Lamp MITSUBISHI LANCER 2005 Workshop 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

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 COOLING14-37
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

AIR CLEANER
INTAKE AND EXHAUST15-3
AIR CLEANER
REMOVAL AND INSTALLATIONM1151002100486
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
•Avoid any shock or load to these parts when removing and installing them.
•When installing, securely set the air cleaner cover clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws.
AC303618
4.0 ± 1.0 N·m 4.0 ± 1.0 N·m
10*9*4
1*5
11
12 ± 1 N·m
9.0 ± 1.0 N·m 9.0 ± 1.0 N·m
AB
12 ± 1 N·m
Clamp
8*
3* <4G1>

AIR CLEANER
INTAKE AND EXHAUST15-4
AC303619
4.0 ± 1.0 N·m 4.0 ± 1.0 N·m10*9*4
1*5
11
12 ± 1 N·m
9.0 ± 1.0 N·m 9.0 ± 1.0 N·m
AB
12 ± 1 N·m
Clamp
8*
3* <4G6>
6 7
N
2
8.8 ± 1.0 N·m
Removal steps
1. Air cleaner intake duct
2. Air cleaner air flow sensor connector
<4G6>
3. Air cleaner assembly <4G1> or Air
cleaner and air cleaner air flow sensor
assembly <4G6>
4. Rocker cover breather hose
connection
5. Air cleaner to throttle body duct6. Air cleaner air flow sensor <4G6>
7. Air cleaner air flow sensor gasket
<4G6>
8. Air cleaner cover
9. Air cleaner element
10. Air cleaner body assembly
11. Air cleaner bracketRemoval steps (Continued)

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)

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)