Mitsubishi Galant

1990 — 2001 of release

Repair and car operation



Mitsubishi Galant
+ Identification numbers of the car
+ Governing bodies
+ Settings and routine maintenance
- Engine
   + Removal/installation of the power unit, dismantle of components
   - Regenerative repair of the engine
      General information
      Check of kompressionny pressure in engine cylinders
      Check of oil pressure
      Alternative versions of schemes of regenerative repair of the engine
      Good advice on carrying out regenerative repair of the engine
      Preparation for performance of major maintenance
      Order of dismantling of the engine by its preparation for major maintenance
      Regenerative repair of a head of cylinders
      Regenerative repair of the block of cylinders
      Trial start and engine running in after major maintenance
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Control systems of the engine
+ Manual transmission
+ Coupling and transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Regenerative repair of a head of cylinders

General information

In engines of modern cars heads of cylinders of one of two types are used: with the top arrangement of valves (OHV) and with the top arrangement of a camshaft (OHC). The last type can be broken on the subgroup sensor switch: with one camshaft of the top arrangement (SOHC, or OHC is simple) and with two camshafts of the top arrangement (DOHC).

Now heads of cylinders are made by a molding method of an aluminum alloy that allows to lower considerably total the power unit at preservation of such vital properties, as reliability and ability to heat removal.
To be fair it is necessary to notice that on a level with aluminum when manufacturing heads of cylinders rather wide circulation has also traditional cast iron. Regardless of a material all heads are completed with saddles of valves. In some heads it is the share of each of cylinders on two valves though recently the increasing distribution is received by a multiklapanny configuration where each of cylinders can be equipped by three, four and even five valves. Thin mechanical grinding in of working facets of plates to saddles provides tightness of chambers of combustion in a closed position of valves. Use of directing plugs provides unambiguity of back and forth motion of valves and centering of the last concerning saddles. In view of told critical value is gained by size of a gap of landing of a core of the valve in the directing plug. At excessive gaps the consumption of impellent oil usually raises, there can be losses of depression and the probability of damage of klapanny saddles raises. Too dense landing of valves in directing plugs is fraught with their zakusyvaniye that conducts to inevitable decrease in capacity developed by the power unit and increase of risk of jamming of the engine. Besides directing plugs valves also surely are completed with the springs providing necessary density of pressing of plates to saddles and their return to a closed position after compelled opening under the influence of effort, a camshaft developed by ekstsentrikovy cams (ов). For fixing of springs on cores of valves special plates and two-section cutting locks (crackers) are used. In the heads made of an aluminum alloy, for protection of the last against a wipe on klapanny springs special adjusting washers are established.

In an ideal, during carrying out major (regenerative) maintenance of a head of cylinders replacement of all valves complete with springs and directing plugs should be made. However, depending on a condition of the served engine defined mainly by integrity of the owner of the car, need for such replacement can disappear. The main reason for premature wear of components of the klapanny mechanism is abnormality of adjustment of adjusting parameters of the engine. So, long operation of the unit on the reenriched air and fuel mix often leads to oil washing away from directing plugs gasoline. Repauperization of a mix conducts to excessive temperature increase of its combustion that leads to a burn-out of plates of valves and their saddles. Duration of service life of klapanny springs it is directly connected with inherent in the driver of a vehicle a driving manner, - frequent excess of turns of the engine inevitably leads to faster exit of springs out of operation.

Unfortunately, completely to prevent wear of internal components of a head of cylinders it is not obviously possible. Nevertheless, by timely carrying out regenerative repair with careful grinding in of valves will allow the owner of a vehicle to reduce material inputs at the expense of extension of service life of a head of cylinders.

It is necessary to notice that at a burn-out of only separate valves it will be reasonable to make replacement of all their set. This statement belongs as well to other components of the klapanny mechanism.

As it is not unpleasant, to define a condition of internal components of a head of cylinders probably after its preliminary dismantling. The description of procedure of dismantle of a head of cylinders on models of cars of the Mitsubishi brand Considered in the real Management is provided below in this Section.

Cleaning

 PERFORMANCE ORDER

1. Careful cleaning of a head of cylinders and components of the klapanny mechanism with the subsequent detailed check of their condition will help to define approximate volume of the forthcoming recovery operations.

Strong overheats of the engine can lead to deformation of a head of cylinders and violation of planeness of its interfaced surfaces.

2. Scratch out from the interfaced planes of a head of cylinders, the inlet pipeline and a final collector all traces of a material of old laying and hermetic, - try not to damage surfaces. Will essentially facilitate work application of a special razmyagchitel to which should impregnate previously the stuck deposits, - ask in shops of automobile accessories.
3. Remove from walls of water channels all traces of a scum.
4. A rigid wire brush carefully clean all available cavities and openings. At strong pollution of channels it is necessary to charge pro-cleaning of a head to experts.
5. "Banish" a tap suitable on the size each of boltovy openings, having removed from a carving corrosion products, traces of old hermetic and having restored the damaged rounds. In the presence of access to a source of the compressed air, blow openings, having removed from them shaving and small garbage.

When using the compressed air do not forget to put on goggles!

6. A wire brush smooth out a carving of hairpins of fastening of the inlet pipeline and a final collector.
7. Wash out a head solvent and carefully dry it. Use of the compressed air will allow to reduce essentially term of drying and will give a quality assurance of pro-cleaning of badly available cavities and openings.

For removal of traces of the deposit, procedures of cleaning essentially facilitating performance, it is possible to get different structures in many shops of automobile accessories. Remember that such means usually are chemically aggressive and should be applied with observance of the appropriate measures of precaution, - strictly adhere to instructions of the manufacturers who have been usually brought on a label of container.

8. Wash out solvent pushers of valves, then carefully dry them. Use of the compressed air will essentially facilitate procedure performance (do not forget to put on goggles).

The pushers equipped with hydroproof-readers should be put upside down in an oil bath. Remember that at assembly all components should be established strictly on the former places.

9. Wash out in solvent and carefully dry klapanny springs, their plates, saddles and crackers of cutting locks, - try not to mix components.
10. Scratch out bulk of the valves of deposits created on surfaces, then a wire nozzle to an electrodrill finally smooth out surfaces of cores and plates of valves - watch, that valves did not appear are mixed.


Dismantling

General information

The design of a head of cylinders used on the concrete engine (SOHC or DOHC) does not render basic value on an order of performance of procedure of dismantle of components of the mechanism of a drive of valves. Examples of appearance of heads of cylinders are presented on illustrations. It is necessary to notice only that when dismantling a head of the DOHC type it is necessary to give special attention to care of marking of all removed components, - components of a drive of inlet valves should not be mixed at assembly with components final at coincidence of number of the cylinder and almost absolute external identity. As a mnemonic rule when marking details it is necessary to remember that the inlet camshaft with accompanying components settles down from the inlet pipeline, final - from a final collector.



Heads with pushers of chashechny type

 PERFORMANCE ORDER

1. In the majority of heads of cylinders in the mechanism of a drive of valves pushers of chashechny type are used. Crackers of the cutting lock of a klapanny spring are located at such design in a pusher nest. For dismantling of a head of this kind be required the tool for a szhimaniye of klapanny springs of strubtsinny type, an opravka for removal of klapanny springs and a small magnet for extraction of crackers of the cutting lock.

2. If yet did not do it, take from a head of cylinders a camshaft (ы) and/or pushers of valves.

Put removed components in accurately marked plastic bags. Marking should guarantee possibility of installation of components at assembly strictly on the former places.


3. Overturn a head so that to provide possibility of installation of a clamp on it for a szhimaniye of klapanny springs, - usually the head keeps within horizontally prokladochny surface to the performer and klapanny springs from it.

4. Having enclosed an opravka for spring extraction in a pusher nest, compress a spring.

5. Helping itself a screw-driver, by means of a small magnet take crackers of the cutting lock from the landing nest.
6. Release a clamp and remove a klapanny spring.
7. Take the valve from a head of cylinders. At the corresponding complete set remove a maslootrazhatelny cap.

Special adaptations for removal of maslootrazhatelny caps are issued. It is alternatively possible to use usual nippers, - try not to damage walls of a nest of a pusher that is fraught with decrease in adequacy of landing of the last.

8. At the corresponding complete set remove from a spring an adjusting washer, - again use a magnet or a screw-driver.
9. Operating in a similar manner, remove components of the remained valves. Remember that all components should be put in accurately marked containers or packages.


Heads with pushers of lever type

 PERFORMANCE ORDER

1. For compression of klapanny springs on heads of this type the special tool of standard type is usually used. However, on some models for installation of such tool it can appear insufficiently empty seat, - in such cases it is necessary to use the tool of strubtsinny type described above.
2. If yet did not do it, remove components of the mechanism of a drive of valves (levers of a drive of valves or a yoke with the axes) and take a camshaft (ы). At the corresponding complete set remove also hydraulic proof-readers of klapanny gaps.

All removed components should be put in the organized order, special attention giving clearnesses of marking, - at assembly they should be established strictly on the former places!


3. Overturn a head so that to provide an empty seat under tool installation for compression of klapanny springs.

4. Having got the tool, compress a spring of the first valve, having completely unloaded its plate.

Owing to nagaroobrazovaniye development the plate can "become attached" to crackers of the cutting lock and for its release it is necessary slightly обстучать a hammer.

5. By means of a small magnet take crackers of the cutting lock from a landing flute on a valve core.

6. Release the tool and remove a plate and a spring from a valve core.

7. At the corresponding complete set remove a maslootrazhatelny cap.

Usually maslootrazhatelny cap is easier for removing from the valve taken from the engine (see below).

8. Overturn a head so that to provide possibility of removal of the valve from it.
9. Take the valve from a head of cylinders.

In case of need previously process flute edges under installation of crackers and an end face of a shaft of the valve a file with small tooth.


10. At the corresponding complete set remove an adjusting washer of a klapanny spring, - use a magnet or a screw-driver.

11. Operating in a similar manner, remove from a head the remained valves. Remember that all components should be put in accurately marked containers or packages.


Check of a condition of components

After careful washing and drying of the components of the klapanny mechanism removed from a head it is possible to start check of their condition. Carrying out some control measurements for what will be necessary a micrometer with divorce of sponges of 0 ÷ 25 mm, - for measurement of diameter of cores of valves, a tsiferblatny measuring instrument of plunzherny type / a telescopic nutromer, - for measurement of internal diameter of directing plugs, a calliper and the special tool for an assessment of degree of sag and correctness of a tortsovka of klapanny springs is required. In the absence of near at hand listed tools it is necessary to charge performance of check of a condition of components to specialists of car-care center.

Valves

 PERFORMANCE ORDER

1. Check working facets of plates of valves on existence of cracks, cavities and traces of excessive wear. Burn-out traces most easier come to light at survey of a cylindrical part (corbel) of a plate. The corbel should be present on a plate without fail and have identical width on all perimeter of the valve. The rounding off or an oplavleniye of edges of a corbel specifies on прогар the valve. It is necessary to estimate also degree of not planeness of a face surface of a plate, - in the presence of an excessive deflection in its central part the valve is subject to replacement (it is desirable complete with the others).
2. Further it is necessary to check a condition of a shaft of a core of the valve, - attentively examine its end face and flute edges under installation of crackers of the cutting lock, - make sure of absence задиров and agnails (especially if at removal of the valve it was necessary to resort to data processing of sites by a file). The end face of a core of the valve should be absolutely flat while some rounding off always takes place at considerable run of the unit. In case of need make restoration of planeness of an end face by a valve pro-point.

3. Having taken for a drive a valve core on a flat surface (as that the windowpane can serve), check it on existence of signs of a bend.

4. In summary measure diameter of a core of the valve in several places by means of a micrometer. Compare among themselves results of measurement, - the core should have uniform thickness on all the length. If the minimum tolerance of diameter of a core of the valve is not specified in Specifications, it is necessary to accept value of 0.025 mm as a reference point.

5. The valves defective or worn-out over an admissible limit are subject to replacement (it is desirable complete with the others).


Klapannye of a spring, their holders and crackers of the cutting lock

 PERFORMANCE ORDER

1. First of all check klapanny springs on existence of cracks, chips and other mechanical damages. Further it is necessary to measure free length of springs, - try not to mix springs of inlet valves with springs of the final. Compare results of measurements to requirements of Specifications.

2. By means of a ruler and a plotnitsky corner estimate adequacy of a tortsovka of each spring.

3. In the presence of near at hand special device, check effort developed by springs. Compare results of measurements to requirements of Specifications.
4. Given, defective and excessively worn-out springs are subject to replacement (it is desirable all set).
5. Plates of springs seldom need replacement, nevertheless, estimate a condition of their working surfaces contacting to a spring and crackers of the cutting lock. In case of identification of signs of deformation or cracks make replacement.
6. Estimate degree of wear of internal and external working surfaces of crackers of cutting locks. In case of need crackers are replaced in a set with the valve.


Head of cylinders

At survey of a head of cylinders it is necessary to give special attention to a condition of directing plugs and saddles of valves. Also it is necessary to check head molding on existence of cracks and other mechanical damages and to estimate degree of not planeness of interfaced surfaces.

Directing plugs of valves

 PERFORMANCE ORDER

1. Having made sure of serviceability of a condition of valves, it is necessary to estimate degree of wear of directing plugs on size of gaps of landing of cores of valves at them.

Preferably valves nevertheless to replace.

2. Before starting measurements, attentively examine directing plugs on existence of cracks, задиров, agnails and other mechanical damages. When using plugs of demountable type (on all heads made of an aluminum alloy) estimate density of their landing, - existence of any weak point is inadmissible. All plugs should act on identical height (considering from saddles of springs).

3. Fix a tsiferblatny measuring instrument of plunzherny type from the spring party of a head of cylinders. Slightly grease a core of the valve and fill it on the regular place. Densely press a plunzher of a measuring instrument to a lateral surface of a core of the valve around a shaft and null the device. Pull the valve here and there in the directing plug and consider the measuring instrument indication, - result write down. Develop a measuring instrument under 90 ° rather initial situation and repeat check. Having compared results of measurements among themselves, estimate size of ovality of the directing plug. Also compare results of both measurements to requirements of Specifications.

The special telescopic nutromer intended for determination of internal diameter of directing plugs of valves are issued, - when using the such device compare results of measurements to the standard requirements provided in Specifications.

4. The worn-out or damaged directing plugs are subject to replacement or a pro-point.


Saddles of valves

 PERFORMANCE ORDER

1. Make visual survey of saddles of valves. Pay attention to existence of cracks, cavities and traces прогара. Approximately estimate depth of landing of saddles in a head, - the excessive zaglubleniye speaks about wear of components. In case of identification of cracks of a saddle are subject to replacement.
2. In the presence of near at hand special tool, check saddles on existence of signs of ovality. Compare results of measurements to requirements of Specifications, in case of need make a pro-point.

In the absence of standard values it is necessary to consider maximum admissible ovality in size of 0.051 mm.


Assessment of planeness of a head

 PERFORMANCE ORDER

1. Carefully smooth out interfaced surfaces of a head of cylinders, having completely removed from them all traces of a material of old laying.
2. Check of planeness is made by means of a special measuring instrument and щупа lezviyny type. Measurement is made along DP of a head and on both diagonals of an interfaced surface.

As a measuring instrument of planeness the steel ruler put on an edge can be used.


3. If the size of not planeness exceeds 0.076 mm on length of 15.2 mm (or 0.152 mm for full length of an interfaced surface), the head of cylinders is subject to a pro-point.

After a pro-point of heads of V-shaped cylinders of engines it is necessary to pierce as appropriate also landing flange of the inlet pipeline for the purpose of compensation of change of provision of interfaced surfaces.


Check of a condition of molding of a head

 PERFORMANCE ORDER

1. Usually cracks in molding of a head appear around an arrangement of chambers of combustion the probability of their education and near candle openings, saddles of valves and basic surfaces of levers of a drive of valves, however, is not excluded.
2. It is necessary to give special attention to check of a condition to flow near final ports.
3. It is necessary to remember that visual survey does not allow to reveal the latent defects of molding. Much more detailed picture of structure of a body of a head can be received during defektoskopiya performance with application of methods of a magnetic resonance (Magnaflux®), - for the heads made of cast iron, or with application of fluorescing structures (Ziglo®), - for light-alloy heads. This sort of checks can be always made for quite reasonable payment at car repair shops.
4. The head having mechanical damages is subject to replacement.


Camshafts and pushers of valves

The description of procedures of check of a condition of camshafts and components of the mechanism of a drive of valves see in the Section Removal and installation of camshafts and pushers of a drive of valves.

Methods of restoration of components

General information

The most part of regenerative procedures should be made in the conditions of a car-care center workshop.

Grinding in of valves

 PERFORMANCE ORDER

Grinding in of valves is carried out in the last turn after the condition of all components of a head will be checked and is carried out their necessary regenerative repair/replacement.

1. If valves are recognized suitable for further use, it is necessary to make a pro-point of face surfaces of their shafts and grinding in of working facets to the saddles.

New valves also are subject to grinding in after which implementation they become rigidly adhered to the saddles.

2. Overturn a head of cylinders upside down.
3. Slightly grease cores of valves and fill them on the regular places in a head.
4. Raise the valve subject to grinding in over a saddle and put on a working surface of the last of a little special pritirochny paste.
5. Slightly moisten a sucker of the pritirochny holder and fix the last on the flat party of a plate of the valve.
6. Rotating the driving handle of the tool between palms, start to grind in the valve to the saddle. Try to intercept more often the handle, at the same time slightly changing position of the valve concerning a saddle in order to avoid formation of furrows.
7. Continue grinding in until on a working surface of a saddle the equal ring of opaque gray color of identical width on all perimeter is not formed.
8. Separate a drive and pass to grinding in of the next valve.
9. In summary do not forget to wipe carefully components, having removed from their surface all traces of pritirochny paste and an abrasive.
Springs, plates and crackers of cutting locks
10. Listed in subsection heading components are not subject to regenerative repair and in case of an exit of their system should be replaced.


Directing plugs of valves

 PERFORMANCE ORDER

1. In automobile engines only two types of directing plugs are applied: demountable (are used in light-alloy heads) and built in (are used the heads made of cast iron).

Pig-iron heads sometimes also are completed with demountable plugs.

2. Restoration of worn-out directing plugs can be made by one of four ways: nakatka; installation of inserts; boring and replacement.
3. At a nakatka metal of a detail is deformed that leads to gap reduction. Plug centering is at the same time restored. Nakatka is the simplest and cheap method of restoration of directing plugs, however demands existence of special tool base and leads to considerable reduction of service life of the restored detail.
4. The bronze insert can be established in the worn-out directing plug after its preliminary boring. The inserts equipped with a carving are issued, - for their installation the plug it is necessary to cut previously a tap of the corresponding size. Thin-walled plugs of cutting type can be alternatively established, - they refuel in the chiseled plug then развальцовываются by the special tool and are pierced under the necessary size.
5. In the effective way, especially at restoration of plugs of the built-in type their boring under valves of the bigger size is. Boring is made by means of a special vertical drill in a range from 0.076 to 0.762 mm (more often - 0.381 mm). It is necessary to get repair valves of the corresponding size.
6. For replacement of plugs of the built-in type they are necessary for drilling from a head. Then nests are chiseled under the demanded size and in them repair plugs are pressed. Landing of new plugs is carried out by means of a hammer and a step drift. The special attention at installation of repair plugs should be given to centering of their rather klapanny saddles. The landing height of the new plug also should be strictly to correspond original, - do not forget to measure it before removal of old plugs. Old plugs are tapped from a head also by means of a hammer and a drift. Before installation of repair plugs it is necessary to define, whether they should carry out sealing of a water shirt of a head or not, - if yes, it is necessary to use the corresponding hermetic, otherwise the plug and before landing it is necessary to grease walls of a reception nest with assembly greasing. Landing of plugs in a head is made from installation of klapanny springs.

 Use of a set of technological washers will help at control of depth of landing of plugs.


Saddles of valves

 PERFORMANCE ORDER

The pro-point of saddles of valves should be made only after adjusting parameters of directing plugs will be brought into accord with requirements of Specifications.

After performance of replacement of directing plugs of a saddle of valves are pierced without fail!

1. If saddles of valves are in a satisfactory condition, after implementation of grinding in of valves (see above) it is possible to start assembly of a head of cylinders (see below).
2. Restoration of the worn-out or damaged saddles should be made in the conditions of a car-care center workshop. At a pro-point of saddles the special attention is given to centering of their rather directing plugs of valves.


Pro-point of a head of cylinders

 PERFORMANCE ORDER

At restoration of strongly deformed head also bearing necks of a camshaft (ов) should be subjected to an aligning pro-point. Default of this requirement is fraught with serious internal damages of the engine in attempt of its start!

1. At especially strong deformation of interfaced surfaces the head is subject to replacement.
2. The pro-point of interfaced surfaces of a head (if in it there is a need) should be made in the conditions of a car-care center workshop.

At removal a pro-point course from surfaces of a head of a layer of metal standard requirements to geometrical parameters should be observed.

3. After head return from its work it is necessary to clean very carefully once again (see above).


Seal of cracks in molding to a head

In certain cases burst head of cylinders can be restored. Along a crack in the head made of cast iron carving inserts are established. At restoration of light-alloy heads more effective welding application though use of carving inserts is also admissible is. Some defects can be eliminated only with soldering or welding application, - address for consultation to specialists of car-care center.

Assembly

First of all it is necessary to prepare a workplace, special attention having given to purity of surfaces and existence of sufficient free space. Take care of the place equipment under warehousing of components subject to installation. All established details also should be very carefully cleaned and dried up.

Heads with pushers of chashechny type

 PERFORMANCE ORDER

1. Installation drowned in a nest of a pusher of components of valves on heads of this type needs a small screw-driver, a clamp for compression of klapanny springs from opravky, a little white greasing (циатима) and mass of patience.
2. Slightly grease cores of valves and establish them on the regular places in a head of cylinders.
3. At the corresponding complete set establish where follows adjusting washers of klapanny springs.
4. Establish new maslootrazhatelny caps (if those are provided by a design). If the cap is put on directing plug, previously slightly grease an external surface of the last. If instead of a cap the sealing ring is used, it is established after compression of a klapanny spring, but before landing to a core of the valve of crackers of the cutting lock.
5. Dress on a valve core a spring and its plate.
6. Establish an opravka and compress a spring by means of a special clamp.
7. Working with a screw-driver as a shpatel, fill bends of crackers of the cutting lock with dense greasing, is will help to fix temporarily crackers on a valve core to a spring otpuskaniye.
8. Picking up a screw-driver (again use greasing), plant crackers on the regular places on a valve core, having densely pressed them to a surface of the last.
9. Slowly release compressing klapanny spring a clamp, - track, that crackers did not drop out, - and remove it from the engine.
10. Operating in a similar manner, establish components on the remained valves.

11. Establish pushers, a camshaft (ы) (do not forget to check installation of klapanny gaps) and other components acting in film in the course of dismantle.


Heads with pushers of lever type

 PERFORMANCE ORDER

1. Slightly grease cores of valves and establish the last on the regular places in a head of cylinders.
2. At the corresponding complete set establish where follows adjusting washers of klapanny springs.
3. Establish new maslootrazhatelny caps (if those are provided by a design). If the cap is put on directing plug, previously slightly grease an external surface of the last. If instead of a cap the sealing ring is used, it is established after compression of a klapanny spring, but before landing to a core of the valve of crackers of the cutting lock.
4. Dress on a valve core a spring and its plate.
5. By means of the special tool compress a klapanny spring.
6. Plant on a valve core crackers of the cutting lock.
7. Slowly release a klapanny spring, - track, that crackers did not drop out of a flute on a valve core.
8. Remove from a head the tool compressing a spring.
9. Operating in a similar manner, establish components on the remained valves.
10. Establish pushers, a camshaft (ы) (do not forget to make adjustment of klapanny gaps, - see. Head of Control and routine maintenance) and other components acting in film in the course of dismantle.