2005 Mitsubishi Galant Technical Highlights

ENGINE

The 2005 Mitsubishi Galant is available with a choice of two powerful engines. The DE and ES trim lines come equipped with a 2.4-liter four-cylinder unit that is mated to a four-speed automatic transmission. This engine delivers 160 horsepower and 157 pound-feet of torque with the aid of its patented Mitsubishi Innovative Variable timing and lift Electronic Control (MIVEC) system. For even more performance, the LS and GTS trim lines are equipped with a high-output 3.8-liter, 24-valve SOHC V6 engine mated to a four-speed Sportronic(TM) transmission that allows the driver to select shift points. The Galant's V6 develops 230 horsepower and 250 pound-feet of torque.

4G69: 2.4-Liter SOHC Four Cylinder Engine (MIVEC)

The 2.4-liter SOHC four-cylinder engine found in the Galant DE and ES trim lines utilizes advanced Mitsubishi Innovative Valve timing and lift Electronic Control (MIVEC) system technology to improve power output over a wide rpm range without compromising fuel economy or emissions in the process.

The MIVEC system features separate cam profiles optimized to help deliver maximum power at high and low engine speeds, which translates to greater usable power and torque in the widest variety of driving conditions. At lower rpm, MIVEC selects the smaller cam profile, which provides stable combustion and lower emissions, and better low-speed response. But when the throttle is opened wide and engine speed increased, MIVEC allows the valves a longer duration and longer stroke, thus providing maximum and efficient power and torque over a broader range of engine speeds.

The enhanced power output of the MIVEC system (160 horsepower and 157 pound-feet of torque) is achieved by its ability to vary the lift and duration of the intake valves. In the MIVEC system, there are three distinct cam profiles that create two engine modes: a low-speed mode, consisting of low- and mid-lift cam profiles; and a high-speed mode. The low- and mid-lift cams and rocker arms - which drive separate intake valves - are positioned on either side of a centrally located high-lift cam. The high-lift cam is directly connected to a T-shaped lever, which controls valve lift and duration of both intake valves in the high engine-speed mode.

At lower engine speeds, the T-shaped levers connected to the high-lift cams reciprocate freely without contacting intake-valve rocker arms, thus allowing the low- and mid-lift cam lobes to control corresponding intake-valve lift and timing. The intake rocker arms contain internal pistons that are retained by springs in a lowered position at less than 3500 rpm, to avoid contacting the high-lift T-shaped levers. The benefit of the dual-profile low-speed mode is to induce swirl within the cylinder, which help create stable combustion and improve emissions.

The high-speed mode opens the valves longer due to its higher lift. At high engine speeds, the pistons within the rocker arms elevate when MIVEC sends increased oil pressure through an oil control valve. The high-lift cams'
T-shaped levers are then able to directly contact the elevated rocker-arm pistons, overriding the low-speed cam lobes and fully controlling intake-valve lift and duration.

The switch occurs at approximately 3500 rpm, when the powertrain control module opens the valves longer to increase the amount of intake airflow, resulting in higher engine output. More precisely, MIVEC switches to the higher cam profile at 3600 rpm as engine speed increases, and drops back to the lower cam profile at 3400 rpm as engine speed decreases; the output torque of the low- and high-speed modes overlap at those speeds. This also means the cam switch operation is virtually transparent to the driver, who is simply rewarded with more power.

Under low-rev conditions the low- and mid-lift cam lobes drive the intake valves, providing better fuel economy and lower emissions. But when the throttle is opened wide and engine speed increased, MIVEC gives the valves a longer duration and higher lift, thus providing maximum and efficient power and torque over a very broad range of engine speeds. Despite its technological complexity, the basic workings of the MIVEC engine system can be expressed quite simply: MIVEC alters the cam profiles, tailoring engine performance to suit your driving needs.

2.4-Liter Engine with MIVEC(4G69)

Aside from the MIVEC system valvetrain enhancement, the 2.4-liter (4G69) engine has a number of other mechanical features that help it breathe and exhale more efficiently and also helps to reduce the weight of moving parts. The 4G69 2.4-liter engine features enhancements over the previous 4G64 that include:

• Intake. Several modifications were made to improve both efficiency and performance. Starting with the incoming air, the aluminum intake manifold's interior surface was smoothed to increase intake efficiency. The intake runners are also longer, and they feature a bell-mouth shape to reduce air intake resistance.
• Exhaust. More air coming in means more air needs to get out, so the exhaust manifold was switched from single to dual ports, which reduces interference and improves the flow of gases out of the combustion chamber.
• Rocker cover. For better noise reduction and to reduce weight, the rocker cover is made of aluminum instead of steel.
• Combustion. More efficient combustion has been achieved by increasing the compression ratio to 9.5:1 (from 9.0:1).
• Valves. To improve high-speed efficiency, the valve sizes were increased - intake valves are larger by 1 millimeter in diameter (to 34 mm), and exhaust valves were increased by 1.5 mm in diameter (to 30.55 mm).
• Pistons. With the compression height reduced, the piston height was reduced to match. Even though the pistons have a slightly larger diameter (87 mm versus 86.5 mm), they are significantly lighter in weight (278 grams per unit compared to 354 grams). For moving parts, lower mass also means better efficiency.
• Connecting rods. Each connecting rod was reduced from 623 g to 530 g of weight.
• Crankshaft. Once again engineers found a way to reduce the mass of a moving part. The crankshaft's weight was reduced from 15.8 kg to 14.9 kg. In addition, the crankshaft pulley's weight was reduced at the same time its size was increased. By using aluminum in the hub in place of steel, the pulley's weight was reduced from 2.9 kg to 1.8 kg, a savings of 1.1 kg.
• Timing belt. Weight and friction were reduced by shortening the width of the timing belt. To further reduce weight, the auto tensioner is now made of aluminum instead of cast iron.
• Serpentine drive belt. The 4G69 MIVEC engine uses a single serpentine belt to operate the engine's accessory drives for the power steering, alternator and air conditioning unit. In addition to saving space compared to the dual-belt drive system used on the previous engine, the low-maintenance serpentine belt features an auto tensioner.
• Cylinder Block. The height of the cylinder block was reduced to decrease weight, and the water jacket's length was shortened to help warm the engine faster for better fuel consumption. Also, air bleed holes were added to the main webs to reduce piston movement resistance, which is created by pressure pulsation when the piston is in motion. Also, the new cylinder block reroutes the oil returning from the head to reduce interference between the oil and the rotating crankshaft.

3.8-Liter V6 Engine (Engine 6G75)

The 2005 Mitsubishi Galant LS and GTS models are powered by a transversely mounted 3.8-liter, 60-degree V6 engine designed to engage drivers with a broad, responsive torque curve.

The new 3.8-liter displacement is the result of an oversquare 95.0 mm bore combined with a 90.0 mm stroke to achieve its 3828 cc displacement. In the interest of durability, the 3.8-liter engine's pistons are high-pressure castings attached to forged steel connecting rods that swing from a heat-treated forged steel crankshaft. The high nickel content cast-iron, 60-degree engine block is dimensionally taller than the 3.5-liter engine's block and features revised oil passages for improved lubrication and durability. In addition, the 3.8-liter block is a new casting that has been structurally enhanced for additional cylinder-bore rigidity and includes improved chassis mounting points to reduce vibration and harshness. A pair of single-overhead-cam, four-valve-per-cylinder aluminum heads sit atop this cast-iron block; their intake and exhaust port volumes and valve diameters have been carefully designed to maintain optimal mixture velocity at low- to mid-range rpm helping to deliver the best off-the-line and highway passing response.

This free-revving engine package produces a peak of 230 horsepower at 5250 rpm with peak torque of 250 pound-feet occurring at 4000 rpm.

Induction

Fuel and air delivery to the combustion chambers of Galant's 3.8-liter motor is governed by a throttle-by-wire control system that eliminates the mechanical control between the accelerator pedal and the throttle plate. The throttle-valve-control microprocessor has also been integrated into the vehicle's main ECU. With this arrangement, inter-processor communication that would otherwise be transmitted by a complex body of harnesses and connectors is now handled by a circuit board, improving the system's reliability. Acting in conjunction with traction control - a
standard feature on the Galant LS and GTS-the throttle control computer receives data from wheel speed sensors to govern engine speed and regain traction when necessary.

Cold Air Intake System

Galant is fitted with an efficient cold-air induction system that feeds ambient air to the intake manifold, which helps improve engine performance. The shape of the air inlet duct is designed to guard against the ingestion of water or snow, and draws large volumes of cool, dense, onrushing air from the grille opening. A sound-absorbing resonator attached to this intake ducting helps control intake suction noise. The Galant's intake system removes particulate from the incoming air using a low-restriction filter element that is contained in a sturdy air cleaner housing. A resonator is also used on the injection molded thermoplastic intake hose that leads from the air cleaner assembly to the engine.

Exhaust

The Galant utilizes high-flow, welded tubular exhaust manifolds to expel the engine's spent fumes. The catalytic converter is integrated into the clamshell assembly near the cylinder heads where they can sooner achieve effective operating temperature, retain heat and promote quicker, more efficient catalyzation and increase emissions performance. The rest of the stainless steel exhaust system is designed to utilize a minimum number of hanging points, which lessens the amount of vibration transmitted to the body. A high-flow muffler minimizes backpressure while also producing a pleasant, sporty exhaust note.

Cooling System

The Galant is equipped with a high-capacity aluminum radiator with plastic tanks that is very effective at transferring heat from the circulating coolant. This radiator uses dual electrical fans that are mounted in an airflow-efficient shroud for optimal cooling at low vehicle speeds. The radiator core size is 757 mm x 400 mm x 16 mm.

AUTOMATIC TRANSMISSIONS

The 2005 Galant is available with two different four-speed automatic transmissions. These transmissions integrate next-generation electronic controls with more refined mechanical technologies to offer superior driving satisfaction, performance, and durability. The Galant's versions of the four-speed automatics build upon years of accumulated development in design and production technologies to produce transmissions with superior structural rigidity, enhanced durability, improved efficiency and reduced weight.

Both of the Galant's transmissions are equipped with the latest version of the INVECS II processor that helps the transmission match its shifting actions to both the road conditions and the operator's driving style and inputs. INVECS II provides drivers with what they perceive to be the optimum shift points. It also includes a "learned control" function whereby the computer measures the timing of the driver's accelerator inputs and tailors shift action accordingly for softer or firmer shifts. In addition, the version of the four-speed transmission mated to the V6 is equipped with a Sportronic(TM) mode that offers dynamic manual shifting by simply moving the shift lever into the sports mode gate for more fun-to-drive control.

CHASSIS

The Galant's chassis utilizes a nimble four-wheel independent suspension attached to a pair of flex-resistant reinforced steel front and rear subframe members that are joined by supports spanning the length of the floorpan. This all-steel structure features multiple reinforcement locations with strategically placed support members that help develop a stiff, safe unibody. Built using modern construction and adopting MASH seam welding techniques to help increase structural rigidity without incurring major weight penalties, this vehicle's unibody achieves a high level of strength and rigidity. Mitsubishi's own evaluations have confirmed that the Galant meets or exceeds the federally mandated performance criteria in the 30-mph frontal, 30-mph oblique and the 35-mph rear collision tests.

SUSPENSION

The 2005 Mitsubishi Galant's four-wheel independent suspension design endows it with refined driving characteristics more atypical of luxury sedans than a midsize segment contender. A wide track (61.8 inches, front and rear) and long wheelbase (108.3 inches) help the Galant provide a comfortable, stable ride, regardless of pavement conditions. The Galant's rigid unibody chassis and four-wheel-independent suspension are engineered to deliver equal parts performance and comfort.

Front Suspension

The Galant's front wheels utilize the proven MacPherson front suspension design to provide the precise control and superior handling capability that sedan buyers demand. Large-diameter strut cylinders (V6 models) and springs are matched according to the mass of the wheels, tires, and vehicle weight in order to deliver the best combination of ride and agility. Each strut uses a gas-charged insert to dampen the road's imperfections, and a large urethane bump stopper helps to absorb road shock and keeps the suspension from bottoming out. The front coil spring pressures are optimized to strike the ideal balance between ride compliance and responsive, sporty handling. The Galant's front strut assemblies ride on large, reinforced steel lower control
arms. These control arms are supported by a rigid crossmember that spans the distance between the control arm mounting points, controlling lateral movement of the control arms and helping to maintain a more consistent suspension geometry resulting in better, more predictable handling. The large, low-profile crossmember was designed without a "kick-up" in its main section and increases rigidity at the suspension mounting points while helping to reduce component weight.

The design of this flat suspension crossmember also facilitates an optimized, lower steering box mounting location that helps realize more linear toe changes and improves the vehicle's straight-line handling on uneven surfaces. The lower control arms swing from the chassis using dual-density rubber bushings made of more compliant material in the top half of the bushing shell to reduce the harshness of road input. A harder rubber material maintains the shape of the lower half of the bushing shell to help improve cornering performance. The movement of the long control arms was engineered to help generate ample wheel stroke to Galant's suspension track surfaces. This design enables more effective and predictable toe and camber changes across its range of movement for superior traction and control on uneven surfaces.

All Galant models are equipped with a front stabilizer bar that is attached to the struts using ball joints; the bar's friction surfaces are Teflon(TM) coated on GTS, which helps the stabilizer respond quickly to suspension changes with smoother movement. In addition, the Galant's hub unit is designed to use angular contact wheel bearings that help lower friction and improve ride while also reducing noise and drag.

Rear Suspension

The Galant's rear suspension is a sophisticated low-mount, multi-link arrangement. A
compact suspension design helps the Galant achieve excellent ride quality and handling stability while offering a low cargo floor in the trunk. The low-profile positioning of the entire rear suspension - with its strategic location of coil springs, shock absorbers and links, and reduced mounting point height - helps to enhance the utility of the trunk space.

At the Galant's rear, a pair of gas-charged shocks and coil springs absorb and help negotiate the road's imperfections as long, lower control arms track over the road. Strong rear trailing arms mounted with large, vibration-absorbing rear bushings and rigid upper suspension links help provide increased stability. The reduced height of the insulation system used atop the shock and coil spring has also helped reduce the suspension's intrusion into the trunk area. A large lattice structure made of steel helps increase suspension rigidity - especially at the control link mounting points - and provides a dramatic reduction in the ability of vibration and road noise to penetrate the passenger cabin.

In an effort to provide superior handling, Galant's suspension designers made the rear suspension control arms as long as possible to maximize the movement of the independent suspension and allow for optimal toe and camber changes over uneven surfaces. Large-diameter rubber suspension bushings located at the friction points of the lower control arms and upper links also help reduce the vibration and road noise that are transmitted by the suspension's steel links and control arms. In addition, an eccentric cam in the lower rear control arm mounting points can allow for the slight tuning of toe and camber.

As with the front suspension, the Galant rear suspension incorporates stabilizer bars that attach to the rear lower control arm and uses ball joints for improved, less-restricted movement. In addition, the suspension bump stopper is made of a more resilient urethane material to offer superior shock absorption properties and to prevent the suspension from exceeding its travel.

POWER STEERING

The 2005 Mitsubishi Galant relies on a hydraulic rack-and-pinion power steering system to help deliver a sense of direct, responsive steering feel and control that drivers expect from a passenger car. The low positioning of the steering assembly on the front crossmember helps improve steering feel and response with a more linear path for the control links to the knuckle arms and front hubs. The power steering gearbox is attached to the crossmember using rubber bushings engineered with multi-directional hardness that offer support for front to rear movement and increased compliance for lateral movement. The Galant's speed-sensitive hydraulic power steering pump reduces its fluid flow at higher speeds to increase the steering effort at highway speeds. This system maximizes power multiplication in slow-speed situations such as parking, and helps provide a safer, more enjoyable driving experience.

BRAKES, WHEELS & TIRES

All Galants are equipped with a vacuum-assisted four-wheel-disc braking system that includes vented front discs and solid rear discs. The front rotors measure 10.9 inches in diameter (11.6 inches for V6-equipped LS and GTS trim lines) and the solid rear discs measure 10.3 inches in diameter. The Galant utilizes a powerful single-piston caliper design up front with dual 60 mm pistons and a single 35 mm caliper piston at the rear. Anti-lock braking with Electronic Brakeforce Distribution (EBD) is standard equipment on every V6 Galant, though ABS is also offered as optional equipment on the Galant ES.

The Galant DE, ES and LS trim lines ride on 16-inch wheels and all-season 215/60R16
tires. The sportier GTS trim level features five-spoke, 17-inch aluminum alloy wheels and 215/55R17 tires that help provide the Galant with undeniable curb appeal. The sporty cast aluminum wheels add a sense of athleticism to this midsize sedan. The optional Diamond Package on the ES and LS offers a sporty ten-spoke design.

SAFETY

The Galant is equipped with advanced driver and front-seat passenger front air bags in order to help optimize occupant safety. For 2005, front seat-mounted side impact airbags are standard equipment on all Galants. Front seatbelts are equipped with pre-tensioners and force limiters that help to maximize the performance of the front safety belts in severe frontal collisions. The Galant's steering column shaft is secured by a fall-away bracket and a slide plate mounting system that allows the column to better absorb impact energy in the event of a collision.

WARRANTY AND MANUFACTURING

As part of Mitsubishi Motors "Best-Backed Car" program, all models are backed by a comprehensive new vehicle limited warranty that covers the vehicle from bumper-to-bumper for five-years/60,000 miles. In addition, the powertrain is covered by a 10-year/100,000 mile limited warranty, while body panels have a seven-year/100,000 mile anti-corrosion/perforation limited warranty. The "Best-Backed Car" program also includes 24-hour emergency roadside assistance with free towing to the nearest authorized Mitsubishi retailer for warranty-related repairs for five years/unlimited miles.

Mitsubishi Motors North America, Inc., (MMNA) is responsible for all manufacturing, finance, sales, marketing, research and development operations of Mitsubishi Motors Corporation in the United States and Canada. Mitsubishi Motors sells coupes, convertibles, sedans and sport utility vehicles through a network of approximately 650 dealers. For more information, contact the Mitsubishi Motors News Bureau at (888) 560-6672 or visit http://media.mitsubishicars.com.