaft bolt

118 N

⋅

m (87 ft-lb)

Crankshaft position sensor bolt

8.8 N

⋅

m (78 in-lb)

Engine support bracket bolt and nut

49 N

⋅

m (36 ft-lb)

Idler pulley bolt

44 N

⋅

m (33 ft-lb)

Oil pump sprocket nut

35 N

⋅

m (26 ft-lb)

Power steering pump bolt

49 N

⋅

m (36 ft-lb)

Tensioner arm bolt

22 N

⋅

m (16 ft-lb)

Tensioner B bolt

19 N

⋅

m (14 ft-lb)

Tensioner pulley bolt

48 N

⋅

m (35 ft-lb)

Timing belt cover flange bolt M6

11 N

⋅

m (95 in-lb)

Timing belt cover flange bolt M8

14 N

⋅

m (122 in-lb)

Timing belt cover washer assembled bolt M6

8.8 N

⋅

m (78 in-lb)

Fuel and emission control parts

EGR valve bolt

19 N

⋅

m (14 ft-lb)

Fuel pressure regulator bolt

8.8 N

⋅

m (78 in-lb)

Injectors and fuel rail

12 N

⋅

m (104 in-lb)

Throttle body bolt

19 N

⋅

m (14 ft-lb)

Throttle body stay bolt

19 N

⋅

m (14 ft-lb)

Water pump and intake manifold

Engine coolant temperature gauge unit

11 N

⋅

m (95 in-lb)

Engine coolant temperature sensor

29 N

⋅

m (22 ft-lb)

Engine hanger

19 N

⋅

m (14 ft-lb)

Intake manifold plenum bolt and nut

20 N

⋅

m (14 ft-lb)

Intake manifold plenum stay M8

21 N

⋅

m (15 ft-lb)

Intake manifold plenum stay M10

30 N

⋅

m (22 ft-lb)

Manifold differential pressure sensor

4.9 N

⋅

m (43 in-lb)

Oil dipstick guide bolt

14 N

⋅

m (122 in-lb)

Thermostat housing bolt

24 N

⋅

m (17 ft-lb)

Water inlet fitting bolt

13 N

⋅

m (113 in-lb)

Water inlet pipe bolt

13 N

⋅

m (113 in-lb)

Water pump bolt

14 N

⋅

m (122 in-lb)

Exhaust manifold

ITEMS

SPECIFICATIONS

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-63

GENERAL SPECIFICATIONS

M1113000200100

Exhaust manifold bracket bolt

35 N

⋅

m (26 ft-lb)

Exhaust manifold cover bolt

14 N

⋅

m (122 in-lb)

Bracket

35 N

⋅

m (26 ft-lb)

Exhaust manifold nut M8

29 N

⋅

m (22 ft-lb)

Exhaust manifold nut M10

49 N

⋅

m (36 ft-lb)

Oxygen sensor

44 N

⋅

m (32 ft-lb)

Water outlet fitting bolt

13 N

⋅

m (113 in-lb)

Rocker arms and camshaft

Rocker cover bolt

3.5 N

⋅

m (30 in-lb)

Rocker arm shaft bolt

31 N

⋅

m (23 ft-lb)

Cylinder head and valve

Cylinder head bolt [Tighten to 78 N

⋅

m (58 ft-lb) and then completely

before tightening to final torque specification]

25 N

⋅

m (14 ft-lb) + 90

+ 90

Front case, counterbalance shaft and oil pan

Drain plug

39 N

⋅

m (29 ft-lb)

Flange bolt

36 N

⋅

m (27 ft-lb)

Front case bolt

24 N

⋅

m (17 ft-lb)

Oil filter part number MD36093514 N

⋅

m (122 in-lb)

Oil filter other than MITSUBISHI genuine filter

17 N

⋅

m (13 ft-lb)

Oil filter bracket bolt

19 N

⋅

m (14 ft-lb)

Oil pan bolt

6.9 N

⋅

m (61 in-lb)

Oil pressure switch

11 N

⋅

m (95 in-lb)

Oil pump cover bolt

17 N

⋅

m (12 ft-lb)

Oil pump cover screw

9.8 N

⋅

m (87 in-lb)

Oil screen bolt

19 N

⋅

m (14 ft-lb)

Plug

24 N

⋅

m (17 ft-lb)

Relief plug

44 N

⋅

m (33 ft-lb)

Piston and connecting rod

Connecting rod cap nut

20 N

⋅

m (14 ft-lb) + 90

°τ

o 94

Crankshaft and cylinder block

Bearing cap bolt

25 N

⋅

m (18 ft-lb) + 90

Bell housing cover

8.8 N

⋅

m (78 in-lb)

Drive plate bolt

132 N

⋅

m (98 ft-lb)

Oil seal case bolt

11 N

⋅

m (95 in-lb)

Rear plate bolt

11 N

⋅

m (95

•

9 in-lb)

ITEMS

SPECIFICATIONS

DESCRIPTIONS

SPECIFICATIONS

Type

In-line OHV, SOHC

Number of cylinders

Combustion chamber

Pentroof type

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L>

11B-64

SERVICE SPECIFICATIONS

M1113000300107

Total displacement dm

(cu in)

2,350 (143.4)

Cylinder bore (in)

86.5 (3.41)

Piston stroke mm (in)

100.0 (3.94)

Compression ratio

9.5

Valve timing

Intake valve

Opens (BTDC)

Closes (ABDC)

Exhaust valve

Opens (BBDC)

Closes (ATDC)

Lubrication system

Pressure feed, full-flow filtration

Oil pump type

Involute gear type

DESCRIPTIONS

SPECIFICATIONS

ITEM

STANDARD
VALUE

LIMIT

Timing belt

Auto-tensioner rod projection length mm (in)

12 (0.5)

Auto-tensioner rod pushed-in amount [When pushed with a
force of 98

−

196 N (22

−

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

36.83 (1.450)

Minimum 36.33
(1.430)

Camshaft journal outside diameter mm (in)

45 (1.8)

Cylinder head and valves

Cylinder head flatness of gasket surface mm (in)

Less than 0.05
(0.002)

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)

Cylinder head bolt shank length mm (in)

99.4 (3.91)

Valve thickness of valve head
(margin)

Intake

1.0 (0.03)

Minimum 0.5 (0.02)

Exhaust

1.2 (0.04)

Minimum 0.7 (0.03)

Valve overall height mm (in)

Intake

112.30 (4.421)

Minimum 111.80
(4.402)

Exhaust

114.11 (4.493)

Minimum 113.61
(4.473)

Valve stem outside diameter mm
(in)

Intake

6.0 (0.24)

Exhaust

5.9 (0.23)

Valve thickness to valve guide
clearance mm (in)

Intake

0.02

−

0.05

(0.0008

−

0.0019)

0.10 (0.003)

Exhaust

0.03

−

0.07

(0.0012

−

0.0027)

0.15 (0.005)

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