Mitsubishi Galant (2004+). Manual - part 586

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-33

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION

M1113006900594

Required Special Tools:

• MB991654: Cylinder Head Bolt Wrench (12)

• MD998735: Valve Spring Compressor

• MD998774: Valve Stem Seal Installer

AK301262AC

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20

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

78 ± 2 N·m    

 0 N·m     20 ± 2 N·m

58 ± 1 ft-lb     0 in-lb    15 ± 1 ft-lb

→             →                     →  + 90˚ → + 90˚

REMOVAL STEPS

<<A>> >>D<<

1. CYLINDER HEAD BOLT
2. CYLINDER HEAD ASSEMBLY
3. CYLINDER HEAD GASKET

<<B>> >>C<<

4. RETAINER LOCK
5. VALVE SPRING RETAINER

>>B<<

6. VALVE SPRING
7. INTAKE VALVE

<<B>> >>C<<

8. RETAINER LOCK
9. VALVE SPRING RETAINER

>>B<<

10.VALVE SPRING

11.EXHAUST VALVE

>>A<<

12.VALVE STEM SEAL
13.VALVE SPRING SEAT

>>A<<

14.VALVE STEM SEAL
15.VALVE SPRING SEAT
16.INTAKE VALVE GUIDE
17.EXHAUST VALVE GUIDE
18.INTAKE VALVE SEAT
19.EXHAUST VALVE SEAT
20.CYLINDER HEAD

REMOVAL STEPS (Continued)

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-34

REMOVAL SERVICE POINTS

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<<A>> CYLINDER HEAD BOLTS REMOVAL
Using special tool MB991654, loosen the cylinder head bolts. 
Loosen each bolt evenly, little by little, in two or three steps.

.

<<B>> RETAINER LOCK REMOVAL
1. Set special tool MD998735 as illustrated to compress the 

valve spring. Remove the retainer lock.

2. Relieve the spring tension and remove the valve, retainer, 

spring, etc. Tag the removed valves, springs, and other 
parts, to indicate their cylinder number and location for 
reassembly.

INSTALLATION SERVICE POINTS

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>>A<< VALVE STEM SEAL INSTALLATION

CAUTION

The special tool must be used to install the valve stem 
seal. Improper installation could result in oil leaking past 
the valve guide.
1. Install the valve spring seat.
2. Using special tool MD998774, install a new valve stem seal.

.

>>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

AK300162

MB991654

AC

AK300163

MD998735

AC

AK300164

MD998774

AC

AK300717

PAINTED END

AD

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-35

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>>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.

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>>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.

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)

AK300163

MD998735

AC

AK300591AE

SHANK LENGTH

AK300165

MB991654

AC

AK301394AC

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TIMING BELT SIDE

CYLINDER HEAD AND VALVES

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-36

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

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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)

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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)

.

AK300166

90˚

90˚

PAINT MARK

AC

AK300167

AK300593AD

MARGIN

CONTACT 
(SHOULD BE AT
CENTER OF FACE)

AK103808AD

TOTAL LENGTH