Mitsubishi Galant (2004+). Manual - part 600

 

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Mitsubishi Galant (2004+). Manual - part 600

 

 

TIMING BELT

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-17

6. Abnormal wear of belt sides. Normal wear is indicated if the 

sides are sharp as if cut by a knife. Abnormal wear is 
indicated if the sides are ragged.

7. Abnormal wear on teeth. 

Initial stage:
Canvas worn (fluffy canvas fibers, rubbery texture 
gone, white discoloration, canvas texture indistinct)
Final stage:
Canvas worn, exposing rubber (tooth width reduced)

8. Missing tooth.

.

TENSIONER PULLEY AND IDLER PULLEY
Turn the pulley. If it does not rotate smoothly, or develops noise 
or excessive play, replace the pulley.

.

AUTO-TENSIONER
1. Check for oil leaks. If oil leaks are evident, replace the 

auto-tensioner.

2. Check the rod end for wear or damage and replace the 

auto-tensioner if necessary.

3. Measure the rod protrusion. If it is out of specification, 

replace the auto-tensioner.

Standard value: 12 mm (0.5 inch)

AKX00750

ROUNDED EDGE

ABNORMAL WEAR 
(RAGGED)

AB

AKX00751

RUBBER EXPOSED

TOOTH MISSING AND
CANVAS FIBER EXPOSED

AC

AKX00650

AK204323AB

12 mm (0.5 in)

INTAKE MANIFOLD AND FUEL PARTS

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ENGINE OVERHAUL <3.8L ENGINE>

11D-18

4. Press the rod with a force of 98 to 196 N (22 to 44 pounds) 

and measure the movement of the rod.
If the measured value is out of the standard value, replace 
the auto-tensioner.

Standard value: 1.0 mm (0.03 inch) or less

INTAKE MANIFOLD AND FUEL PARTS

REMOVAL AND INSTALLATION

M1113004300206

AK204324

MOVEMENT

98 TO 196 N
(22 TO 44 lb)

AB

AK203973

12 ± 1 N·m
107 ± 8 in-lb

20 – 23 N·m
15 – 17 ft-lb

2

1

8

3

10

10

6

5

4

9

7

AB

INTAKE MANIFOLD AND FUEL PARTS

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ENGINE OVERHAUL <3.8L ENGINE>

11D-19

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD INSTALLATION
1. Tighten the nuts "R" to 6.4 

± 1.5 N⋅m (57 ± 13 in-lb).

2. Tighten the nuts "L" to the specified torque.

Tightening torque: 20 

 23 Nm (15  17 ft-lb)

3. Tighten the nuts "R" to the specified torque.

Tightening torque: 20 

 23 Nm (15  17 ft-lb)

4. Tighten the nuts "L" to the specified torque.

Tightening torque: 20 

 23 Nm (15  17 ft-lb)

5. Tighten the nuts "R" to the specified torque.

Tightening torque: 20 

 23 Nm (15  17 ft-lb)

.

>>B<< INJECTOR INSTALLATION

CAUTION

Use care not to let engine oil enter the fuel rail.
1. Apply clean engine oil to the O-ring.
2. Insert the injector into the fuel rail.
3. Make sure the injector rotates smoothly. If not, remove the 

injector to check the O-ring for damage, and replace the 
O-ring if necessary. Then reinsert the injector and check that 
it rotates smoothly.

4. Confirm the protrusion of injector is at center. If not, rotate 

the injector for protrusion to be center.

REMOVAL STEPS

1. INJECTOR HARNESS
2. INJECTOR AND FUEL RAIL
3. INSULATOR
4. INSULATOR

>>B<<

5. INJECTOR

6. O-RING
7. FUEL RAIL
8. CONED DISC SPRING

>>A<<

9. INTAKE MANIFOLD
10. INTAKE MANIFOLD GASKET

REMOVAL STEPS (Continued)

AKX00680

TIMING
BELT SIDE

NUT "R"

NUT "L"

AB

AK302905AB

FUEL RAIL

INJECTOR

AK302906AB

INJECTOR

FUEL RAIL

WATER PUMP & WATER HOSE

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ENGINE OVERHAUL <3.8L ENGINE>

11D-20

WATER PUMP & WATER HOSE

REMOVAL AND INSTALLATION

M1113017900286

AK302897AB

19 ± 1 N·m
14 ± 1 ft-lb

19 ± 1 N·m
14 ± 1 ft-lb

19 ± 1 N·m
14 ± 1 ft-lb

11 ± 1 N·m
95 ± 9 in-lb

29 ± 10 N·m
22 ± 7 ft-lb

42 ± 8 N·m
31 ± 6 ft-lb
(M10 BOLT)

24 ± 3 N·m
17 ± 2 ft-lb
(M8 BOLT)

4

5

2

6

3

1

9

12

11

8

7

7

10

REMOVAL STEPS

1. WATER HOSE
2. WATER HOSE

>>D<<

3. ENGINE COOLANT TEMPERATURE 

SENSOR

4. WATER INLET FITTING

>>C<<

5. THERMOSTAT
6. THERMOSTAT HOUSING

>>B<<

7. THERMOSTAT HOUSING GASKET

>>A<<

8. O-RING 

>>A<<

9. WATER INLET PIPE

>>A<<

10. O-RING
11. WATER PUMP
12. WATER PUMP GASKET

REMOVAL STEPS (Continued)

 

 

 

 

 

 

 

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