MITSUBISHI LANCER 2005 Service Manual

THERMOSTAT
ENGINE COOLING14-27
REMOVAL SERVICE POINT
<> RADIATOR LOWER HOSE
DISCONNECTION
Make mating marks on the radiator lower hose and
the hose clamp. Disconnect the radiator lower hose.
INSTALLATION SERVICE POINTS
>>A<< THERMOSTAT INSTALLATION
CAUTION
Make absolutely sure that no oil adheres to the
rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
Install the thermostat so that the jiggle valve is facing
straight up. Be careful not to fold or scratch the
rubber ring.
>>B<< RADIATOR LOWER HOSE
CONNECTION
1. Insert radiator lower hose as far as the projection
of the Cooling water inlet hose fitting.
2. Align the mating marks on the radiator lower hose
and hose clamp, and then connect the radiator
lower hose.
INSPECTIONM1141002500427
THERMOSTAT CHECK
1. Immerse the thermostat in water, and heat the
water while stirring. Check the thermostat valve
opening temperature.
Standard value:
88 ± 1.5°C <4G1>
82 ± 1.5°C <4G6>
Removal steps
1. Water temperature gauge unit
connector <4G6>
2. Water temperature sensor unit
connector <4G6>
<> >B<<3. Radiator lower hose connection4. Engine control oxygen sensor
connector and connector bracket
<4G1>
5. Control wiring harness clip <4G6>
6. Cooling water inlet hose fitting>>A<<7. ThermostatRemoval steps (Continued)
AC200641AC
Mating marks
AC000279
Jiggle valve
Rubber ring
AB
AC200642
Mating marks
Projection
Cooling water inlet
hse fitting
AH
ACX00400
AB

THERMOSTAT
ENGINE COOLING14-28
2. Check that the amount of valve lift is at the
standard value when the water is at the
full-opening temperature.
NOTE: Measure the valve height when the
thermostat is fully closed, and use this
measurement to compare the valve height when
the thermostat is fully open.
Standard value:
100°C <4G1>
95°C <4G6>
Amount of valve lift: 8.5 mm or more
ACX00401AC
Valve lift

WAT ER P U M P
ENGINE COOLING14-29
WAT E R P U M P
REMOVAL AND INSTALLATION <4G1>M1141002700421
INSTALLATION SERVICE POINT
>>A<< WATER PUMP ASSEMBLY
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 water pump
assembly. Do not apply the sealant in an area
more than the required.
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Refilling (Refer to P.14-22).
•Valve Timing Belt Removal and Installation (Refer to
GROUP 11A P.11A-33).
AC303372
24 ± 3 N·m 23 ± 2 N·m
14 ± 1 N·m
1
2
Bolt specifications
Screw diameter × length mm 8 × 50
8 × 308 × 25
AB
2
2
Sealant: Mitsubishi Genuine Part
No. MD970389 or equivalent
Removal steps
1. Alternator adjusting brace
>>A<<2. Water pump assembly

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