engine MITSUBISHI LANCER 2005 Service Manual

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

GENERAL INFORMATION
INTAKE AND EXHAUST15-2
GENERAL INFORMATION
M1151000100402The exhaust pipe is divided into three parts.
SERVICE SPECIFICATION
M1151000300428
SPECIAL TOOL
M1151000600399
Item Standard value Limit
Manifold distortion of the installation surface mm 0.15 or less 0.20
Tool Number Name Use
MD998770 Oxygen sensor wrench Removal and installation of
engine control oxygen sensor

INLET MANIFOLD
INTAKE AND EXHAUST15-5
INLET MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003000749
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13A-389).
•Engine Coolant Draining (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Removal (Refer to GROUP 13A
P.13A-400).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A P.13A-398).Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A P.13A-398).
•Throttle Body Assembly Installation (Refer to GROUP
13A P.13A-400).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service P.17-2).
•Fuel Leak Check
AC303642AB
15
3
6
5
412 10 71
2
11
913
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m18 ± 2 N·m5.0 ± 1.0 N·m
31 ± 3 N·m
49 ± 9 N·m
N
N
N
8
Removal steps
1. Inlet manifold absolute pressure
sensor
2. Engine control pressure sensor
O-ring
3. Engine control detonation sensor
connector
4. T/M housing front lower cover stay
(L.H.)
5. Battery wiring harness clamp
connection
6. Inlet manifold stay
7. Brake booster vacuum hose
connection8. Emission control equip hose
connection
9. Fuel vapour control hose
connection
10. Inlet manifold stay
11. Inlet manifold
12. Inlet manifold gasket
13. EGR valve
14. EGR valve gasket
15. Emission vacuum hose & pipe and
emission solenoid valve assembly Removal steps (Continued)

INLET MANIFOLD
INTAKE AND EXHAUST15-6
REMOVAL AND INSTALLATION <4G6>M1151003001236
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13A-389).
•Engine Coolant Draining (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Removal (Refer to GROUP 13B
P.13B-336).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13B P.13B-334).Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13B P.13B-334).
•Throttle Body Assembly Installation (Refer to GROUP
13B P.13B-336).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service P.17-2).
•Fuel Leak Check
AC303657
9.0 ± 1.0 N·m11 ± 1 N·m
20 ± 2 N·m
31 ± 3 N·m 36 ± 6 N·m
20 ± 2 N·m
20 ± 2 N·m
36 ± 6 N·m
36 ± 6 N·m
11
9 10 212
N1413N
AB
5.0 ± 1.0 N·m
3
1
11 ± 1 N·m
4
N
13 ± 1 N·m
5
6
(Engine oil)
7
8
Removal steps
1. Emission control equip hose
connector
2. Brake booster vacuum hose
connection
3. Earth cable connection4. Engine control detonation sensor
connector
5. Engine oil level gauge and guide
assembly
6. Engine oil filler O-ring
7. Emission vacuum hose connectionRemoval steps (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-7
INSPECTIONM1151003100616
Check the following points; replace the part if a
problem is found.
Inlet Manifold Check
1. Check for damage or cracking of any part.2. Clogging of the negative pressure (vacuum) outlet
port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003300568
8. Battery wiring harness clamp
9. Inlet manifold stay
10. Inlet manifold
11. Inlet manifold gasket
12. Emission vacuum hose & pipe and
emission solenoid valve assembly
13. EGR valve
14. EGR valve gasketRemoval steps (Continued)
AC30366250 ± 10 N·m 24 ± 4 N·m
35 ± 6 N·m17 ± 2 N·m 29 ± 3 N·m
N
3
7
12 4
N
6
8
44 ± 5 N·m
AB
9
5N
29 ± 3 N·m
29 ± 3 N·m
29 ± 3 N·m
(Engine oil)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN
SENSOR (FRONT) REMOVAL
Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (front).
INSTALLATION SERVICE POINT
>>A<< ENGINE CONTROL OXYGEN
SENSOR (FRONT) INSTALLATION
Use special tool oxygen sensor wrench (MD998770)
to install the engine control oxygen sensor (front).
Removal steps
1. Front exhaust pipe connection
2. Exhaust pipe gasket
<> >>A<<3. Engine control oxygen sensor (front)
4. Engine oil level gauge and guide
assembly
5. Engine oil filler O-ring6. Exhaust manifold cover
7. Exhaust manifold bracket
8. Exhaust manifold
9. Exhaust manifold gasketRemoval steps (Continued)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)