MITSUBISHI GALANT 1989 Service Manual Online

ENGINE - Winder Head Gasket
3-3.5
Nm2.2-2.5 ft.lbs. 28 Cold Engine80 Nm + 0 Nm - 20 Nm - +1/4
turn + +I/4 turn
58 ft.lbs. - 0 ftlbs. -+ 14fWbs. - +I/4 turn - +1/4 turn
/g$j?&-
- Tiff i ”.\,)
/
3
2
lo-12 Nm7-nu,L.,
40-50 Nm29-36 ftJbs.9
;;I:: k. I@@
30-40 Nm22-29 ft.lbs./18-25 Nm13-18 ft.lbs.
G
R
‘2

4
OlA0660
23. Connection for radiator upper hose
24. Connection for radiator lower hose
1)+25. Water inlet fitting, thermostat and
thermostat case assembly
26. Timing belt upper cover
4*27. Camshaft sprocket 28. Rocker cover
29. Self-locking nuts
30. Gasket
*431_ Cylinder tiead
bolt+e +432. Cylinder head assembly
l +33. Cylinder head gasket
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11-32ENGINE >
- Winder Head Gasket
sprocket
’lG90001
Intake side Front of engine e
I
Exhaust side\olCOll!iLoosening order
SERVICE POINTS OF REMOVALMllJEAZ
27. REMOVAL OF CAMSHAFT SPROCKET
(1) Rotate the crankshaft in the forward (right) direction
and align the timing mark.
Caution
The crankshaft must always be rotated in the for-
ward direction only.
(3) Use the special tool to remove the camshaft sprocketwith the timing belt attached.
Caution
After removing the camshaft sprocket, be sure not
to rotate the crankshaft.
32. REMOVAL OF CYLINDER HEAD ASSEMBLY
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head as-
sembly.
SERVICE POINTS OF INSTALLATIONMllJDCV
33. INSTALLATION OF CYLINDER HEAD GASKET
(1) Use a scraper or gasket remover to remove the gasket adhering of the cylinder block.
Caution
When doing this, be careful not to let any foreign
substances such as gasket scraps enter the cylin-
der or the engine coolant and oil passages.
(2) Tie the camshaft sprocket and timing belt with a cord
so that the position of the camshaft sprocket will notmove with respect to the timing belt.
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ENGINE - Cvlinder Head GasketII-33
Identification markr3
Intake
side “4G63K”
Front of
Exhaust side
OlA0669
Front of engine
I)Intake side
Exhaust side
OlR0391
Ei;. -Qmm (in.)0140674 (2) Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as in the illustration.
Caution
The cylinder head gasket is easy to mis-install, so
be sure to check it. If it is mis-installed, malfunc-
tions such as no oil rising to the cylinder head will
occur.
32. INSTALLATION OF CYLINDER HEAD ASSEMBLYI31.
CYLINDER HEAD BOLT
(1) Use a scraper to clean the gasket surface of the cylin-
der head assembly.
Caution
Take care that no foreign material gets into the
engine coolant passages or oil passages.
(2) When installing the cylinder head bolts, check that theshank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm (3.91 in.)
(3) Apply engine oil to the threaded part of the bolt and the
washer.
(4) According to the tightening sequence, tighten the bolts to the specified torque 80 Nm (58 ftlbs.).
(5) Loosen bolts completely.
(6) Torque bolts to 20 Nm (14.5
ft.lbs.).
(7) Tighten bolts l/4 turns (90”) more.
(8) Tighten bolts
l/4 turns (90”) additionally.
25. INSTALLATION OF WATER INLET FITTING, THERMOSTAT AND THERMOSTAT CASE ASSEMBLY
(1) Loosen the water inlet pipe bolt shown in the illustra-tion.
(2) Apply specified sealant to the thermostat case assem- bly as shown in the illustration.
Specified sealant: MITSUBISHI GENUINE PART
No.MD970389 or equivalent
(3) Apply a small amount of water to the O-ring of the
water inlet pipe, and press the thermostat case assem-bly onto the water inlet pipe.
(4) Install the thermostat case assembly mounting bolt.
(5) Tighten the water inlet pipe bolt.
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11-34
ENGINE - Timina Belt
TIMING BELT (8 VALVE>MIlKA-A
REMOVAL AND INSTALLATION
Pre-removal OperationaRemoval of under cover 50-65
Nm
36-47 ftlbs.
\ 22-29

ft.lbs.
ft.lbs.
IO-12 Nm
7-9 ft.lbs. 10
m\../.8-10 N6-7 ft.lbs.\
20-30 N,/ v \R \OlAO43414-22 ft.lbs. \I3
10-12’
Nm7-S ftlbs.
6
23-27 Nm 17-20
ft.lbs.
Removal steps
1. Clamp for pressure hose (power steering)
and high pressure hose (air conditioning)
l *2. Engine mount bracket
3. Drive belt (generator)
4. Drive belt (power steering)
5. Tensioner pulley bracket
6. Drive belt (air conditioning)
7. Water pump pulley
8. Crankshaft pulley
9. Timing belt front upper cover
10. Gasket
11. Timing belt front lower cover
12. Gasket
13. Access cover
14. Crankshaft sprocket bolt
15. Special washer
16.Tensioner spacer17.Tensioner spring
18. Timing belt tensioner
19.Spacerl *20. Timing belt21.Camshaft sprocket*‘I)22. Oil pump sprocket23.24.Crankshaft sprocketFlange25. Timing belt tensioner “B”l *26. Timing belt “B”
27. Right silent shaft sprocket
28.Spacer29. Crankshaft sprocket “B”30.Key31. Timing belt under cover
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ENGINE - Timing BeltII-35
IPost-installation Operationl installation of under coverIaService Adjustment Procedures
(Refer to P.ll-7.)I 50-60

Nm36-43 ftlbs.
31
\\15-22 Nm
11-16 ft.lbs. 24
01 A0437
30. KevIL. -I"..--+A ‘IIT:m;nn halt fmnf lower cover
Installation steps
31. Timing belt under cover
30. Key
l * 29. Crankshaft sprocket
“B”l 28. Spacer 27. Right silent shaft sprocket
25. Timing belt tensioner “B”
l * 26. Timing belt “B”
l 4Adjustment of timing belt “B” tensionl * 24. Flange23. Crankshaft sprocket
22. Oil pump sprocket
21. Camshaft sprocket
19. Spacer
l 18. Timing belt tensioner
~~ 17. Tensioner springl + 16. Tensioner spacer++ 20. Timing beltl 4Adjustment of timing belt tension
15. Special washer 14. Crankshaft sprocket bolt
tic 24. Flanae
, UtiIL , , WI ,t upper cover!hcaft n, dlqy
lb. :;d)rtroning)
\..“.w.
.-c
T-mrinnar r
nliny bracket
er steering)1 2.)
19. Spacer
++ 20. Timing belt13. Access cover
12. Gasket
l +
11. Timing belt front lower cover10. Gasketl +9. Timing belt front upper cover 8. Crankshaft pulley
7. Water pump pulley
6. Drive belt (air conditioning) (Refer to P.l l-l 2.)
5. Tensioner pulley bracket
4. Drive belt (power steering)
(Refer to
P. 1 l-l 2.)
3. Drive belt (generator) (Refer to P.l l-l 2.)
2. Engine mount bracket 1. Clamp for pressure hose (power steering)
and high pressure hose (air conditioning)
NOTE*I: Vehicles built up to N O
V. 1988
+2: Vehicles built from Dec. 1988 lrator)
U. Vll”” ““SC \y”v’ulRpfcw tn P 1 l-l
2.)
racket
NOT=
ure hose (power steering)
s-4, I” I “..J’I p.. .#““.are hose (air conditioning)
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11-36
ENGINE - Timinn Belt
Timing mark
\
Camshaft sprocket
;/
i
\
IlEN0017
Tit
e
I;
OlAO550
01A0551
SERVICE POINTS OF REMOVALMllKBDF
2. REMOVAL OF ENGINE MOUNT BRACKET
(1) Jack up the vehicle after placing a wooden block
between the jack and the engine’s oil pan.
Caution
Jack up carefully so as not to apply an excessive
load to the various parts.
(2) Remove the engine mount bracket.
20. REMOVAL OF TIMING BELT
(1) Turn the crankshaft clockwise and align the timing
marks.
Caution
The crankshaft must always be turned clockwise.
(2) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the
same direction if it is to be reused.
(3) Loosen the bolt and tension spacer of the timing belt tensioner.
(4) Move the timing belt tensioner to the water pump side and loosely tighten the bolt so that the tensioner
doesn’t return; then remove the timing belt.
NOTE
If the timing belt is to be re-used, use chalk to mark (on
its flat side) an arrow indicating the clockwise direc-
tion.
Caution
1. As water or oil on the belt can seriously reduce
its usable life, ensure that the timing belt,
sprocket, and tensioner stay clean and dry while
removed, and never wash them. Parts that have
become too dirty should be replaced.
2. When any of the parts are oily, check to see
whether there are any oil leaks in any of the oil
seals or the cam shaft oil seal on the front of the
engine.
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ENGINE - Timing BeltII-37
-
u
w
rack
rack
Separ
Crack’
7EN207
Rounded belt side
Abnormal wear (fluffy canvas fiber)
7EN20E-1 TSB Revision 22. REMOVAL OF OIL PUMP SPROCKET
(1) Remove the plug on the side of the cylinder block.
(2) Insert a Phillips screwdriver [shank diameter 8 mm
(.31
in.)] to block the left silent shaft.
(3) Remove the oil pump sprocket nut.
(4) Remove the oil pump sprocket.
26. REMOVAL OF TIMING BELT “B” Make a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
Caution
Water or oil on the belt shorten its life drastically, so
the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be
washed. Replace parts if seriously contaminated.
If there is oil or water on each part check the front case
oil seals, camshaft oil seal and water pump for leaks.
INSPECTIONMIlKCAD
TIMING BELTS
The timing belts must be checked closely. Should the following defects be evident, replace the belt with a new one.
(1) Hardened back surface rubber Glossy, non-elastic, and so hard that no mark is produced
even when scratched by a fingernail.
(2) Cracked back surface rubber.
(3) Cracked or separated canvas.
(4) Cracked tooth bottom.
(5) Cracked side.
(6) Abnormal wear on side.
NOTE
Normal belt should have clear-cut sides as if cut by a sharp
knife.

11-38
ENGINE - Timing Belt
Rubber
exposed
Tooth missing
and
canvas fiber exposed
lEN0002
Crankshaft
sprocket “B”
Crankshaft
aENzo4
Spacer
Chamfered
6EN009
(7) Abnormal wear on teeth.Initial stage:Canvas on load side tooth flank worn (Fluffy canvas
fibers, rubber gone and color changed to white, and unclear canvas texture)
Final stage: Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
(8) Missing tooth.
TENSIONER PULLEY
Turn the pulleys to check for possible binding, excessive play, and unusual noise. Replace the pulley if any of these defects is
evident.
SERVICE POINTS OF INSTALLATION
MllKDCE
29. INSTALLATION OF CRANKSHAFT SPROCKET “B”
Install the crankshaft sprocket “B” as shown while paying
attention to its direction.
28. INSTALLATION OF SPACER
(1) Apply a thin coat of engine oil to the outer circumfer-
ence of the spacer.
(2) Install the spacer with the chamfered end facing the oil
seal.
NOTE
If the spacer is installed adversely, the oil seal may be
damaged, resulting in the oil leaks.
26. INSTALLATION OF TIMING BELT “B”
(1) Ensure that crankshaft sprocket “B” timing mark and the silent shaft sprocket timing mark are aligned.
(2) Fit timing belt “B” over crankshaft sprocket “B” and
the silent shaft sprocket. Ensure that there is no slack in
the belt.
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ENGINE - Timing Belt
11-39
Crankshaft
sprocket
F,a,!,ge Crankshaft
6EN272
0180047
Crankshaft
sprocket “B”
tensioner . ADJUSTMENT OF TIMING BELT “B” TENSION
(1) Temporarily fix the timing belt “B”
tensioner such that
the centre of the tensioner pulley is to the left and
above the centre of the installation bolt, and temporari-
ly attach the tensioner pulley so that the flange is
toward the front of the engine.
(2) Holding the timing belt “B” tensioner up with your finger in the direction of the arrow, place pressure on
the timing belt so that the tension side of the belt is
taut. Now tighten the bolt to fix the
tensio,ier.
Caution
When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension on the belt.
(3) To ensure that the tension is correct, depress the belt (point A) with a finger.
If not, adjust.
Standard value: 5-7 mm (.20-.28

in.)
24. INSTALLATION OF FLANGE
Install the flange in correct direction as shown.
18. INSTALLATION OF TIMING BELT
TENSIONER/
17. TENSIONER
SPRING/lG. TENSIONER SPACER
(1) Install the tensioner spring, tensioner spacer and
timing belt tensioner.
(2) Place the upper end of the tensioner spring against the water pump body.
1

II-40ENGINE - Timing Belt
OlRO372
1(3) Move tensioner fully toward water pump and tempo-rarily secure tensioner.
Timing mark Timing mark
(on cylinder head)
Timing mark
“1(on front case) ,A.
Timing mark6EN063
3ENOO5
Tensiorof belt-I sid
e
Tension side of belt
6EN0065
20. INSTALLATION OF TIMING BELT
(1) Ensure that the timing marks of the camshaft sprock- et, the crankshaft sprocket, and the oil pump sprocket
are all aligned.
(2) When aligning the timing mark of the oil pump sprocket, remove the plug of the cylinder block; then
insert the shaft of a cross-tip
(+) screwdriver with a
shaft diameter of 8 mm
(.31 in.) into the plug hole and
check to be sure that the screwdriver’s shaft can be
inserted at least 60 mm (2.36 in.). Do not remove the
screwdriver until the timing belt is completely at-
tached.
If the screwdriver’s shaft can be inserted only to a
depth of about 20 to 25 mm
(.79 to .98 in.) because it
contacts the silent shaft, turn the sprocket by one rotation and align the timing mark once again; then
check again to be sure that the screwdriver’s shaft can be inserted at least 60 mm (2.36 in.).
(3) Install timing belt. While making sure that tension side
of belt is not slackened, install timing belt onto
crankshaft sprocket, oil pump sprocket and camshaf
t
sprocket in that order.
Caution
If the timing belt is reused, install so that the arrow
marked on it at the time of removal is pointing in
the clockwise direction.
l ADJUSTMENT OF TIMING BELT TENSION
(1) Loosen tensioner mounting bolt. By so doing, tension- er will be moved by spring and will apply tension to
belt.
(2) Recheck to be sure that each sprocket’s timing mark iscorrect.
1 TSB RevisionI