Mitsubishi Galant (2004+). Manual - part 1663

 

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Mitsubishi Galant (2004+). Manual - part 1663

 

 

SPECIFICATIONS

TSB Revision

INTAKE AND EXHAUST

15-23

Exhaust manifold <Left bank> <3.8L ENGINE>
Engine oil dipstick bolt

14 

± 1 N⋅m (120 ± 13 in-lb)

Exhaust manifold nut

44 

± 5 N⋅m (33 ± 3 ft-lb)

Front exhaust pipe bolt

49 

± 9 N⋅m (37 ± 6 ft-lb)

Exhaust manifold stay, left A bolt

M8

19 

± 3 N⋅m (14 ± 2 ft-lb)

M10

44 

± 8 N⋅m (33 ± 5 ft-lb)

Heat protector bolt

14 

± 1 N⋅m (120 ± 13 in-lb)

Heated oxygen sensor

44 

± 5 N⋅m (33 ± 3 ft-lb)

Exhaust manifold <Right bank> <3.8L ENGINE>
EGR pipe

59 

± 10 N⋅m (44 ± 7 ft-lb)

EGR pipe clamp bolt

19 

± 3 N⋅m (14 ± 2 ft-lb)

EGR pipe connecting nut

19 

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust manifold nut

44 

± 5 N⋅m (33 ± 3 ft-lb)

Exhaust manifold stay, right B bolt

44 

± 8 N⋅m (33 ± 5 ft-lb)

Heat protector bolt

14 

± 1 N⋅m (120 ± 13 in-lb)

Heated oxygen sensor

44 

± 5 N⋅m (33 ± 3 ft-lb)

Exhaust pipe and main muffler
Crossmember stay bolt

45 

± 5 N⋅m (34 ± 3 ft-lb)

Center exhaust pipe nut

49 

± 9 N⋅m (37 ± 6 ft-lb)

Front floor backbone brace bolt

22 

± 4 N⋅m (16 ± 3 ft-lb)

Front no.1 exhaust pipe nut <2.4L ENGINE>

35 

± 4 N⋅m (26 ± 3 ft-lb)

Front no.2 exhaust pipe bolt <2.4L ENGINE>

49 

± 4 N⋅m (37 ± 3 ft-lb)

Front no.1 exhaust pipe bolt <3.8L ENGINE>

35 

± 4 N⋅m (26 ± 3 ft-lb)

Front no.1 exhaust pipe to front no.2 exhaust pipe bolt <3.8L ENGINE>

49 

± 4 N⋅m (37 ± 3 ft-lb)

Front no.1 exhaust pipe to right bank exhaust manifold nut <3.8L ENGINE>

49 

± 9 N⋅m (37 ± 6 ft-lb)

Front no.1 exhaust pipe to left bank exhaust manifold bolt <3.8L ENGINE>

49 

± 9 N⋅m (37 ± 6 ft-lb)

Hanger bolt

12 

± 2 N⋅m (107 ± 17 in-lb)

Heated oxygen sensor <2.4L ENGINE>

44 

± 5 N⋅m (33 ± 3 ft-lb)

Main muffler bolt

49 

± 4 N⋅m (37 ± 3 ft-lb)

Intake manifold <2.4L ENGINE>
Engine oil dipstick guide bolt

13 

± 1 N⋅m (115 ± 9 in-lb)

Evaporative emission purge solenoid valve bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Evaporative emission vacuum pipe bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Exhaust gas recirculation valve bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Harness clamp bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Intake manifold bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Intake manifold nut

20 

± 2 N⋅m (15 ± 1 ft-lb)

Intake manifold stay bolt

31 

± 3 N⋅m (23 ± 2 ft-lb)

Knock sensor connector bracket bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Manifold absolute pressure sensor bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

ITEM

SPECIFICATION

SPECIFICATIONS

TSB Revision

INTAKE AND EXHAUST

15-24

SERVICE SPECIFICATION

M1151000300462

SEALANTS

M1151000500187

Pressure hose clamp bolt

12 

± 2 N⋅m (102 ± 22 in-lb)

Thermostat case assembly bolt

24 

± 4 N⋅m (18 ± 3 ft-lb)

Intake manifold <3.8L ENGINE>
Control harness clamp bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Engine mounting stay bolt

36 

± 6 N⋅m (27 ± 4 ft-lb)

Fuel rail and injector bolt

12 

± 1 N⋅m (102 ± 13 in-lb)

Fuel high-pressure hose bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Intake manifold bolt

22 

± 1 N⋅m (16 ± 1 ft-lb)

Timing belt front upper cover bolt

M6

11 

± 1 N⋅m (98 ± 8 in-lb)

M8

14 

± 1 N⋅m (120 ± 13 in-lb)

Water pump bracket bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Intake manifold plenum
EGR valve bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

EGR pipe

59 

± 10 N⋅m (44 ± 7 ft-lb)

EGR pipe clamp bolt

19 

± 3 N⋅m (14 ± 2 ft-lb)

EGR pipe connection nut

19 

± 3 N⋅m (14 ± 2 ft-lb)

Evaporative emission purge solenoid bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Harness bracket bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Intake manifold plenum bolt

18 

± 2 N⋅m (13 ± 2 ft-lb)

Intake manifold plenum stay bolt

M8

18 

± 2 N⋅m (13 ± 2 ft-lb)

M10

36 

± 6 N⋅m (27 ± 4 ft-lb)

Manifold absolute pressure sensor bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Power steering pressure hose clamp nut

12 

± 2 N⋅m (102 ± 22 in-lb)

Power steering pressure hose clamp bracket bolt

12 

± 2 N⋅m (102 ± 22 in-lb)

Power steering pump bracket connecting bolt

41 

± 8 N⋅m (30 ± 6 ft-lb)

Vacuum pipe bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

ITEM

SPECIFICATION

ITEM

STANDARD VALUE

LIMIT

Manifold distortion of the installation surface   mm (in) 0.15 (0.006) or less

0.20 (0.008)

ITEM

SPECIFIED SEALANT

Thermostat case assembly

3M

 AAD Part No.8672, 3M AAD Part No.8679/8678 or 

equivalent

Thermostat case assembly bolt

3M

 AAD Part No. 8730, 8731 or equivalent

13C-1

GROUP 13C

FUEL SUPPLY

CONTENTS

GENERAL DESCRIPTION. . . . . . . . .

13C-2

FUEL SUPPLY DIAGNOSIS . . . . . . .

13C-2

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 

13C-2

TROUBLESHOOTING STRATEGY . . . . . . 

13C-2

SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 

13C-2

SYMPTOM PROCEDURES . . . . . . . . . . . . 

13C-3

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

13C-5

ON-VEHICLE SERVICE. . . . . . . . . . .

13C-6

FUEL LEVEL SENSOR CHECK . . . . . . . . . 

13C-6

FUEL LEVEL SENSOR REPLACEMENT . . 

13C-6

FUEL PUMP OPERATION CHECK  . . . . . . 

13C-7

FUEL PUMP MODULE REPLACEMENT . . 

13C-7

LEVELING VALVE CHECK. . . . . . . . . . . . . 

13C-9

FUEL TANK  . . . . . . . . . . . . . . . . . . . .

13C-10

REMOVAL AND INSTALLATION  . . . . . . . . 

13C-10

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

13C-16

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

13C-17

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

13C-17

SERVICE SPECIFICATION  . . . . . . . . . . . . 

13C-17

GENERAL DESCRIPTION

TSB Revision

FUEL SUPPLY

13C-2

GENERAL DESCRIPTION

M1135000100435

• The fuel tank is located under the floor below the 

rear seats.

• A fuel cut-off valve is utilized to prevent fuel from 

leaking out in the event of a collision.

• A fuel pump module, including fuel pump, fuel fil-

ter, reservoir and fuel level sensor, is used to 
lighten weight and improve serviceability.

CONSTRUCTION DIAGRAM

FUEL SUPPLY DIAGNOSIS

INTRODUCTION

M1135004000388

The fuel system is used to supply an appropriate fuel 
mixture to the engine. The system consists of the 
fuel tank, fuel filter, fuel pump and fuel pipes. An 
evaporative emission system is provided to prevent 
evaporated fuel from escaping into the atmosphere.

Engine malfunctions caused by insufficient fuel sup-
ply and evaporative emission system operation mal-
functions can be caused by faults in the vapor line, 
fuel pipe, hose, or fuel tank pressure control valve, 
etc.

TROUBLESHOOTING STRATEGY

M1135004100277

Use these steps to plan your diagnostic strategy. If 
you follow them carefully, you will be sure to find 
most of the fuel supply faults.
1. Gather information from the customer.

2. Verify that the condition described by the 

customer exists.

3. Find the malfunction by following the Symptom 

Chart.

4. Verify malfunction is eliminated.

SYMPTOM CHART

M1135004200382

AC305896

FUEL INJECTOR

FUEL RAIL

FUEL PIPE 

FUEL PUMP MODULE

FUEL LEVEL SENSOR (SUB)

FUEL TANK LEVELING VALVE

EVAPORATIVE 
EMISSION 
CANISTER

FUEL TANK DIFFERENTIAL 
PRESSURE SENSOR

AB

FUEL TANK

SYMPTOM

INSPECTION PROCEDURE

REFERENCE PAGE

Engine Malfunctions Due to Insufficient Fuel Supply

1

P.13C-3

 

 

 

 

 

 

 

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