torque MITSUBISHI GALANT 1989 Service Repair Manual

00-l
GENERAL
CONTENTS
GENERAL DATA AND SPECIFICATIONS.....23
HOWTOUSETHISMANUAL......................
3
Definition of Terms ......................................3
ExplanationofCircuitDiagrams..................7
Explanation of
ManualContents .................4
Explanation of the Troubleshooting
Guide .............................................................
6
Model
Indications .........................................3
Scope of Maintenance, Repair and
Servicing Explanations
..................................
3
Troubleshooting .............................................3
LUBRICATIONANDMAINTENANCE............
34
MAINTENANCE SERVICE............................... 39
AirCleanerElement
.....................................39
Automatic
Transaxle
.....................................43
Ball Joint and Steering Linkage Seals ........45
Brake Hoses................................................. 45
Disc Brake Pads ........................................... 44
Drive Belt (For Water Pump and
Generator) .......................................................
41
Drive
Shaft Boots .........................................45
Engine Coolant
............................................. 44
Engine Oil .....................................................
41
Engine Oil Filter ...........................................41
Exhaust System
............................................ 45
FuelHoses
...................................................39
Fuel System
.................................................39
Manual Transaxle ..........................................42
RearAxle......................................................45
Rear Drum Brake Linings and
RearWheel Cylinders
..................................44
Spark
Plugs...................................................40
Timing Belt...................................................40
MASTER
TROUBLESHOOTING.....................28
PRECAUTIONS
BEFORESERVICE................15
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIESTABLE..................35
SCHEDULED
MAINTENANCETABLE ...........38
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS
.......................................20
TABLE OF MAIN SEALANTS
AND
ADHESIVES ............................................46
TIGHTENING TORQUE
................................... 27
TOWING
ANDHOISTING ..............................17
VEHICLE
IDENTIFICATION .............................8
Chassis Number ...........................................
11
EngineModel
Stamping
...............................12
Theft Protection ............................................12
Vehicle Identification Code Chart Plate.......
8
Vehicle Identification Number List
..............8
Vehicle Identification Number Location .......
8
Vehicle Information
CodePlate...................1 1
Vehicle SafetyCertificationLabel................12

00-4GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTSIndicates procedures to
be performed before the
work in that section is
started, and procedures
to be performed after
the work in that section
is finished.
Maintenance and Servicing Procedures
(1) A diagram of the component parts is provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol
mindicates a non-reusable part; the tighten-
ing torque is provided where applicable. l Removal steps:
The part designation number corres-
ponds to the number in the illustration
to indicate removal steps.
l Disassembly steps: The part designation number corres-
ponds to the number in the illustration
to indicate disassembly steps.
l Installation steps: Specified in case installation is impossi-
ble in reverse order of removal steps.
Omitted if installation is possible in
reverse order of removal steps.
8 Reassembly steps: Specified in case reassembly is im-
possible in reverse order of disassem-
bly steps.
Omitted if reassembly is possible in reverse order of disassembly steps.
Classificationsof Major Maintenance/
Service Points
When there are major points relative to mainte-
nance and servicing procedures (such as essential
maintenance and service points, maintenance and
service standard values, information regarding the
use of special tools, etc.), these are arranged
together as major maintenance and service points
and explained in detail.
*+ : Indicates that there are essential points for
removal or disassembly.
I)+ : Indicates that there are essential points forinstallation or reassembly. necessary. In this exam-
ple, sealant is applied
(where indicated) to the
I---
Symbols for Lubrication, Sealants and
Adhesives
4 . . . . .Grease
(multipurpose grease unless there is Information
concerning the locations for lubrica-
tion and for application of sealants and adhesives
is provided, by using symbols, in the diagram of
component parts or on the page following the
component parts page, and explarned.
a brand or type specified)
4 . . . . Sealant or adhesive
a. . . . .Brake fluid. automatic transmission
fluid or air conditioner compressor oil
a. . . . . Engine oil or gear oil
. . .Adhesive tape or butyl
rubber tape

GENERAL - Tightening Torque00-27
TIGHTENING TORQUE
Each torque value in the table is a standard value for tightening under \
the following conditions.
(1) Bolts, nuts and washers are all mode of steel and plated with zinc\
.
(2) The threads and bearing surface of bolts and nuts are all in dry c\
ondition.
The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast inserted nuts.
(4) If self-tapping screws or self-locking nuts are used.
Standard bolt and nut tightening torque Bolt nominal
PitchTorque Nm (ft.lbs.1diameterb-m-dh-n)Head mark@Head mark@Head mark@
M50.8 2-3 (1.4-2.2) 4-6 (2.9-4.3)
5-7 (3.6-5.1)M6
1 .o4-6 (2.9-4.3)7-11 (5.1-8.0)8-12 (5.8-8.7)
M8
1.259-14 (6.5-10)17-26 (12-19)20-30 (14-22)
Ml01.2519-28(14-20)35-5
5
(25-40)45-60 (33-43)
Ml21.2534-50(25-36)70-95(51-69)85-110 (61-80)
Ml41.560-85 (43-61)120-160(87-116)130-180(94-130)
Ml61.595-130 (69-94)180-240(130-174)200-270(145-195)
Ml81.5140-190 (101-137)260-350(188-253)300-400(217-289)
Bolt nominal
Pitch Torque Nm (ft.lbs.1
diameterh-n)b-m-dHead mark@Head mark0Head mark@
M61 .o4-6 (2.9-4.3)8-12 (5.8-8.7)9-14 (6.5-10)
M81.25lo-15 (7.2-11)19-28 (14-20)22-33 (16-24)
Ml01.2521-31 (15-22)39-60 (28-43)50-65 (36-47)
Ml01.519-29 (14-21)
36-54 (26-39)45-65 (33-47)
Ml21.2538-55 (27-40)80-1'10 (58-80)90-120 (65-87)
Ml21.7534-52 (25-38)70-95 (51-69)85-110 (61-80)
.
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1.5190-260(137-188)
M22
1.5260-350(188-253)M24
1.5340-460(246-333)630-860(456-622)
Flange bolt and nut tightening torque

00-28GENERAL - Tightening Torque/Master Troubleshooting
Taper thread tightening torque
Thread size
ITorque Nm (ftlbs.)I
r~Female thread material: Light alloy1-Female thread material: SteelI
NPTF II65-8 (3.6-5.8)
PT 1188- 12 (5.8-8.7)
PT 114, NPTF11420-30 (14-22)
PT
31840-55 (29-40)
NOTE: NPTF IS dry seat pope thread, while PT is pipe thread.
8- 12 (5.8-8.7)
16-20 (12-14)
35-45 (25-33)
60-75 (43-54)
MASTER TROUBLESHOOTING hlooKAAB
ENGINE OVERHEATS Symptom
Engine overheats Probable cause
Reference pageCoolrng system faulty14-5
Incorrect ignition timing
16-39, 40
ENGINE WILL NOT CRANK OR CRANKS SLOWLY Symptom Probable cause
Engine will not crank Starting system faulty
or cranks slowly Reference page
16-14
ENGINE WILL NOT START OR HARD TO START (CRANKS OK)
Symptom Probable cause Reference page
Engrne WIII not start or hard to
start (Cranks OK) No fuel supply to injector Injection
system problems
Ignition system problems
Vacuum leaks l Purge control valve hose
l Vacuum hoses
l intake manifold
l Intake manifold plenum
l Throttle body
l EGR valve13-90, 181, 295
13-90, 181, 295
16-32
17-3
Compression too low11-6
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GENERAL - Maintenance Service00-43
1
O.AUTOMATIC
TRANSAXLE
Inspect fluid levelMOOSSDA
1. Drive until the fluid temperature reaches the usual ternperature
[70-80°C (160- 18O”F)I.
2. Plaice vehicle on level floor.
3.Move selector lever sequentially to every position to fill
torque converter and hydraulic circuit with fluid, then place lever in “N” Neutral position. This operation is
necessary to be sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the
condition of the fluid.
The transaxle should be overhauled under the following
conditions.l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
l If there is a noticeably great amount of metal particles in the fluid.
5.Chleck to see if fluid level is in “HOT” range on dipstick.
If fluid level is low, add ATF until level reaches “HOT”
range.
LO\N fluid level can cause a variety of conditions
because it allows pump to take in air along with fluid. Air
trapped in hydraulic circuit forms bubbles which make
fluid spongy. Therefore, pressures will be erratic. Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of ATF.In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch,
and servo operation. Foaming can also result in fluid escaping from transaxle vent where it may be mistaken
for a leak.
6. Be sure to examine fluid on dipstick closely. Chaqge
fluid
Drain
tlhe fluid and check whether there is any evidence of
contamination. Replenish with new fluid after the cause of any contamina-
tion
has been corrected.
(1) Rernove drain plugs to let fluid drain.
(2) Rernove the oil pan.
(3) Check the oil filter for clogging and damage and replace
if necessary.
(4) Clean the inside of oil pan and 5 magnets.
(5) Attach the five magnets to the concave part of the oil
pan.
1 TSB Revision
(6) Clean both gasket surfaces of transaxle case and oil
pan.
(7) Install oil pan with new gasket and tighten oil pan bolts
to
IO-I 2 Nm (7.5-8.5 ftlbs.)
(8) Tighten drain plug with gasket to 30-35 Nm (22-25 ft.lbs.).
(9) Supply 4
dm3 (4.23 qts.) of specified ATF into case
through dipstick hole. [Total quantity of ATF required is 6.1
dm3 (6.45 qts.).
Actually however, approx. 4.5 dm3 (4.76 qts.) of fluid
car1 be replaced because rest of fluid remains in torque converter.]
1

11-I
CONTENTSM11AA-
ENGINE
>
........................
53
CAMSHAFT AND CAMSHAFT OIL
SEALS..........................................68
CYLINDER HEAD GASKET
.................73
ENGINE ASSEMBLY
.........................63
OIL PAN AND OIL SCREEN ...............71
SERVICE ADJUSTMENT
PROCEDURES................................
57
Basic
Idle Speed Adjustment
...........................
.
Refer to GROUP 13
Compression Pressure Check ..............
59
Curb- Idle Speed Adjustment_.___..__._____....___._....Refer to GROUP 13
Dash Pot Inspection and Adjustment 58
Drive Belts Tension Adjustment . 6
1
Engine Oil Check . . .
_. _. . . _. . . . . . . 57
Ignition Timing Adjustment
__..._.__...................Refer to GROUP 16
Lash Adjusters Check ......................
.
57
Manifold Vacuum Inspection
..............
.
60
SPECIAL TOOLS.............................56
SPECIFICATIONS
............................53
General Specifications .....................
.
53
Sealants and Adhesives ....................
56
Service Specifications......................
.
53
Torque Specifications
......................
.
54
TIMINGBELT.................................80
TROUBLESHOOTING
........................56
E,NGINE . . . . . . . . . . ..m...........2
CAMSHAFT AND CAMSHAFT OIL
SEAL. . . . . . . . . . . . . . . . . . . ..*............ . . . . . . . . . .19
CYLINDER HEAD GASKET..................25
ENGINE ASSEMBLY.........................14
OIL PAN AND OIL SCREEN. . . . . . . . . . . . . . . .23
SERVICE ADJUSTMENT
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . ..*.......7
Basic Idle Speed Adjustment
. . . . . . . .._......... . Refer to GROUP 13
Compression Pressure Check . .
.
8
Curb Idle Speed Adjustment
.__................ _. . . . Refer to GROUP 13
Drive Belts Tension Adjustment .........
.
12
Engine Oil Check
..........................
.
7
Ignition Timing Adjustment
_...___............... . . . . . Refer to GROUP 16
Lash Adjusters Check . . . . . . . . . . . .
7
Manifold Vacuum Inspection . . . . . . . . . .9
Timing Belt Tension Adjustment . . . .10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
.5
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
General Specifications _. _.2
Sealants and Adhesives
._ _. . . . . . . .5
Service Specifications . . . .2
Torque Specifications . . . . . . . . . . . . . . . .4
TIMING BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . m.. .6
Compression Too Low
Connecting Rod Noise/Main Bearing Noise Excessive Engine Rolling and Vibration
Noisy Valves
Oil Pressure Drop
Oil Pressure Too High
Timing Belt Noise

II-4ENGINE - Specifications
TORQUE SPECIFICATIONS Items
Nm ft.lbs.
Engine mount insulator nut (large)
60-8043-58
Engrne mount insulator nut (small)30-4022-29
Engine mount bracket nut and bolt
50-6536-47
Front roll stopper insulator nut
50-6536-47
Front roll stopper bracket to center member
40-5029-36
Rear roll stopper insulator nut
40-5029-36
Rear roll stopper bracket to crossmember
40-5029-36
Transaxle mount insulator nut
60-8043-58
Transaxle mount bracket to body
40-5029-36
Fuel high pressure hose to fuel rail 4-
6
3-4
Accelerator cable adjusting bolt 4-63-4
Front exhaust pipe clamp bolt
30-4022-29
Front exhaust pipe to exhaust manifold
40- 5029-36
Power steering oil pump to bracket 35-4525-33
Air conditioning compressor to bracket 23-27
17-20
Oil pan drain plug35-4526-33
Oilpan6-
8
4-6
Oil screen 15-2211-16
Timing belt cover
IO-127-
9
Cylinder head bolt (Cold engine)
90- 10065-72
Camshaft sprocket
80-10058-72
dater pump pulley bolt8-106-
7
Crankshaft pulley bolt
20-3014-22
Crankshaft sprocket bolt
110-13080-94
Timrng belt B tensioner bolt 15-2211-16
Tension pulley bracket bolt 23-2717-20
Right silent shaft sprocket bolt34-40”’ [43-49]*’ 25-29” [31-351”
Oil sprocket nut pump
50-6036-43
Control wiring harness and intake manifold plenum or air intake manifold\
4-
6
3-4
Front roll stopper bracket bolt 55-75
40-54
Front engine support bracket bolt50-7036-51
Exhaust pipe support bracket bolt
30-4222-30
Left engine support bracket bolt30-4222-30
Rear roll stopper bracket bolt110-13080-94
Front case bolt20-2714-20
Bear cover bolt 5-
7
4-5
Iistributor nutIO-137-
9
Rocker arm and shaft assembly bolt (large) 19-2114-15
?ocker arm and shaft assembly bolt (small)20-2714-20
ntake manifold stay bolt
18-2513-18
-iming belt tensioner spacer and bolt
43-5531-40
NOTE*I: When a 2.0 mm (.08 in.) thick washer is used.~2: When a 2.6 mm (.I0 in.) thick washer is used.
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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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ENGINE - Timing BeltII-47
~7 12
rym
I
(.47 In.)-0
io
‘0
6EN0161
/
AL
@
Plug
6EN0281
Crankshaft
sprocket “B” (3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
(.47 in.)
(4) Using a vise with soft jaws push in the auto tensioner rod. If the rod can be easily retracted, replace the auto
tensioner. You should feel a fair amount of resistance when
pushing the rod in.
Caution
1.Clamp the auto tensioner in the vise so it maintains
a level position.
2. If the plug at the bottom of the auto tensioner protrudes, surround it with a plain washer as
illustrated to prevent the plug from being in direct
contact with the vise.
SERVICE POINTS OF INSTALLATION
M1lKDCF
28. INSTALLATION OF ENGINE SUPPORT BRACKET
BOLT
Apply sealant to the bolt shown in the figure and tighten it
to the specified torque.
Specified sealant: 3M ATD Part No.8660
or equivalent
26. INSTALLATION OF CRANKSHAFT SPROCKET “B”
Install the crankshaft sprocket “B” as shown while paying
attention to its direction.
Crankshaft
6EN304
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ENGINE - Timing Belt11-51
r
L Camshaft sprocket
Idler
pulley
/Oil pumpOlA0668
sprocket
6EN0175
(3) Install the timing belt around sprockets as follows.
@ Install the timing belt around the tensioner pulley
and crankshaft sprocket and secure the timing belt
onto the tensioner pulley with your left hand.
@Pulling the belt with your right hand, install it around
the oil pump sprocket.
@Install the belt around the idler pulley.
@ Turn the camshaft sprocket one tooth clockwise to align its timing mark with the cylinder head top sur-
face (see illustration in step
0). Then, pulling the
belt with both hands, install it around the camshaft
sprocket.
@ Gently raise the tensioner pulley as shown by the arrow, so that the belt does not sag, and temporar-
ily tighten the center bolt.
. ADJUSTMENT OF TIMING BELT TENSION (1) After turning the crankshaft
l/4 turn counterclockwise,
turn it clockwise to move the
No.1 cylinder to top dead
center.
(2) Loosen the center bolt, and then, as shown in the illus- tration, attach the special tool and a torque wrench and
apply a torque of 2.6-2.8 Nm
(1.88-2.03 ft.lbs.). If the
body interferes with the special tool and the torque
wrench, use a jack to slightly raise the engine assem-
bly.
NOTE
Use a torque wrench that is capable of measurement
within a range of
O-3 Nm (O-2.2
ftlbs.)
(3) Holding the tensioner pulley with the special tool and
torque wrench, tighten the center bolt to specification.
(4) Screw the tool into the engine left support bracket until its end makes contact with the tensioner arm. At that
point, screw the tool in some more and then remove
the set wire attached to the auto tensioner.
(5) Remove the tool.
(6) Rotate the crankshaft two complete turns clockwise and leave it as is for about 15 minutes. Then, measure
the auto tensioner protrusion “A” (distance between
the tensioner arm and auto tensioner body) to ensure
that it is up to specification.
Standard value: 3.8-4.5 mm
(.15-.18 in.)
If it is out of specification, repeat steps (6) through (11)
until the specified value is obtained.
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I