Remove/install/overhaul Mitsubishi Galant VI

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt on procedure, a simple tightening specification may be all that is furnished.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Removal

Remove air cleaner. Disconnect engine coolant, vacuum, fuel and vapor hoses from carburetor. Disconnect throttle cable and automatic transmission kickdown cable (if equipped). Disconnect electrical connectors. Remove hold-down bolts and remove carburetor.

Note. DO NOT invert carburetor during disassembly. Do not remove choke valves, choke levers and related parts, round nut from accelerator pump link, adjusting screws (except idle speed, idle mixture and dashpot), or throttle valves.

Scheme 7

1. Remove damper spring, throttle return spring and bracket. Remove throttle opener/dashpot and bracket. Remove vacuum hoses, vapor hoses and vacuum delay valve.
2. Use a pin or other small tool to depress stopper tabs on the 3 throttle position sensor terminals. Remove wire and terminal from rear of connector. DO NOT bend terminal.
3. Remove 2 long and 4 short float chamber cover screws. Remove throttle body. (Scheme 7) Remove 4 short screws holding air horn assembly to mixing body and separate by gently prying with screwdriver between enrichment jet cover and air horn. (Scheme 8) Set mixing body aside.
4. From air horn assembly, remove float pin, float, and needle valve. To remove needle valve seat, use 2 flat bladed screwdrivers to carefully pry up on projecting edges of valve seat. Remove and discard "O" ring and gasket under seat.
5. Use pin or other small tool to depress stopper tabs on 2 feedback solenoid valve terminals and remove wire from rear of connector. Remove feedback solenoid valve and retainer, discard "O" rings.
6. Use pin or other small tool to depress stopper tabs on the 2 slow-cut solenoid valve terminals and remove wire from rear of connector. Remove slow-cut solenoid valve retainer. Hold valve body and pull out. Discard "O" rings.
7. If choke housing is to be removed, it is necessary to grind away the 2 rivets securing retainer plate. Remove single screw and use punch to knock out remaining rivet bodies. Remove choke plate assembly. Remove wire and terminal from rear of connector. DO NOT bend terminal.
8. Remove 3 screws holding the enrichment cover. Remove cover, 2 diaphragms, spring seat, body, 2 springs and valve. Keep in order of disassembly. Remove the mixture control valve assembly. Keep springs and diaphragms in order of disassembly. Remove any brackets.
9. Remove check weight and ball, and steel ball of anti-overfill device from mixing body. Remove main jets from jet blocks. Using a screwdriver, remove pilot jet retainer and pilot jet. Remove accelerator pump mounting screws, pump cover and link assembly, diaphragm, spring, body and gasket from mixing body.
10. Remove choke unloader and vacuum hose. Remove throttle lever assemblies. Keep in order for reassembly purposes. Remove throttle position sensor. The idle mixture adjustment screw is accessible only by drilling and knocking out plug in carburetor base. NOTE: Do not immerse synthetic parts, electrical components or diaphragm assemblies in carburetor cleaner.

Cleaning & Inspection

1. Clean all parts with soft brush and solvent. Check throttle valve and choke valve shafts for proper operation. If not operating properly, clean and lubricate.
2. Check jets for damage or clogging. Clean with compressed air. Never use wire or other metal objects. Check idle mixture adjusting screw for grooves, ridges or other damage.
3. Check needle valve assembly, strainer screen and vacuum chamber. Thoroughly inspect carburetor main body, throttle body and float chamber cover for cracks or other damage. Apply vacuum to diaphragms. Check for leakage. NOTE: Idle mixture adjustment is accessible only by drilling and knocking out the plug covering idle mixture adjusting screw.

Reassembly

1. To reassemble, reverse disassembly procedure. Ensure that all air and fuel passages are clear. Lubricate linkage after cleaning. Check throttle and choke linkage for smooth operation.
2. If a main or pilot jet needs to be replaced, make sure replacement jet is of the same size. A number is stamped on each jet.
3. To prevent carburetor-to-intake manifold gasket from being installed incorrectly, match holes of gasket to throttle body. Place gasket on intake manifold.

Installation

To install, reverse removal procedure.

Scheme 8

Removal & Installation

1. Fuel pump assembly is located inside fuel tank. Release fuel pressure from system. Raise vehicle on hoist. Drain fuel into suitable container. Disconnect electrical connectors and fuel hoses at fuel tank.
2. Remove fuel filler hose from fuel tank. Remove nuts securing fuel tank. Remove fuel tank from vehicle and remove fuel pump assembly. To install, reverse removal procedure.

Disassembly (4-Cylinder)

1. Depressurize fuel system by disconnecting fuel pump wiring harness at fuel tank. Start engine. Let run until fuel is exhausted and engine stops. Turn ignition switch to "OFF" position. Disconnect negative battery cable. On Mitsubishi Van/Wagon models remove front seats, parking brake lever, fuel filler door release handle, battery cover, seat belt and seat underframe to access engine compartment.
2. Disconnect air intake hose. Disconnect PCV, brake booster and vacuum hoses and position out of way. Drain radiator if coolant lines are to be disconnected. Disconnect coolant lines as necessary for clearance. Disconnect injector electrical connectors. Position all lines, hoses and electrical connectors out of way. On Van/Wagon models remove throttle body assembly and position out of way.
3. Disconnect high pressure fuel line at fuel rail. On models equipped with 2.0L and 2.4L engines, remove banjo bolt securing high pressure fuel line to fuel rail. Disconnect fuel return line and vacuum line connection at fuel rail. Remove fuel rail securing bolts and lift fuel rail and injectors from engine.

Disassembly (3.0L V6)

1. Depressurize fuel system by disconnecting fuel pump wiring harness at fuel tank. Start engine. Let run until fuel is exhausted and engine stops. Turn ignition switch to "OFF" position. Disconnect negative battery cable. Disconnect air intake hose. Remove throttle body assembly and position out of way (do not disconnect throttle cables or hoses).
2. Disconnect PCV, brake booster and vacuum hoses from intake plenum chamber. Remove condenser from rear of plenum. Remove EGR valve (if necessary) and EGR pipe. Unbolt ground cable and plenum support brackets near EGR pipe. Remove air intake plenum bolts and remove plenum.
3. Disconnect injector electrical connectors. Disconnect high pressure fuel line at fuel rail. Disconnect fuel return line and vacuum line connection at fuel rail. Remove fuel rail securing bolts and lift off fuel rail and injectors. (Scheme 6)

To install, reverse removal procedure. Use new gaskets, "O" rings and injector insulators. Do not drop injectors while removing or installing fuel rail.

Port Fuel Injection

Injectors may be removed after fuel rail has been removed from intake manifold. Use new insulators and "O" rings when installing injectors. Use spindle oil or gasoline on "O" ring. Install in fuel rail with a twisting motion. See FUEL RAILS (PFI) .

Throttle Body Injection

The injectors are removed as part of TBI overhaul procedure. See TBI FUEL INJECTION MIXER .

1. Drain engine coolant. To release fuel system pressure, remove side panel in luggage compartment floor. Start engine and disconnect fuel gauge connector. Once engine has stopped, turn ignition switch to "OFF" position. Disconnect negative battery cable.
2. Remove 2 hose clamps and air hose. Remove air intake pipe. Remove accelerator cable connection, coolant hose and vacuum hose connectors. Remove engine control wiring harness connnector. Remove high pressure fuel hose connection. Remove "O" ring and fuel return hose connection. Remove injector mixer and gasket from intake manifold. NOTE: Do not remove throttle valve, injector holder screen and fuel return nipple.

Scheme 9

1. If replacement is necessary, remove throttle position sensor. Remove injector holder, fuel pressure regulator, "O" ring and pulsation damper cover. Remove spring, diaphragm and "O" ring from injector holder. (Scheme 9)
2. Remove both injectors by hand. After injector removal, seal fuel inlet to prevent dirt from entering system. Remove injector "O" rings. Remove injector collar, "O" rings and seal rings. Remove damper spring, return spring, connector brackets and throttle cable bracket.
3. If replacement is necessary, remove Idle Speed Control (ISC) servo assembly. Do not disassemble ISC servo. Remove attaching screws and mixing body. Remove seal ring, throttle valve set screw, kickdown lever, adjusting screw and free lever. Remove ring, throttle lever, spring and return spring.

Cleaning

1. Clean all parts but do not immerse the following in solvent: throttle position sensor, variable resistor or ISC servo. Immersing these parts will damage the insulation. Wipe these parts with a cloth only.
2. To clean injectors and fuel pressure regulator, seal fuel inlet and outlet with sealing tape and clean in solvent. Check vacuum port of passage for clogging. Clean vacuum passage and fuel passage with compressed air.

Scheme 10

Scheme 11

1. Install new seal ring into groove of throttle body. Install mixing body onto throttle body. Install ISC servo and bracket. Install connector bracket to throttle body and clamp ISC connector into bracket. Install damper and throttle return springs.
2. Insert new seal rings (flat side up) into mixing body. (Scheme 10) Install new "O" ring onto injectors. Install injectors into mixing body, pushing injector down firmly by hand. Injectors may be color coded. Blue or Black injector has a large orifice and is installed on right side of mixing body. Gray or Brown injector has a small orifice and is installed on left side of mixing body.
3. Insert diaphragm into injector holder. Install spring and cover, and tighten screws. (Scheme 11) Install new "O" rings onto fuel pressure regulator and position unit onto injector retainer. Check retainer filters for obstruction or damage and replace as necessary. Install injector retainer and push down firmly. Gradually and alternately tighten screws to specification.

1. Ensure mounting surfaces are clean and new gaskets are used. To install, reverse removal procedure. When connecting high pressure fuel hose to injection mixer, coat hose union with gasoline. Use care not to damage "O" ring during installation of hose.
2. Adjust ISC servo and throttle position sensor settings. Connect accelerator cable to throttle lever of injection mixer and adjust accelerator free play. Run engine and check for fuel or coolant leaks.

Removal (PFI)

Disconnect air intake hose. Remove connections on accelerator and automatic speed control cable (if equipped). Disconnect fuel vapor hose, electrical harness connector, vacuum hose and the 2 coolant hoses. Remove throttle body retaining bolts.

Disassembly

Remove throttle position sensor. Remove idle speed control motor. Remove throttle bracket and connector bracket (if equipped). Remove idle position switch and adjusting nut.

Note. Do not remove throttle valve. Do not use cleaning solvents on throttle position sensor, idle speed control motor or idle position switch.

Clean all parts except those noted in solvent. Check vacuum port and passage for clogging. Clean vacuum, vapor and fuel passages with compressed air.

To reassemble, reverse disassembly procedure.

To install, reverse removal procedure.

Remove heat protector and oxygen sensor. Remove catalytic converter to turbocharger retaining nuts. Disconnect oil hose from oil return pipe and timing chain case. Remove oil pipe from turbocharger and oil filter bracket. Remove air intake pipe connecting bolt. Remove turbocharger mounting nuts and remove turbocharger assembly from exhaust manifold.

Inspection

Check turbocharger case for cracks or damage and replace as necessary. Remove any carbon or corrosion and check turbine and compressor wheels for damage. Make sure turbine and compressor wheels turn smoothly. Apply pressure into wastegate actuator through nipple and make sure actuator and wastegate valve linkage operate properly.

To install, reverse removal procedure. Before oil pipe flare nut (above turbocharger) is installed, pour clean engine oil into turbocharger. Make sure oil and air hoses are properly installed and securely clamped. Use new gaskets. Check for oil or coolant leaks.

Removal (2.6L Turbo)

Remove heat shields from turbocharger and catalytic converter as necessary to gain access to oxygen sensor. Remove 2 nuts securing oxygen sensor to catalytic converter inlet. Remove sensor.

Removal (All Others)

On all other models, the oxygen sensor is a simple screw-in device. No information available from manufacturer.

To install, reverse removal procedure. Tighten to specification. See TORQUE SPECIFICATIONS table.

THROTTLE POSITION SENSOR/SWITCH

Note. Do not remove throttle position sensor unless it has tested defective and is being replaced.

Carbureted

1. Loosen accelerator cable tension. Loosen idle speed adjusting screws to completely close throttle valve (count and record number of turns out). Ensure fast idle cam is not holding throttle valve open. Disconnect carburetor wire connectors and install Test Harness (MD998464 ). Connect DVOM to terminal No. 8 (Blue Clip on harness) and terminal No. 3 (Red clip) of the harness.
2. Turn ignition switch to "ON" position. DVOM should read .25 volt. If outside this range loosen TPS and turn until correct reading is obtained (clockwise increases voltage). Tighten TPS. Turn ignition to "OFF" position. Remove test harness.
3. Reset idle speed screws as recorded in step 1). Start engine. Check idle speed. Idle should be 625-900 rpm.

PFI

1. Loosen accelerator cable tension. Disconnect TPS wire harness and install Test Harness (MD998464 ). Connect DVOM to terminal No. 4 (Blue Clip on harness) and terminal No. 2 (Red clip) of the TPS.
2. Turn ignition switch to "ON" position. DVOM should read .48-.52 volt. If reading is outside this range, loosen TPS and turn until correct reading is obtained. Tighten TPS. Turn ignition switch to "OFF" position. Remove test harness.
3. Start engine. Check idle speed (600-800 RPM). Turn ignition off. Disconnect battery for 5 seconds or more. Adjust accelerator cable. Restart engine and allow to idle for 5 minutes or more.

Scheme 12

1. Insert joint "A" of TPS to joint "B" and temporarily tighten screws. (Scheme 12) After installing injection mixer assembly to engine, adjust throttle position sensor. Clamp connector into bracket.
2. Check for proper installation of TPS. Measure resistance value between terminals No. 1 and 2 or 2 and 3 (2 and 3 or 1 and 3 on Van/Wagon) while moving throttle lever from open to close. If resistance value changes proportionally as throttle lever is moved, TPS is okay.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• FUEL RAILS (PFI)