cooling MITSUBISHI LANCER 2005 Owner's Guide

WAT E R P U M P
ENGINE COOLING14-30
REMOVAL AND INSTALLATION <4G6>M1141002700432
INSTALLATION SERVICE POINT
>>A<< COOLING WATER LINE O-RING
INSTALLATIONFit the cooling water line O-ring to the groove in the
water pump inlet pipe. Then lubricate the cooling
water line O-ring and the inside of the water pump
assembly with water, and then insert the water pump
inlet pipe to the water pump assembly.
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Refilling (Refer to P.14-22).
•Valve Timing Belt and Balancer Timing Belt Removal and
Installation (Refer to GROUP 11C P.11C-35).
AC301467
22 ± 4 N·m
23 ± 3 N·m
14 ± 1 N·m
12
3 4
N
N
Bolt specifications
Screw diameter × length mm
8 × 708 × 22
8 × 14
8 × 22 8 × 25
2
AB
Removal steps
1. Alternator adjusting brace
2. Water pump assembly3. Water pump gasket
>>A<<4. Cooling water line O-ringRemoval steps (Continued)
AC103005
Water pump assembly
Cooling water
line O-ring
Water pump inlet pipe
AF

WATER HOSE AND WATER PIPE
ENGINE COOLING14-31
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATION <4G1>M1141003300415
Pre-removal and Post-installation Operation
•Under Cover Removal and Installation
•Engine Coolant Draining and Supplying (Refer to
P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-26).
AC203411
1 234
5 67
8
10 9
13 ± 2 N·m 23 ± 4 N·m
13 ± 2 N·m
N
N
AC
111213
N
Removal steps
1. Water temperature sensor unit
connector
2. Water temperature gauge unit
connector
3. Control wiring harness and harness
bracket
<> >>B<<4. Radiator upper hose connection
5. Throttle body water feed hose
6. Thermostat case assembly7. Thermostat case gasket
>>A<<8. Cooling water line O-ring
9. Control wiring harness clamp
10. Throttle body water return hose
11. Heater water hose connection
12. Water pump inlet pipe
>>A<<13. Cooling water line O-ringRemoval steps (Continued)

WATER HOSE AND WATER PIPE
ENGINE COOLING14-32
REMOVAL SERVICE POINT
<> RADIATOR UPPER HOSE
DISCONNECTION
After making mating marks on the radiator upper
hose and hose clamp, disconnect the radiator upper
hose.
INSTALLATION SERVICE POINTS
>>A<< COOLING WATER LINE O-RING
INSTALLATION
CAUTION
Do not allow engine oil or other grease to adhere
to the O-ring
Insert the cooling water line O-ring to the water pump
inlet pipe, and coat the outer portion of the cooling
water line O-ring with water or engine coolant.
>>B<< RADIATOR UPPER HOSE
CONNECTION
1. Insert radiator upper hose as far as the projection
of the thermostat case assembly.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then connect the radiator
upper hose.AC200641AC
Mating marks
AC200644
AD
Cooling water
line O-ring
Water pump inlet pipeWater pump or thermostat case
AC200642
Mating marks
Projection
Thermostat case assemblyAI
Radiator upper
hose

WATER HOSE AND WATER PIPE
ENGINE COOLING14-33
REMOVAL AND INSTALLATION <4G6>M1141003300426
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to
P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-26).
AC303471
1 23 4
56
7 8 9
9
13 ± 2 N·m
23 ± 4 N·m 13 ± 2 N·m
N
N
AB
2
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalentØ3 mm
Ø3 mm
5
Removal steps
<> >>C<<1. Radiator upper hose connection
>>B<<2. Cooling water outlet hose fitting
3. Throttle body water return hose
4. Throttle body water feed hose
>>B<<5. Thermostat case assembly
6. Heater water hose connection7. Control wiring harness clamp
8. Water pump inlet pipe
>>A<<9. Cooling water line O-ringRemoval steps (Continued)

WATER HOSE AND WATER PIPE
ENGINE COOLING14-34
REMOVAL SERVICE POINT
<> RADIATOR UPPER HOSE
DISCONNECTION
After making mating marks on the radiator upper
hose and hose clamp, disconnect the radiator upper
hose.
INSTALLATION SERVICE POINTS
>>A<< COOLING WATER LINE O-RING
INSTALLATION
CAUTION
Do not allow engine oil or other grease to adhere
to the cooling water line O-ring
Insert the cooling water line O-ring to the water pump
water inlet pipe, and coat the outer portion of the
cooling water line O-ring with water or engine
coolant.
>>B<< THERMOSTAT CASE
ASSEMBLY/COOLING WATER OUTLET
HOSE FITTING INSTALLATION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
mounting surface.
2. Apply a bead of the specified sealant.
Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent
3. With the sealant still wet (within 15 minutes after
the sealant is applied), install the thermostat case
assembly or cooling water outlet hose fitting. Do
not apply the sealant in an area more than the
required.
>>C<< RADIATOR UPPER HOSE
CONNECTION
1. Insert radiator upper hose as far as the projection
of the cooling water outlet hose fitting.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then connect the radiator
upper hose.
INSPECTIONM1141003400296
WATER PUMP INLET PIPE AND
THROTTLE BODY WATER HOSES
CHECK
Check the water pipe and hoses for cracks, damage
and clogs. Replace them if necessary.
AC200641AC
Mating marks
AC200644AC
O-ring
Water inlet pipe
Water pump or thermostat case
AC200642
Mating marks
Projection
Cooling water outlet
hose fitting
AJ
Radiator upper
hose

RADIATOR
ENGINE COOLING14-35
RADIATOR
REMOVAL AND INSTALLATIONM1141001500468
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to
P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
AC303472
18
17 1520 12 9
14
5 2
9
3
4
1
10
6 10
AB
12 ± 2 N·m
12 ± 2 N·m<4G1 (Vehicles without A/C)>
7

RADIATOR
ENGINE COOLING14-36
AC303473
18 171520 12
9
14
5 2
9
3
4
1
10
6 10
12 ± 2 N·m
AB
12 ± 2 N·m<4G1 (Vehicles with A/C)>
16
19
8
11
7
AC303474
18 1715
20 12 9
14
5 2
9
3
4
1
10
6 10
12 ± 2 N·m
AB
<4G6>
13
7
12 ± 2 N·m
Radiator removal steps
1. Drain plug
2. Radiator cap
3. Radiator condenser tank hose
4. Radiator condenser tank assembly
<> >>A<<5. Radiator upper hose
<> >>A<<6. Radiator lower hose
7. Cooling fan motor drive control unit
connector8. T/M oil cooler line hose connection

9. Radiator support upper insulator
•Radiator and cooling fan motor &
shroud assembly
10. Radiator support lower insulator
11. T/M oil cooler line hose Radiator removal steps

RADIATOR
ENGINE COOLING14-37
REMOVAL SERVICE POINT
<> RADIATOR UPPER
HOSE/RADIATOR LOWER HOSE
DISCONNECTION
Make mating marks on the radiator hose and the
hose clamp. Disconnect the radiator hoses.
INSTALLATION SERVICE POINT
>>A<< RADIATOR LOWER
HOSE/RADIATOR UPPER HOSE
CONNECTION
1. Insert radiator lower hose as far as the projection
of the cooling water inlet hose fitting.
2. Insert radiator upper hose as far as the projection
of the thermostat case assembly <4G1> or the
cooling water outlet hose fitting <4G6>.
3. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
12. Cooling fan motor & shroud
assembly
13. A/C condenser fan motor & shroud
assembly <4G6>
14. Radiator assembly
Cooling fan motor removal
steps
3. Radiator condenser tank hose
<> >>A<<5. Radiator upper hose
7. Cooling fan motor drive control unit
connector Radiator removal steps
12. Cooling fan motor & shroud
assembly
15. Cooling fan (L.H.)
16. Cooling fan (R.H.) <4G1 (Vehicles
with A/C)>
17. Cooling fan motor drive control unit
18. Cooling fan motor (L.H.)
19. Cooling fan (R.H.) motor <4G1
(Vehicles with A/C)>
20. Cooling fan shroudCooling fan motor removal steps
(Continued)
AC200641AC
Mating marks
AC200642
Mating marks
Projection
Cooling water hose fitting
or thermostat case assembly
AK
Radiator hose

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-69
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL
TEST
M1552008400378
1. Start the engine.
2. Operate the air-conditioner, and then set the
temperature to maximum cooling.
3. Hold the engine speed at 1500 r/min.
4. Check the refrigerant level (bubble state) through
the sight glass.
CAUTION
Use the low-pressure service valve.
NOTE: Use the refrigerant recovery station to
charge the specified refrigerant because you can
not calculate the amount of the refrigerant
properly with the sight glass.
MAGNETIC CLUTCH TESTM1552008500405
1. Disconnect the magnetic clutch connector to the
magnetic clutch.
2. Connect positive battery voltage directly to the
connector for the magnetic clutch.3. If the magnetic clutch is normal, there will be a
"click." If the pulley and armature do not make
contact ("click"), there is a malfunction.
COMPRESSOR DRIVE BELT
ADJUSTMENT
M1552001000335
<1300, 1600>
Refer to GROUP 11A, On-vehicle Service − Drive
Belt Tension Check P.11A-7.
<2000>
Refer to GROUP 11C, On-vehicle Service − Drive
Belt Tension Check P.11C-7.
DUAL PRESSURE SWITCH CHECKM1552010400320
1. Remove the dual pressure switch connector and
connect the high/low pressure side terminals
located on the harness side as shown in the
illustration..
2. Install a gauge manifold to the high-pressure side
service valve of the refrigerant line. (Refer to
P.55-98, P.55-99.)
3. When the high/low pressure sides of the dual
pressure switch are at operation pressure (ON)
the resistance should less than two ohms
between the terminals. If open circuit, replace the
switch. Items State
Insufficient Many bubbles are seen.
If refrigerant is extremely
low, it appears white.
Sufficient or excess
refrigerantNo bubbles are seen.
AC005963
Bubbles Insufficient
refrigerantSufficient or excess
refrigerant
AC
AC005671
Magnetic clutch connector
AC
AC001368AD High/Low
Pressure Side
Low-pressure side
High-pressure side
ON
OFFON
OFF
2650 ± 200 2060 ± 200230 ± 20 210 ± 25
(kPa)

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-73
PERFORMANCE TEST M1552001400355
1. The vehicles to be tested should be in a place that
is not in direct sunlight.
2. Close the high and low-pressure valve of the
gauge manifold.
3. Connect the charging hose (blue) to the
low-pressure valve and connect the charging
hose (red) to the high-pressure valve of the gauge
manifold.
CAUTION
•To connect the quick joint, press section A
firmly against the service valve until a click is
heard.
•When connecting, run your hand along the
hose while pressing to ensure that there are
no bends in the hose.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).NOTE: The high-pressure service valve is on the
A/C pipe and the low-pressure service valve is on
the suction hose.
5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick
joint (for high-pressure) to the high-pressure
service valve.
6. Start the engine.
7. Set the A/C controls as follows:
•A/C switch: A/C − ON position
•Mode selection: FACE position
•Temperature control: MAXIMUM COOLING
position
•Air selection: RECIRCULATION position
•Blower switch: "4" (Fast) position
8. Keep engine speed to idling speed with A/C clutch
engaged.
9. Engine should be warmed up with doors and all
windows opened.
10.Insert a thermometer in the centre air outlet and
operate the engine for 20 minutes.
NOTE: If the clutch cycles, take the reading before
the clutch disengages.
11.Note the discharge air temperature.
Performance Temperature Chart
AC001388
Low-pressure
valveHigh-pressure
valve
Gauge manifold
Charging
hose (red)
A
Sleeve Charging
hose (blue)
Adaptor valve
(for low-
pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
AB
Adaptor valve
(for high-
pressure)
AC304576
Thermometer
AB
Garage ambient temperature °C20 25 30 35
Discharge air temperature °C8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
Compressor high pressure kPa 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
Compressor low pressure kPa 150 − 190 190 − 240 240 − 300 300 − 375