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Mitsubishi Galant (2004+). Manual - part 584

INTAKE MANIFOLD AND WATER PUMP

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-25

INTAKE MANIFOLD AND WATER PUMP

REMOVAL AND INSTALLATION

M1113025500034

Required Special Tool:

• MD998054: Oil Pressure Switch Wrench

AK303215 AB

20 ± 2 N·m
15 ± 1 ft-lb

24 ± 3 N·m
18 ± 1 ft-lb

14 ± 1 N·m
124 ± 8 in-lb

13 ± 2 N·m
115 ± 17 in-lb

24 ± 4 N·m
18 ± 2 ft-lb

31 ± 3 N·m
23 ± 2 ft-lb

23 ± 2 N·m
17 ± 1 ft-lb

19 ± 3 N·m
14 ± 2 ft-lb

13 ± 2 N·m
115 ± 17 in-lb

30 ± 9 N·m
22 ± 6 ft-lb

24 ± 3 N·m
18 ± 1 ft-lb

5.0 ± 1.0 N·m
45 ± 8 in-lb

13 ± 2 N·m
115 ± 17 in-lb

11 ± 1 N·m
98 ± 8 in-lb

10 ± 2 N·m
89 ± 17 in-lb

REMOVAL STEPS

1. WATER HOSE
2. WATER HOSE
3. WATER PUMP
4. WATER PUMP GASKET

>>H<<

5. O-RING

>>H<<

6. WATER INLET PIPE

>>H<<

7. O-RING

>>G<<

8. INTAKE MANIFOLD STAY
9. WATER INLET FITTING

>>F<<

10. THERMOSTAT

>>E<<

11. THERMOSTAT HOUSING

12. MANIFOLD ABSOLUTE PRESSURE

SENSOR

13. INTAKE MANIFOLD
14. INTAKE MANIFOLD GASKET
15. ENGINE HANGER
16. KNOCK SENSOR

>>D<<

17. ENGINE OIL PRESSURE SWITCH

<<A>> >>C<<

18 ENGINE OIL PRESSURE SWITCH

>>B<<

19. ENGINE COOLANT TEMPERATURE

SENSOR

>>A<<

20. WATER OUTLET FITTING

REMOVAL STEPS (Continued)

INTAKE MANIFOLD AND WATER PUMP

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-26

REMOVAL SERVICE POINT

<<A>> ENGINE OIL PRESSURE SWITCH REMOVAL
Using special tool MD998054, remove the engine oil pressure
switch.

INSTALLATION SERVICE POINTS

>>A<< WATER OUTLET FITTING INSTALLATION
1. Apply a 3 mm (0.12 inch) diameter bead of sealant.

(MITSUBISHI Genuine Part number MD970389) to the
groove as shown in the illustration.

2. Install the housing quickly (within 15 minutes) while the

sealant is wet and tighten the bolts to the specified torque.

Tightening torque: 13

± 2 N⋅m (115 ± 17 in-lb)

NOTE: After installation, keep the sealed area away from the
coolant for approximately one hour.

>>B<< SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR
Apply 3M

 AAD Part number 8731 or equivalent to the engine

coolant temperature sensor.

AK300156

MD998054

AK301336AC

ø 3 mm
(0.12 in)

AK300712 AD

INTAKE MANIFOLD AND WATER PUMP

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-27

>>C<< SEALANT APPLICATION TO ENGINE OIL
PRESSURE SWITCH

CAUTION

Do not block the oil passage with sealant.
Apply 3M

 AAD Part number 8672 or equivalent to the threads

of the engine oil pressure switch.

>>D<< SEALANT APPLICATION TO ENGINE OIL
PRESSURE SWITCH

CAUTION

Do not block the oil passage with sealant.
1. Apply 3M

 AAD Part number 8672 or equivalent to the

threads of the engine oil pressure switch.

2. Using special tool MD998054, tighten the engine oil

pressure switch to the specified torque.

Tightening torque: 19

± 3 N⋅m (14 ± 2 ft-lb)

>>E<< THERMOSTAT HOUSING INSTALLATION
1. Apply a 3 mm (0.12 inch) diameter bead of sealant

MITSUBISHI Genuine Part number MD970389 or equivalent
to the groove as shown in the illustration.

AK301855

5 mm
(0.20 in)

1 mm
(0.04 in)

AK300715 AD

AK300157

MD998054

AK301337AC

ø 3 mm
(0.12 in)

INTAKE MANIFOLD AND WATER PUMP

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-28

2. Coat the threads of the seal bolt in the illustration with 3M



AAD Part number 8672 or equivalent before tightening.

3. Install the housing quickly (within 15 minutes) while the

sealant is wet and tighten the bolts to the specified torque.

Tightening torque: 24

± 4 N⋅m (18 ± 2 ft-lb)

NOTE: After installation, keep the sealed area away from
the coolant for approximately one hour.

>>F<< THERMOSTAT INSTALLATION
1. Check that the rubber ring is undamaged and seated

correctly in the thermostat flange.

2. Install the thermostat as shown in the illustration. The jiggle

valve must be at the top position.

>>G<< INTAKE MANIFOLD STAY INSTALLATION
1. Install the intake manifold stay and tighten the bolts just

finger tight.

2. Check to ensure that the stay is in close contact with the

bosses of the intake manifold and cylinder block.

3. First tighten the intake manifold side bolts to the specified

torque, then the cylinder block side bolts to the specified
torque.

Tightening torque: 31

± 3 N⋅m (23 ± 2 ft-lb)

>>H<< WATER INLET PIPE/O-RING INSTALLATION

CAUTION

Keep the O-ring free of oil or grease.
1. Attach a new O-ring to each end of the water inlet pipe.
2. Wet the O-ring with water.
3. Insert the rear end of the pipe into the thermostat housing.

AK300158

AK301862AB

JIGGLE VALVE

THERMOSTAT
HOUSING

AK301361

CYLINDER BLOCK

INTAKE
MANIFOLD

AK301861

O-RING

WATER INLET PIPE

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