Mitsubishi Galant (2004+). Manual - part 594

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-65

6. Measure the width of the plastic gauging material at its 

widest part by using a scale printed on the plastic gauging 
material package.

Standard value: 0.02 

− 0.04 mm (0.0008 − 0.0015 inch)

Limit: 0.1 mm (0.003 inch)

.

CYLINDER BLOCK 
1. Visually check for scratches, rust, and corrosion. 

Use also a flaw detecting agent for the check. If defects are 
evident, correct or replace.

2. Using a straightedge and feeler gauge, check the block top 

surface for warpage. Make sure that the surface is free from 
gasket chips and other foreign matter.

Standard value: 0.05 mm (0.0020 inch)
Limit: 0.1 mm (0.003 inch)

3. If the distortion is excessive, correct within the allowable 

limit or replace.

Grinding limit: 0.2 mm (0.007 inch)
*Includes/combined with cylinder head grinding
Cylinder block height (when new):
290 mm (11.4 inches)

4. Check cylinder walls for scratches and seizure. If defects 

are evident, replace or bore to oversize and replace pistons 
and piston rings.

5. Using a cylinder gauge, measure the cylinder bore and 

cylindrically. If worn badly, correct the cylinder to an oversize 
and replace the piston and piston rings. Measure at the 
points shown in the illustration.

Standard value:

Cylinder inner diameter 87.0 mm (3.43 inches)
Cylindrically 0.01 mm (0.0003 inch) or less

.

AK300204

PLASTIC GAUGING MATERIAL

AC

AK300205

A

B

C

D

E

F

G

AK300206

12mm

(0.47 in)

AC

A

B

CENTER

BOTTOM

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-66

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 (0.0008 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 over-
size. 

SIZE

IDENTIFICATION MARK

0.50 mm (0.020 in) 
oversize diameter

50

AK300577AC

THRUST
DIRECTION

PISTON OUTSIDE
DIAMETER

AC

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-67

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1113023400718

ITEM

SPECIFICATION

Generator and ignition system
Auto-tensioner bracket bolt M10

44 

± 10 N⋅m (33 ± 6 ft-lb)

Auto-tensioner bracket bolt M8

22 

± 4 N⋅m (17 ± 2 ft-lb)

Camshaft position sensing cylinder bolt

22 

± 4 N⋅m (17 ± 2 ft-lb)

Camshaft position sensor bolt

8.5 

± 0.5 N⋅m (75 ± 4 in-lb)

Camshaft position sensor support bolt

14 

± 1 N⋅m (124 ± 8 in-lb)

Connector bracket bolt

10 

± 1 N⋅m (89 ± 8 in-lb)

Crankshaft pulley bolt

25 

± 4 N⋅m (19 ± 2 ft-lb)

Generator bolt

49 

± 9 N⋅m (36 ± 6 ft-lb)

Generator pivot nut

44 

± 10 N⋅m (33 ± 6 ft-lb)

Idler pulley bolt

79 

± 5 N⋅m (58 ± 3 ft-lb)

Ignition coil bolt

10 

± 2 N⋅m (87 ± 17 in-lb)

Oil dipstick guide bolt

13 

± 1 N⋅m (115 ± 9 in-lb)

Spark plugs

25 

± 5 N⋅m (19 ± 3 ft-lb)

Water pump pulley bolt

8.8 

± 1 N⋅m (78 ± 8 in-lb)

Exhaust manifold
Engine hanger bolt

24 

± 3 N⋅m (18 ± 1 ft-lb)

Exhaust manifold bracket bolt (Bolt, washer assembly)

34 

± 5 N⋅m (26 ± 2 ft-lb)

Exhaust manifold bracket bolt (Flange bolt)

36 

± 5 N⋅m (27 ± 3 ft-lb)

Exhaust manifold cover bolt

14 

± 1 N⋅m (124 ± 8 in-lb)

Exhaust manifold nut

49 

± 5 N⋅m (36 ± 3 ft-lb)

Oxygen sensor

44 

± 5 N⋅m (33 ± 3 ft-lb)

Timing belt
Auto-tensioner bolt

24 

± 2 N⋅m (18 ± 1 ft-lb)

Camshaft sprocket bolt

89 

± 9 N⋅m (66 ± 6 ft-lb)

Counterbalance shaft sprocket bolt

45 

± 3 N⋅m (33 ± 2 ft-lb)

Crankshaft bolt

167 N

⋅m (123 ft-lb)

Crankshaft position sensor bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Engine support bracket bolt and nut

49 

± 5 N⋅m (36 ± 3 ft-lb)

Generator bracket bolt

49 

± 9 N⋅m (36 ± 6 ft-lb)

Idler pulley bolt

35 

± 6 N⋅m (26 ± 4 ft-lb)

Oil pump sprocket nut

54 

± 4 N⋅m (40 ± 2 ft-lb)

Tensioner "B" bolt

19 

± 3 N⋅m (14 ± 2 ft-lb)

Tensioner arm bolt

21 

± 4 N⋅m (16 ± 2 ft-lb)

Tensioner pulley bolt

49 

± 4 N⋅m (36 ± 3 ft-lb)

Timing belt cover bolt M6 (Bolt, washer assembly)

9.0 

± 1.0 N⋅m (80 ± 8 in-lb)

Timing belt cover bolt M6 (Flange bolt and nut)

11 

± 1 N⋅m (98 ± 8 in-lb)

Timing belt cover bolt M8

14 

± 1 N⋅m (124 ± 8 in-lb)

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-68

Fuel and emission parts
EGR valve bolt

24 

± 3 N⋅m (18 ± 1 ft-lb)

Injectors and fuel rail bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Solenoid valve bracket bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Solenoid valve nut

9.0 

± 1.0 N⋅m (80 ± 8 in-lb)

Throttle body bolt

28 

± 4 N⋅m (21 ± 2 ft-lb)

Vacuum pipe and hose bolt

9.0 

± 1.0 N⋅m (80 ± 8 in-lb)

Intake manifold water pump and
Manifold absolute pressure sensor bolt

5.0 

± 1.0 N⋅m (45 ± 8 in-lb)

Engine coolant temperature sensor

30 

± 9 N⋅m (22 ± 6 ft-lb)

Engine hanger bolt

24 

± 3 N⋅m (18 ± 1 ft-lb)

Harness bracket bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

intake manifold bolt

24 

± 3 N⋅m (18 ± 1 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

23 

± 2 N⋅m (17 ± 1 ft-lb)

Engine oil pressure switch

10 

± 2 N⋅m (89 ± 17 in-lb)

Engine oil pressure switch

19 

± 3 N⋅m (14 ± 2 ft-lb)

Thermostat housing bolt

24 

± 4 N⋅m (17 ± 3 ft-lb)

Water inlet fitting bolt

13 

± 2 N⋅m (115 ± 17 in-lb)

Water inlet pipe bolt

13 

± 2 N⋅m (115 ± 17 in-lb)

Water outlet fitting bolt

13 

± 2 N⋅m (115 ± 17 in-lb)

Water pump bolt

14 

± 1 N⋅m (124 ± 8 in-lb)

Rocker arms and camshaft
Accumulator body bolt

44 

± 5 N⋅m (33 ± 3 ft-lb) 

Engine oil control valve bolt

11 

± 1 N⋅m (98 ± 8 ft-lb) 

Positive crankcase ventilation valve

10 

± 2 N⋅m (89 ± 17 in-lb) 

Rocker arms and rocker arm shaft bolt <exhaust side>

13 

± 1 N⋅m (115 ± 8 in-lb)

Rocker arms and rocker arm shaft bolt <intake side>

31 

± 3 N⋅m (23 ± 2 ft-lb)

Rocker cover bolt

3.5 

± 0.5 N⋅m (31 ± 4 in-lb)

Taper plug

47 

± 7 N⋅m (35 ± 4 ft-lb) 

Cylinder head and valves
Cylinder head bolt 

78 

± 2 N⋅m (58 ± 1 ft-lb) → 0 N⋅m (0 

in-lb) 

→ 20 ± 1 N⋅m (15 ± 1 ft-lb) → 

+90

° → +90°

Oil pan and oil pump
Baffle plate bolt M6

9.0 

± 2.0 N⋅m (80 ± 17 in-lb)

Baffle plate bolt M8

22 

± 4 N⋅m (17 ± 2 ft-lb)

Drain plug

39 

± 5 N⋅m (29 ± 3 ft-lb)

Flange bolt

36 

± 3 N⋅m (27 ± 1 ft-lb)

Front case bolt

23 

± 3 N⋅m (17 ± 2 ft-lb)

ITEM

SPECIFICATION