Mitsubishi Galant (2004+). Manual - part 611

 

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Mitsubishi Galant (2004+). Manual - part 611

 

 

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-61

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1113023400688

ITEMS

SPECIFICATIONS

Generator and drive belt
Adjusting bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Crankshaft bolt

185 

± 5 N⋅m (137 ± 3 ft-lb)

Drive belt tensioner nut

49 

± 9 N⋅m (37 ± 6 ft-lb)

Generator bolt

49 

± 9 N⋅m (37 ± 6 ft-lb)

Generator bracket bolt

49 

± 9 N⋅m (37 ± 6 ft-lb)

Idler pulley nut

49 

± 9 N⋅m (37 ± 6 ft-lb)

Oil dipstick guide bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Power steering pump bracket bolt

41 

± 8 N⋅m (30 ± 6 ft-lb)

Power steering pump bracket stay bolt M8

24 

± 4 N⋅m (18 ± 3 ft-lb)

Power steering pump bracket stay bolt M10

44 

± 10 N⋅m (33 ± 7 ft-lb)

Tensioner bracket bolt (Flange bolt)

49 

± 9 N⋅m (37 ± 6 ft-lb)

Tensioner bracket bolt (Bolt, washer assembly)

41 

± 8 N⋅m (30 ± 6 ft-lb)

Intake manifold plenum and throttle body
Boost sensor bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Exhaust gas recirculation pipe bolt

19 

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust gas recirculation pipe nut

19 

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust gas recirculation pipe flare nut

59 

± 10 N⋅m (43 ± 7 ft-lb)

Exhaust gas recirculation valve bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Intake manifold plenum bolt

28 

± 4 N⋅m (21 ± 3 ft-lb)

Intake manifold plenum stay bolt M8

18 

± 2 N⋅m (13 ± 1 ft-lb)

Intake manifold plenum stay bolt M10

36 

± 6 N⋅m (27 ± 4 ft-lb)

Solenoid valve bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Throttle body bolt

28 

± 4 N⋅m (21 ± 3 ft-lb)

Throttle body stay bolt

18 

± 2 N⋅m (13 ± 1 ft-lb)

Vacuum pipe and hose bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Ignition system
Ignition coil bolt

10 

± 2 N⋅m (87 ± 17 in-lb)

Spark plugs

25 

± 5 N⋅m (18 ± 4 ft-lb)

Camshaft position sensor bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Camshaft position sensor support bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Camshaft position sensing cylinder bolt

22 

± 4 N⋅m (16 ± 3 ft-lb)

Timing belt
Adjusting bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Auto-tensioner bolt

23 

± 3 N⋅m (18 ± 2 ft-lb)

Bracket bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Camshaft sprocket bolt

88 

± 10 N⋅m (65 ± 7 ft-lb)

Crankshaft position sensor bolt

8.5 

± 0.5 N⋅m (76 ± 4 in-lb)

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-62

Engine support bracket bolt

45 

± 5 N⋅m (34 ± 4 ft-lb)

Idler pulley bolt

44 

± 5 N⋅m (33 ± 4 ft-lb)

Tensioner pulley bolt

48 

± 6 N⋅m (35 ± 4 ft-lb)

Tensioner arm bolt

44 

± 10 N⋅m (33 ± 7 ft-lb)

Timing belt front cover bolt M6

11 

± 1 N⋅m (95 ± 9 in-lb)

Timing belt front cover bolt M8, M10

14 

± 1 N⋅m (122 ± 9 in-lb)

Timing belt rear cover bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Intake manifold and fuel parts
Injector and fuel rail bolt

12 

± 1 N⋅m (104 ± 9 in-lb)

Intake manifold nut

20 

− 23 N⋅m (15 − 17 ft-lb)

Water pump and water pipes
Engine coolant temperature sensor

29 

± 10 N⋅m (22 ± 7 ft-lb)

Thermostat housing bolt M6

11 

± 1 N⋅m (95 ± 9 in-lb)

Thermostat housing bolt M8

19 

± 1 N⋅m (14 ± 1 ft-lb)

Water inlet fitting bolt

19 

± 1 N⋅m (14 ± 1 ft-lb)

Water pump bolt M8

24 

± 3 N⋅ (17 ± 2 ft-lb)

Water pump bolt M10

42 

± 8 N⋅m (31 ± 6 ft-lb)

Exhaust manifold 
Connector bracket bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Engine hanger bolt

35 

± 6 N⋅m (26 ± 4 ft-lb)

Exhaust manifold nut

44 

± 5 N⋅m (33 ± 4 ft-lb)

Exhaust manifold stay bolt M8

19 

± 3 N⋅m (14 ± 2 ft-lb)

Exhaust manifold stay bolt M10

44 

± 8 N⋅m (33 ± 5 ft-lb)

Exhaust manifold stay bolt M12

75 

± 10 N⋅m (56 ± 7 ft-lb)

Heat protector bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Heated oxygen sensor

44 

± 5 N⋅m (33 ± 4 ft-lb)

Rocker arms and camshaft
Thrust case bolt

13 

± 2 N⋅m (115 ± 17 in-lb)

Positive crankcase ventilation valve

10 

± 2 N⋅m (87 ± 17 in-lb)

Rocker arms and shaft bolt

31 

± 3 N⋅m (23 ± 2 ft-lb)

Rocker cover bolt

3.5 

± 0.5 N⋅m (31 ± 4 in-lb)

Cylinder head and valve
Cylinder head bolt

108 

± 5 N⋅m (80 ± 4 ft-lb) → 0 N⋅m (0 in-lb) 

→ 108 ± 5 N⋅m (80 ± 4 ft-lb)

Oil pan and oil pump
Baffle plate bolt

9.0 

± 2.0 N⋅m (80 ± 17 in-lb)

Cover bolt

10.8 

± 0.9 N⋅m (96 ± 7 in-lb)

Drain plug

39 

± 5 N⋅m (29 ± 4 ft-lb)

Engine oil pressure switch

10 

± 2 N⋅m (87 ± 17 in-lb)

Oil filter bracket bolt M8

23 

± 3 N⋅m (18 ± 2 ft-lb)

ITEMS

SPECIFICATIONS

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-63

GENERAL SPECIFICATIONS

M1113000200553

SERVICE SPECIFICATIONS

M1113000300516

Oil filter bracket bolt M10

41 

± 8 N⋅m (30 ± 6 ft-lb)

Oil filter bracket cover bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Oil pan, lower bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Oil pan, upper bolt

9.0 

± 3.0 N⋅m (80 ± 26 in-lb)

Oil pump case bolt

14 

± 1 N⋅m (122 ± 9 in-lb)

Oil pump cover bolt 

10 

± 2 N⋅m (87 ± 17 in-lb)

Oil screen bolt

19 

± 3 N⋅m (14 ± 2 ft-lb)

Relief plug

44 

± 5 N⋅m (33 ± 4 ft-lb)

Piston and connecting rod
Connecting rod cap nut

27 

± 2 N⋅m (20 ± 1 ft-lb) + 90° to 94°

Crankshaft and cylinder block
Bearing cap bolt

74 

± 4 N⋅m (54 ± 3 ft-lb)

Block heater bolt

2.6 

± 0.2 N⋅m (23 ± 1 in-lb)

Flywheel or drive plate bolt

74 

± 1 N⋅m (54 ± 1 ft-lb)

Knock sensor

23 

± 2 N⋅m (17 ± 1 ft-lb)

Knock sensor bracket bolt

28 

± 2 N⋅m (22 ± 1 ft-lb)

Oil seal case bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

Rear plate bolt

11 

± 1 N⋅m (95 ± 9 in-lb)

ITEMS

SPECIFICATIONS

DESCRIPTIONS

SPECIFICATIONS

Type

60

° V, OHV, SOHC

Number of cylinders

6

Combustion chamber

Pentroof type

Total displacement cm

3

 (cu in)

3,828 (233.6)

Cylinder bore mm (in)

95.0 (3.74)

Piston stroke mm (in)

90.0 (3.54)

Compression ratio

10.0

Valve timing

Intake valve

Opens (BTDC)

7

°

Closes (ABDC)

61

°

Exhaust valve

Opens (BBDC)

61

°

Closes (ATDC)

15

°

Lubrication system

Pressure feed, full-flow filtration

Oil pump type

Trochoid type

ITEMS

STANDARD VALUE

LIMIT

Timing belt
Auto tensioner rod length mm (in)

4.8 

− 6.0 (0.19 − 0.21)

Auto tensioner rod production length mm (in) 12 (0.5)

SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <3.8L ENGINE>

11D-64

Auto tensioner rod pushed-in amount
[when pushed with a force of 98 to 196 N (22 
to 44 lb)] mm (in)

1.0 (0.03) or less

Rocker arms and camshaft
Camshaft cam height 
mm (in)

Intake

37.39 (1.472)

Minimum 36.89 (1.452)

Exhaust

37.71 (1.485)

Minimum 37.21 (1.465)

Camshaft journal outside diameter mm (in)

45 (1.8)

Cylinder head and valves
Cylinder head flatness of gasket surface mm 
(in)

Less than 0.03 (0.001)

0.2 (0.007)

Cylinder head grinding limit of gasket surface 
mm (in) Total resurfacing depth of cylinder 
head and cylinder block

0.2 (0.007)

Cylinder head overall height mm (in)

120 (4.7)

Valve thickness of valve 
head (margin) mm (in)

Intake

1.0 (0.04)

Minimum 0.5 (0.02)

Exhaust

1.2 (0.05)

Minimum 0.7 (0.03)

Valve overall height mm 
(in)

Intake

110.30 (4.343)

Minimum 109.80 (4.323)

Exhaust

112.11 (4.414)

Minimum 111.61 (4.394)

Valve stem outside 
diameter mm (in)

Intake

6.0 (0.24)

Exhaust

6.0 (0.24)

Valve thickness to valve 
guide clearance mm (in)

Intake

0.02 

− 0.05 (0.0008 − 0.0019)

0.10 (0.003)

Exhaust

0.04 

− 0.06 (0.0016 − 0.0023)

0.15 (0.005)

Valve face angle mm (in)

43.5

° − 44°

Valve spring free length mm (in)

51.0 (2.01)

50.0 (1.97)

Valve spring load/installed height N (lb) /mm 
(in)

267/44.2 (60.0/1.74)

Valve spring out-of-squareness

2

° or less

4

°

Valve seat valve contact width mm (in)

0.9 

− 1.3 (0.04 − 0.05)

Valve guide inside diameter mm (in)

6.0 (0.24)

Valve guide projection from cylinder head 
upper surface mm (in)

14 (0.6)

Valve stem projection 
mm (in)

Intake

48.30 (1.902)

48.80 (1.921)

Exhaust

51.71 (2.036)

52.21 (2.056)

Oversize rework 
dimensions of valve 
guide hole mm (in)

0.05 oversize 
diameter

11.05 

− 11.07 (0.4351 − 0.4358) −

0.25 oversize 
diameter

11.25 

− 11.27 (0.4429 − 0.4437) −

0.50 oversize 
diameter

11.50 

− 11.52 (0.4528 − 0.4535) −

ITEMS

STANDARD VALUE

LIMIT

 

 

 

 

 

 

 

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