1989 MITSUBISHI GALANT Service Repair Manual

COOLING -Engine Coolant Temperature Gauge Unit, Engine Coolant
Temperature Sensor and Engine Coolant Temperature Switch14-33
20R0586
ENGINE COOLANT TEMPERATURE SWITCH

(Air conditioning or A/T control)
(1) Remove the engine coolant temperature switch from the
water outlet fitting.
(2) immerse the engine coolant temperature switch in oil and heat by a gas stove or similar method so as to increase the
oil temperature.
(3) Check to be sure that the engine coolant temperature switch is switched ON when the oil temperature reaches
the standard value.
Standard value:
lOO-104% (212-219°F)
CautionUse engine oil for this test; stir it well while heating,
and do not heat more than necessary.
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1

NOTES

15-1
INTAKE AND
EXHAUST
CONTENTSMl!iAn-
AIR CLEANER. . . . . . . . . . . . . a.. . . . . . . . . . . . . . . . . . . .9
CHARGE AIR COOLER
. . . . . . . . . . . . . . . . . . . . . . . . .12
EXHAUST MANIFOLD >
. . . . . . . . . . . . . . . . . . . . . . . .30
EXHAUST MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . . .27
EXHAUST MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . .28
EXHAUST PIPE AND MAIN MUFFLER >
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .33
EXHAUST PIPE AND MAIN MUFFLER >
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .32
INTAKE MANIFOLD
. . . . . . . . . . . . . .21
INTAKE MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . . .14
INTAKE MANIFOLD
(SOHC-16 VALVE>. . . . . . . . . . . . . . . . . . . . . . . . .18 SERVICE ADJUSTMENT PROCEDURES
....
6
Air Cleaner Element Inspection and
Replacement .....
.:............................
.
6
Intake Charge Pressure Control System
Inspection
......................................
.
7
Turbocharger Bypass Valve Inspection
.....
.
8
Turbocharger Supercharging Pressure
Inspection ......................................
.
7
Turbocharger Waste Gate Solenoid
Inspection ......................................
.
8
Intake Manifold Vacuum
Inspection ..................
Refer to GROUP
11
SPECIAL TOOL .................................
.
5
SPECIFICATIONS
..............................
.
2
General Specifications
........................
.
2
Service Specifications
.........................
.
2
Torque Specifications
.........................
.
2
TROUBLESHOOTING...........................5
Abnormal Noise
Exhaust Gas Leakage
TURBOCHARGER ..............................
.
24

15-2INTAKE AND EXHAUST - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSMEch-
Items
Air cleaner
Element
Exhaust systemFront exhaust pipe
Front exhaust pipe
Muffler
Coupling
Suspension system
Turbocharger
Type
Identification No.
intake charge pressure control
Intercooler
Type Specifications
Unwoven cloth type
Dual type
Single type Expansion resonance type
Flat coupling
Rubber hangers and O-rings
Exhaust gas turbine type
TD05H-14B-6
Turbocharger waste gate actuator and valve
Air cooled type
SERVICE SPECIFICATIONS
Items
Intake and exhaust manifolds
StandardLimit
Distortion of cylinder head contacting surface mm (in.) Less than 0.15 (0059)0.3 (.012)
Turbocharger waste gate solenoid terminal resistance[at 20°C (68”F)l5-2 36-4
4
Turbocharger
Supercharging pressurekPa (psi) 31-70 (4.4-10.1)
TORQUE SPECIFICATIONS
Items
Air cleaner
Air cleaner to body
Air duct
Resonator
Branch tube
Charge air cooler
Air hose B
Air pipe A Air pipe
B
Turbocharger by-pas valve to air pipe B
Charge air cooler
Nmft.lbs.
8-106-
7
8-106-7
8-106-

7
8-106-

7
8-106-

7
12-15 9-11
12-15 9-11
15-22 11-16 12-15
9-11
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INTAKE AND EXHAUST - Specifications15-3
Items) Nm1
ftlbs.
Intake manifold
Accelerator cable to intake manifold plenum
Fuel high pressure hose to fuel rail
Fuel rail to intake manifold
Ignition coil <8 VALVE>
Intake manifold stay
Intake manifold to engine
Throttle body
<8 VALVE>

Intake manifold plenum stay
Intake manifold plenum to intake manifold
Water outlet fitting
EGR valve
(8 VALVE>
Cl6 VALVE>
EGR temperature sensor
Distributor
Therm0 valve
Control harness protector to intake manifold plenum
Vacuum pipe and hose assembly to intake manifold
ntake manifold
Accelerator cable to intake manifold
Throttle body stay
Fuel high pressure hose to fuel rail
Fuel rail to engine
Intake manifold stay
Intake manifold to engine
Mounting bolt
(M8)
Mounting nut and bolt (MIO)
Ignition coilIgnition power transistor unit
Throttle body
EGR valve
EGR temperature sensor
Control harness protector to intake manifold
Control harness clamp bolt
xhaust manifold
Heat protector to exhaust
Exhaust manifold to engine
(8 VALVE>
< 16 VALVE>
Oxygen sensor
xhaust manifold
Exhaust manifold cover (A), (8)
Engine hanger to engine mount
Engine manifold to engine
Oxygen sensor
4-6
4-6 IO-13
12-15
18-25
15-20
3-4
3-4
7-
9
9-11
13-18
11-14
IO-13
7-9
15-22 II-16
15-20
II-14
15-20
11-14
17-20
12-14 IO-15
7-11
17-26
13-18 IO-12
7-9 IO-13
7-9 20-40
14-28
4-6 3-4
8-12 6-8
4-6 3-4
15-22 II-16
4-6 3-4 IO-13
7-9 25-30
18-22 15-20
30-42
20-27
IO-12
15-22
15-22
IO-12
4-6 IO-12 II-14
22-30
14-20
7-9 11-16
11-16
7-9
3-4
12-15
7-
9
9-11 15-20 11-14
25-30
18-22
27-33 20-23
40-50
29-36
12-159-11
12-15 9-11 25-30
18-22 40-50
29-36
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I

15-4INTAKE AND EXHAUST - Specifications
Items
Exhaust manifold
Front exhaust pipe to exhaust fitting
Front exhaust pipe to engine
Heat protector
(A), (B)
Engine oil level gauge guide mounting bolt
Engine hanger to engine
Exhaust manifold to engine
Exhaust manifold to turbocharger
Oil pipe to engine
Water pipe.(B) to water inlet pipe
Turbocharger waste gate actuator Oxygen sensor
Water pipe (B) to turbocharger
Air outlet fitting
Oil pipe to turbocharger
Water pipe (A) to turbocharger
Water pipe (A) mounting bolt
Exhaust fitting
Oil return pipe
!xhaust manifold and turbocharger
Front exhaust pipe to turbocharger
Front exhaust pipe to engine
Heat protector
(A), (B)
Engine hanger to engine
Exhaust manifold to engine
Exhaust manifold to turbocharger
Oil pipe to engine
Water pipe
(B) to water inlet pipe
Oxygen sensor
Water pipe (B) to turbocharger
Air outlet fitting Oil pipe to turbocharger
Water pipe (A) to turbocharger
W
ater pipe (A) mounting bolt
Exhaust fitting
Oil return pipe
Exhaust pipe and main muffler
Front exhaust pipe to exhaust manifold



Front exhaust pipe clamp
Rubber hanger
Front exhaust pipe to catalytic converter
Catalytic converter to center exhaust pipe
Hanger bracket to body
Hook to center exhaust pipe
Center exhaust pipe to main muffler
Moulding to main muffler
1 TSBRevision
Nm
40-60
30-40
12-15
12-15
12-15
25-30
55-65
14-19
40-50
IO-13
40-50
35-50
17-20
28-34
35-50
IO-12
55-65
8-10
40-60
30-40
12-15
12-15
25-30
55-65
14-19
40-50
40-50
35-50
17-20
28-34
35-50
IO-12
55-65
8-10
40-50
30-40
40-60
30-40
IO-15
40-60
30-40
IO-15
IO-15
30-40
4-
6
1
ft.lbs.
29-43
22-29
9-11
9-11
9-11
18-22
40-47
10-14
29-36
7-
9
29-36
25-36 12-14
20-25
25-36
7-
9
40-47
6-

7
29-43
22-29
9-11
9-11 18-22
40-47
IO-14
29-36
29-36
25-36
12-14
20-25
25-36
7-
9
40-47
6-

7
29-36
22-29
29-43
22-29
7-11
29-43
22-29
7-11
7-11
22-29
3-
4

INTAKE AND EXHAUST - Special Tool/Troubleshooting15-5
SPECIAL TOOLMlSDA-
ToolNumber
Name1 Use
M 0998703
MD998748Oxygen sensor
wrench
Oxygen sensor
wrench Removal/Installation of oxygen sensor <
Non-Turbo >
Removal/installation of oxygen sensor
TROUBLESHOOTINGYl5EAa8
ISymptom
Probable cause1 RemedyI
Loose joints
Broken pipe or muffler Retighten
Repair or replace
Abnormal noise Broken separator in muffler
Replace
Broken rubber hangers
Interference of pipe or muffler with vehicle body
Broken pipe or muffler Correct
Repair or replace
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15-6INTAKE AND EXHAUST - Service Adjustment Procedures
SERVICE ADJUSTMENT PROCEDU&$
AIR CLEANER ELEMENT INSPECTION AND RE- PLACEMENT

(1) Disconnect the volume air flow sensor connector.
(2) Disconnect the connection of the breather hose.
(3) Remove the air intake hose.
(4) Push the air intake hose backward, and remove the air cleaner cover.
Caution
Care must be taken when removing the air cleaner cover, because the volume air flow sensor is at-
tached.
(5) Take out the air cleaner element.
(6) Check the air cleaner element for dirt or clogging; if necessary, clean by using compressed air.
(7) Replace the air cleaner element if the dirt or clogging is serious.
(8) Insert the element into the air cleaner body and install the air cleaner cover.
(9) Install the air intake hose.
(1O)Connect the breather hose and the volume air flow sensor
connector.

(1) Disconnect
(2) Disconnect the volume air flow sensor connector.
the breather hose, purge hose, by-pass air hose .-.
and boost hose connections.
(3) Remove the air intake hose on the air cleaner cover side and then move the air intake hose to the front of the air
cleaner body.
(4) Unclamp the air cleaner cover.
Caution
Care must be taken when removing the air cleaner
cover, because the volume air flow sensor is at-
tached.
(5) Take out the air cleaner element.
(6) Check the air cleaner element for dirt or clogging; if necessary, clean by using compressed air.
(7) Replace the air cleaner element if the dirt or clogging is serious.
(8) Insert
the element into the air cleaner body and install the
air cleaner cover.
(9) Install the air intake hose. (10)Connect the breather hose, purge hose, by-pass air hose
and boost hose.
(11 )Connect the volume air flow sensor connector.
TSB Revision