Engine: Removal & Installation Mitsubishi Galant VIII

Removal

1. Drain cooling system. Remove hood. Release fuel pressure from fuel system. See «FUEL PRESSURE RELEASE»(ref-49449-S02179145682001011500000) .
2. Drain engine oil and transaxle oil. Remove transaxle. On M/T models, see «CLUTCH»(ref-49446) article in the POWERTRAIN category. On A/T models, see «TRANSMISSION REMOVAL & INSTALLATION - A/T»(ref-49447) article in AUTOMATIC TRANSMISSION SERVICING.
3. On all models, remove radiator and cooling fan assembly. Disconnect all necessary electrical connectors, vacuum hoses, fuel hoses and cables. Leaving hoses connected, remove power steering pump and A/C compressor, and support aside.
4. Disconnect exhaust pipe from exhaust manifold. Using lifting device, support weight of engine. Remove upper engine mount bracket assembly. Raise engine slightly. Ensure all cables, hoses and electrical harnesses are disconnected from engine. Lift engine upward from engine compartment.

Installation

To install, reverse removal procedure. Ensure all hoses and wires are cleared when lowering engine assembly into engine compartment. Perform final tightening of mounting bolts and nuts with weight of engine on insulators. See TORQUE SPECIFICATIONS . Refill all fluids, and adjust all cables and linkages.

1. Release fuel pressure from fuel system. See «FUEL PRESSURE RELEASE»(ref-49449-S02179145682001011500000). Disconnect negative battery cable. Disconnect air intake hose from air intake pipe.
2. Drain cooling system. Disconnect all necessary electrical connectors, vacuum hoses, coolant hoses, fuel hoses and cables from intake manifold, injectors and throttle body. (Scheme 1)
3. Remove air intake pipe and throttle body. Remove air intake plenum from intake manifold. Remove fuel delivery pipe with fuel injectors and pressure regulator attached. DO NOT allow fuel injectors to fall from delivery pipe during removal.
4. Remove intake manifold-to-cylinder block support brace. Remove intake manifold-to-cylinder head bolts. Remove intake manifold and gasket. If necessary, remove remaining components from intake manifold.

To install, reverse removal procedure. Use NEW gaskets, fuel injector insulators and "O" rings. Adjust all control cables. Fill cooling system.

Scheme 1

Remove exhaust manifold heat shield. Disconnect exhaust pipe and gasket from manifold. Remove oxygen sensor. Remove exhaust manifold.

To install, reverse removal procedure. Use NEW gaskets and exhaust pipe-to-manifold nuts.

Scheme 2

1. Release fuel pressure from fuel system. See «FUEL PRESSURE RELEASE»(ref-49449-S02179145682001011500000).
2. Drain cooling system. Drain engine oil. Remove air intake hose and pipe from top of rocker cover. Disconnect all necessary electrical connectors, vacuum hoses, coolant hoses, fuel hoses and cables.
3. Remove power steering and A/C pumps (with hoses connected if possible), and support aside. Disconnect exhaust pipe from exhaust manifold. Remove upper front timing belt cover.
4. Turn crankshaft to TDC of compression stroke on cylinder No. 1 by aligning mark on cylinder head with mark on camshaft sprocket. (Scheme 2) Remove rocker cover.
5. Remove distributor cap. Mark rotor-to-distributor position. Mark distributor-to-cylinder head position. Remove distributor. Mark timing belt in alignment with timing mark on camshaft sprocket. Secure timing belt to camshaft sprocket with plastic tie-wraps to maintain correct position. Remove camshaft sprocket bolt.
6. Slide camshaft sprocket (with belt attached) off camshaft. DO NOT turn crankshaft. Loosen cylinder head bolts in 2-3 steps, in proper sequence. (Scheme 3) Remove cylinder head and gasket.

Scheme 3

1. Install cylinder head using NEW gasket. Ensure identification mark at timing belt end of gasket faces upward. DO NOT apply sealant to head gasket. Apply engine oil to cylinder head bolt threads and washers. Install and tighten cylinder head bolts in 2-3 steps, to specification in proper sequence. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-49449-S04895624952001011500000).
2. To complete installation, reverse removal procedure. Apply sealant to contact surfaces of semi-circular packing. Adjust all control cables. Fill cooling system. Refill with engine oil