Mitsubishi Galant (2004+). Manual - part 609

 

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Mitsubishi Galant (2004+). Manual - part 609

 

 

PISTON AND CONNECTING ROD

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-53

3. Insert the piston ring into the cylinder bore. Force the ring 

down with a piston, the piston crown being in contact with 
the ring, to correctly position it at right angles to the cylinder 
wall. Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.

Standard value:

Number 1: 0.25 

 0.40 mm (0.010  0.016 inch)

Number 2: 0.35 

 0.50 mm (0.014  0.020 inch)

Oil: 0.10 

 0.35 mm (0.004  0.014 inch)

Limit:

Number 1, Number 2: 0.8 mm (0.03 inch)
Oil: 1.0 mm (0.03 inch)

.

CRANKSHAFT PIN OIL CLEARANCE 
<PLASTIC GAUGING MATERIAL METHOD>
The crankshaft oil clearance can be measured easily by using 
plastic gauging material, as follows:
1. Remove oil from the crankshaft pin and the bearing inner 

surface.

2. Cut plastic gauging material to the same length as the width 

of the bearing and place it on the pin in parallel with its axis.

3. Install the connecting rod cap carefully and tighten the nuts 

to the specified torque.

4. Carefully remove the connecting rod cap.
5. Measure the width of the smashed plastic gauging material 

at its widest section by using a scale printed on the plastic 
gauging material bag.

Standard value: 0.02 

 0.04 mm (0.0008  0.0016 inch)

Limit: 0.1 mm (0.003 inch)

AKX00719

PUSH IN BY
PISTON

PISTON
RING GAP

PISTON RING

AB

AKX00731AB

SCALE

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-54

CRANKSHAFT AND  CYLINDER BLOCK

REMOVAL AND INSTALLATION

M1113008700637

CAUTION

Do not remove the block heater unless it is damaged, because it cannot be re-used once it is 
removed’.

Required Special Tool:

• MD998718: Crankshaft Rear Oil Seal Installer

AK302900AB

1

2

4

3

6

5

13

14

16

12

11

10

9

8

7

23 ± 2 N·m
17 ± 1 ft-lb

74 ± 4 N·m
54 ± 3 ft-lb

74 ± 1 N·m
54 ± 1 ft-lb

28 ± 2 N·m
21 ± 1 ft-lb

11 ± 1 N·m
97 ± 9 in-lb

11 ± 1 N·m
97 ± 9 in-lb

APPLY ENGINE OIL
TO ALL MOVING
PARTS BEFORE
INSTALLATION.

15

2.6 ± 0.2 N·m
23 ± 1 in-lb

REMOVAL STEPS

1. ADAPTER PLATE
2. DRIVE PLATE
3. REAR PLATE

>>G<<

4. OIL SEAL CASE ASSEMBLY

>>F<<

5. CRANKSHAFT REAR OIL SEAL
6. OIL SEAL CASE 

>>E<<

7. BEARING CAP BOLT

>>E<<

8. BEARING CAP

>>C<<

9. CRANKSHAFT BEARING, LOWER
10. CRANKSHAFT

>>D<<

11. THRUST BEARING

>>C<<

12. CRANKSHAFT BEARING, UPPER
13. KNOCK SENSOR

>>B<<

14. KNOCK SENSOR BRACKET

>>A<<

15. BLOCK HEATER
16. CYLINDER BLOCK

REMOVAL STEPS (Continued)

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-55

INSTALLATION SERVICE POINTS

.

>>A<< BLOCK HEATER INSTALLATION
Within 30

° of the center, install the block heater as shown in 

Fig.

.

>>B<< KNOCK SENSOR BRACKET INSTALLATION
Check that the bracket is in proper contact with the cylinder 
block boss and tighten to the specified torque in the order 
shown.

Tightening torque: 28 

± 2 Nm (21 ± 1 ft-lb)

.

>>C<< CRANKSHAFT BEARING INSTALLATION
1. Measure the crankshaft journal diameter and confirm its 

classification from the following table. In the case of a 
crankshaft supplied as a service part, identification 
colors/marks of its journals are painted/stamped at the 
positions shown in the illustration.

AK303758AB

30˚    30˚

A-A

B

B

A

A

TIMING BELT SIDE

AKX00649

TIMING BELT SIDE

AB

1

2

3

4

AKX01391

No.4 JOURNAL

No.1 JOURNAL

No.2 JOURNAL

No.3 JOURNAL

LOCATION OF IDENTIFCATION COLOR

AB

CRANKSHAFT AND CYLINDER BLOCK

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-56

2. The cylinder block bearing bore diameter identification 

marks are stamped at the position shown in the illustration 
from left to right, beginning at No.1.

3. From the above table, select a bearing whose size is 

appropriate for the crankshaft journal outside diameter. If the 
crankshaft journal outside diameter ID color is "yellow" and 
the cylinder block bearing bore ID mark is "III," for example, 
select a bearing whose ID color is "green" <No.1, 4> or "red" 
<No.2, 3>.
If there is no ID color paint on the crankshaft, measure the 
journal outside diameter and select a bearing appropriate for 
the measured valve.

4. Install bearings with the groove toward the cylinder block.
5. Install the bearings having no groove to the bearing cap.

.

AKX00648

BEARING BORE 
DIAMETER 
IDENTIFICATION
MARK

CYLINDER INSIDE 
DIAMETER SIZE MARK

TIMING BELT SIDE

AB

No.4

No.2

No.3

No.1

CRANKSHAFT JOURNAL OUTSIDE 
DIAMETER

CYLINDER BLOCK 
BEARING BORE

CRANKSHAFT 
BEARING No.1, 4

CRANKSHAFT 
BEARING No.2, 3

IDENTIFICATION 
COLOR

SIZE   mm (in)

IDENTIFICATION 
MARK

IDENTIFICATION 
COLOR

IDENTIFICATION 
COLOR

Yellow

63.994 

− 64.000

(2.5194 

− 2.5197)

I

Pink

Blue

II

Red

Pink

III

Green

Red

None

63.988 

− 63.994

(2.5192 

− 2.5194)

I

Red

Pink

II

Green

Red

III

Black

Green

White

63.982 

− 63.988

(2.5190 

− 2.5192)

I

Green

Red

II

Black

Green

III

Brown

Black

AK203987

IDENTIFICATION COLOR

AB

AKX00623

GROOVE

FOR UPPER

FOR LOWER

AB

 

 

 

 

 

 

 

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