Removal and installation of valve drive assemblies (Mitsubishi Galant 6)

Engines 1.5 l and 1.8 l

Removal

1. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. On 1.8L models, label and disconnect the high voltage wires from the spark plugs.

3. Disconnect the throttle cable, breather pipe and PCV valve with the hose connected to it.

4. Remove the cylinder head cover (see Section Removal and installation the cylinder head cover). The design of the valve drive assembly is shown in the illustrations.

5. Loosen the fasteners evenly in several steps and remove the axles with the rocker arms attached to them from the engine.

6. If there is a need to remove the rocker arms from the axles, ensure that the components are stored in an organized manner (during assembly, they must be installed strictly in their original places).

Installation

1. Lubricate the rocker arm axles with clean engine oil and install the rocker arms and springs on them (strictly in their original places).

2. Install the axle assemblies with rocker arms into the engine and tighten their mounting bolts to the required torque (32 N·m).

3. Check that the valve clearances are adjusted correctly, make the appropriate adjustments if necessary, then install the cylinder head cover and tighten its mounting bolts to the required torque (1.8 N·m for 1.5 l engines and 3.3 N·m for 1.8 l engines).

4. If removed, connect the high-voltage wiring to the spark plugs.



5. Restore the original connections of the throttle cable, breather pipe and PCV hose.

6. Connect the negative cable to the battery.

Engines 2.0L SOHC

Removal

1. On these engines, the rocker arms of the valve drive are equipped with hydraulic tappets. If necessary, the tappet can be removed from its seat in the rocker arm. The authors of this Manual recommend replacing all tappets and hydraulic valve clearance correctors at the same time. The design of the valve drive assembly is shown in the illustration.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the cylinder head cover.

4. Mark the position of the distributor housing in relation to the cylinder head. Remove the distributor.

5. Remove the timing belt.

6. Moving from the center outward, evenly in several steps in a diagonal order, loosen the fasteners of the camshaft bearing caps.

7. Remove the rocker arm axles with the rocker arms mounted on them, complete with bearing caps. Remember that when assembling, all components must be installed strictly in their original places and in their original positions!

8. Remove the valve train assembly, starting with the rear bearing cover, then moving on from one component to the next.

9. Check the condition and freedom of rotation of the rocker arm rollers, assess the degree of wear of the inner walls of the seats for the tappets. If necessary, replace the rocker arms.

Installation

1. Lightly lubricate the rear edges of the end bearing caps.

2. Place the assemblies into the front bearing cap (with the axle marks facing up). Screw in the mounting bolt, but do not tighten it yet.

3. Screw in the cap bolts of the remaining bearings and tighten them evenly to the required torque (20 Nm). Remove the valve clearance adjuster holders.

4. Install the timing belt.

5. Install the ignition distributor in place, making sure that the mounting marks applied during dismantling are correctly aligned.

6. Remove the devices that secure the hydraulic corrector assemblies.

7. Replace the cylinder head cover - do not forget to replace the gasket and half-ring seals.

8. Connect the negative cable to the battery.

9. Start the engine and check that the ignition timing is set correctly; if necessary, make the appropriate adjustments (see Chapter Settings and ongoing maintenance).

1.6L and 2.0L DOHC engines (turbocharged and non-turbocharged)

Removal

1. The design of the valve train for 1.6L and 2.0L DOHC engines is shown in the illustration.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the cylinder head cover and sealing gasket (the latter must be replaced without fail).

4. Install the valve clearance adjuster locking tools (MD998443 or equivalent).

5. In several steps, evenly loosen and unscrew the valve drive assembly clamping bolts and remove the latter from the engine. If it is necessary to dismantle the assembly, ensure that the components to be removed are stored in an organized manner.

6. Check the condition and freedom of rotation of the rocker arm rollers, assess the degree of wear of the inner walls of the seats for the tappets. If necessary, replace the entire set of rocker arms.

Installation

1. After lubricating the components, assemble the valve drive assembly, installing the rocker arms and springs in their standard places.

2. Install the assembly on the engine and tighten the mounting bolts evenly in several steps to the required torque (29÷35 N·m).

3. Remove the devices used to secure the hydraulic correctors.

4. Replace the cylinder head cover (remember to replace the sealing gasket).

5. Connect the negative cable to the battery.

2.4L engines

Removal

1. The design of the valve mechanism drive for 2.4 l engines is shown in the illustration.



2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Release the throttle cable from the fastening clamps and move it to the side.

4. Remove the air intake sleeve.

5. Disconnect the breather pipe and PCV hose.

6. Disconnect the high voltage wires from the spark plugs.

7. Remove the cylinder head cover with the sealing gasket.



8. Install the valve clearance adjuster locking tools (MD998443 or equivalent).

9. In several steps, evenly loosen and unscrew the valve drive assembly clamping bolts and remove the latter from the engine. If it is necessary to dismantle the assembly, ensure that the components to be removed are stored in an organized manner.

10. Check the condition and freedom of rotation of the rocker rollers, assess the degree of wear of the inner walls of the seats for the tappets. If necessary, replace the entire set of rocker arms.

Installation

1. Immerse the valve clearance adjuster assemblies in clean diesel fuel and fill them, removing all air: using a wire, move the plunger up and down four or five times, while lightly pressing the control ball (repeat the procedure for each of the tappets).

2. Place the pushers each in its own rocker arm and secure them using a special device.

3. Lubricate the axles with clean engine oil and install the rocker arms on them.

4. Temporarily tighten the axle mounting bolts so that the rocker arms of all intake valves do not press on the latter.



5. Place the axle springs on top, positioning them at correct angles to the plug. Place the springs before installing the exhaust valve actuator assembly.

6. Place the exhaust valve drive assembly into the engine, screw it in and tighten its mounting bolts evenly in several steps to the required torque (32 Nm).

7. Remove the fixing assemblies of the hydraulic correctors of the device.

8. Replace the cylinder head cover and tighten its mounting bolts to 3 N·m.

9. Connect the high voltage wires to the spark plugs.

10. Connect the PCV hose and breather pipe to the cylinder head cover.

11. Reinstall the air intake hose.

12. Restore the original gasket and throttle cable connection.

13. Connect the negative cable to the battery.

Engines 3.0L SOHC

Removal

1. On these engines, the valve drive rocker arms are also equipped with hydraulic correctors.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the cylinder head cover.

4. Install the valve clearance adjuster locking tools (MD998443 or equivalent).

5. In several steps, evenly loosen and unscrew the valve drive assembly clamping bolts and remove the latter from the engine. If it is necessary to dismantle the assembly, ensure that the components to be removed are stored in an organized manner.

6. Remove the rear camshaft bearing cover, then remove the valve drive rocker arm, springs and washers from the axle - make sure that the components being removed are stored in an organized manner.

7. Assess the condition and degree of wear of the components; if necessary, replace the entire set of rocker arms.

Installation

1. Immerse the valve clearance adjuster assemblies in clean diesel fuel and fill them, removing all air: using a wire, move the plunger up and down four or five times, while lightly pressing the control ball (repeat the procedure for each of the tappets).

2. Place the pushers each in its own rocker arm and secure them using a special device.

3. Lubricate the axles with clean engine oil and install the rocker arms on them.

4. Place the valve train assembly into the cylinder head.

5. Lightly coat the rear edges of the end bearing caps with sealant.



6. Make sure that the rocker arm axles are turned with the notches facing up, then install the bearing caps (make sure they are oriented correctly), screw in the bearing caps and tighten the mounting bolts evenly in several steps to the required torque (20 Nm).

7. Remove the fixing assemblies of the hydraulic correctors of the device.

8. Replace the cylinder head cover.

9. Connect the negative cable to the battery.

Engines 3.0L DOHC

Remember that gasoline is highly flammable! When working with fuel system components, observe all accepted fire safety measures. Do not smoke! Do not approach the work area with an open flame or unprotected portable appliance! Do not service the system in rooms equipped with natural gas heating devices equipped with a pilot flame (such as water heaters and clothes dryers). Do not forget that gasoline is a carcinogen, i.e., a substance that promotes the development of cancer! Try to avoid fuel coming into contact with exposed areas of the body, use rubber protective gloves, and in case of accidental contact with fuel, wash your hands thoroughly with warm water and soap. Collect spilled fuel immediately and do not store rags soaked in fuel near open flames. Remember that the fuel system of models equipped with fuel injection is constantly under pressure. Before disconnecting fuel lines, relieve residual pressure in the system. Wear safety glasses when servicing fuel system components. Always keep a Class B fire extinguisher on hand!

Removal

1. On these engines, the valve drive rocker arms are mounted directly under the camshaft and rest at one end on the ends of the valve stems and at the other end on the hydraulic corrector assemblies.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the timing belt cover and timing belt (see Section Removal and installation the timing belt cover and timing belt).

4. Remove the center cap, breather tube and PCV hose. Disconnect the spark plug wires.

5. Remove the cylinder head cover.

6. Remove the throttle body stand, gears and oil seals of both camshafts.

7. Remove the camshaft position sensor (CMP) with the attachment from the rear side of the camshaft.

8. Remove the intake and exhaust camshafts.

9. Remove the valve drive rocker arms and hydraulic correctors, assess the degree of wear of the components, and replace the entire set if necessary.

Installation

1. Immerse the valve clearance adjuster assemblies in clean diesel fuel and fill them, removing all air: using a wire, move the plunger up and down four or five times, while lightly pressing the control ball (repeat the procedure for each of the tappets).

2. Lubricate the hydraulic valve clearance adjusters and install them in their seats in the cylinder head.

3. Lubricate the camshafts and place them in the cylinder head.

4. Install the bearing caps, screw in the mounting bolts and tighten them evenly in two or three steps. The caps of the 2nd, 3rd and 4th bearings are equipped with markings applied to their front part - make sure that the marks are aligned with the corresponding marks applied to the surface of the head. The inlet shaft caps are marked with the letter I, the outlet shaft - E. Also make sure that the rocker arms are correctly seated on the hydraulic corrector assemblies and the valve stem tails. The bolts of the front and rear bearing caps are tightened with a force of 20 N·m, the central one - 11 N·m.

5. Install the camshaft seals, after lubricating them with clean engine oil.

6. Install the timing belt (see Section Removal and installation the timing belt cover and timing belt), the cylinder head cover and all other components removed to provide access.

7. Connect the negative cable to the battery, start the engine and check for signs of developing leaks.

3.5L engines

Removal

1. The design of the valve drive used on these engines is shown in the illustration.

2. Disconnect the negative cable from the battery.

If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

3. Remove the cylinder head cover.

4. Use special clamps to secure the valve clearance adjuster assemblies in the rocker arms, then loosen (but do not unscrew) the bearing cap bolts.

5. Remove the rocker arm shafts complete with rocker arms and bearing caps.

6. Assess the degree of wear of components and replace them if necessary.

Installation

1. Install the valve train assembly with bearing caps. Tighten the mounting bolts to the required torque (31 N·m).

2. Remove the clamps securing the hydraulic correctors in the rocker arm sockets.

3. Install the cylinder head cover (remember to replace the sealing gasket).

4. Connect the negative cable to the battery.