service MITSUBISHI LANCER 2006 User Guide

WATER HOSE AND WATER PIPE
ENGINE COOLING14-32
REMOVAL SERVICE POINT
<> RADIATOR UPPER HOSE DISCON-
NECTION
AC200641AC
Mating marks
After making matin g ma rks on the radia t or upp er
hose
and ho se clamp, disconnect the radia t or upp er
hose
.
INST ALLA T ION SER VICE POINT S
>>A< < COOLING W A TE R LINE O-RING
INST
ALLA TION
AC200644AC
O-ring
Water inlet pipe
Water pump or thermostat case
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 cool
-
ant.
>>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
AC200642
Mating marks
Projection
Cooling water outlet
hose fitting
AJ
Radiator upper
hose
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 IN LET PIPE AND
THROTTLE BODY WATER HOSES
CHECK
Check the water pipe and hoses for cracks, damage
and clogs. Replace them if necessary.

RADIATOR
ENGINE COOLING14-35
INSTALLATION SERVICE POINT
>>A<< RADIATOR LOWER HOSE/RADIA-
TOR UPPER HOSE CONNECTION
AC200642
Mating marks
Projection
Cooling water hose fitting
or thermostat case assembly
AK
Radiator hose
1.In sert ra diato r lower h o se as fa r as th e projection
o f the cooling wate r inlet hose fit t ing.
2.In sert radia t or up per h o se as far a s t he pro j ection
o f the th ermost at ca se asse mbly .
3.Align th e ma ting marks on the rad i ator hose and
h o se clamp, an d then conn ect the radiator h o se.
REMOVA L AND INST ALLA TION <4G6>
M11 4100 1501 17 1
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to
P.14-21).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15
P.15-3).
AC504783
1
12 ± 2 N·m
10
2
3
4
5
6
7
8
9
9
10
11 13
15
18
16
17
12
AB
5.4 ± 0.4 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
connector
8.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 COOLING14-36
REMOVAL SERVICE POINT
<> RADIATOR UPPER HOSE/RADIA-
TOR LOWER HOSE DISCONNECTION
AC200641AC
Mating marks
Make mating marks on the rad i ator hose and th e
hose
cla m p. Disconnect the ra diat or hoses.
INSTALLA T ION SER VICE POINT
>>A<< RADIAT OR LOW E R HOSE/RADIA-
TO R UPPER HOSE CONNECTION
AC200642
Mating marks
Projection
Cooling water hose fitting
AO
Radiator hose
1.In sert ra diato r lower h o se as fa r as th e projection
o f the cooling wate r inlet hose fit t ing.
2.In sert radia t or up per h o se as far a s t he pro j ection
o f the cooling wate r outle t hose fitt ing.
3.Align th e ma ting marks on the rad i ator hose and
h o se clamp, an d then conn ect the radiator h o se.
12.A/C con den se r fan mo to r & sh ro ud
assembly
13.Coo ling fan mo to r & sh ro ud
assembly
14.Rad i ator a s sem b ly
Cooling fan mo tor r e mova l
st
ep s

3.Radi ator con den ser t a nk h o se
<>>>A<<5.Radi ator u ppe r ho se
7.Cooling fan mo to r dr ive contr o l unit
con
nector
12.A/C con den se r fan mo to r & sh ro ud
assembly
13.Coo ling fan mo to r & sh ro ud
assembly
15.Coo ling fan ( L .H.)
16.Coo ling fan mo to r dr ive contro l unit
17.Coo ling fan mo to r ( L .H.)
18.Coo ling fan shr o u d
Radiator re mova l st ep s

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATIO N . . . . . . . .15-2
SERVICE SPECIFICATION . . . . . . . .15-2
SPECIAL TOOL . . . . . . . . . . . . . . . . .15-2
AIR CLEANER . . . . . . . . . . . . . . . . . .15-3
REMOVAL AND INSTALLATION . . . . . . . . 15-3
INLET MANIFOLD . . . . . . . . . . . . . . .15-5
REMOVAL AND INSTALLATION <4G1> . . 15-5
REMOVAL AND INSTALLATION <4G6> . . 15-6
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-7
EXHAUST MANIFOLD . . . . . . . . . . . .15-7
REMOVAL AND INSTALLATION <4G1> . . 15-7
REMOVAL AND INSTALLATION <4G6> . . 15-9
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-10
EXHAUST PIPE AND MAIN
MUFFLER . . . . . . . . . . . . . . . . . . . . . .15-10
REMOVAL AND INSTALLATION . . . . . . . . 15-10

GENERAL INFORMATION
INTAKE AND EXHAUST15-2
GENERAL INFORMATION
M1151000100402
The exhaust pipe is divided into three parts.
SERVICE SPECIFICATION
M1151000300428
ItemStandard valueLimit
Manifold distortion of the installation surface mm0.15 or less0.20
SPECIAL TOOL
M1151000600399
ToolNumberNameUse
MD998770Oxygen sensor wrenchRemoval 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-372).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13A
P.13A-383).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A
P.13A-381).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A
P.13A-381).
•Throttle Body Assembly Inst allation (Refer to GROUP
13A
P.13A-383).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service
P.17-2).
•Fuel Leak Check
AC303642AB
15
36
5
4 12
10
7
1
2
11
9 13
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m 18 ± 2 N·m
5.0 ± 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 connection
8.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.13B-325).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13B
P.13B-335).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13B
P.13B-333).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13B P.13B-333).
•Throttle Body Assembly Inst allation (Refer to GROUP
13B P.13B-335).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•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
20 ± 2 N·m
11
9
10
2
12
N14
13N
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 connection
4.Engine control detonation sensor
connector
5.Engine oil level gauge and guide
assembly
6.Engine oil filler O-ring
7.Emission vacuum hose connection
Removal steps (Continued)

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-ring
6.Exhaust manifold cover
7.Exhaust manifold bracket
8.Exhaust manifold
9.Exhaust manifold gasket
EXHAUST MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (FRONT) REMOVAL
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (fro nt).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (FRONT) INSTALLA TION
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (f ront).

EXHAUST PIPE AND MAIN MUFFLER
INTAKE AND EXHAUST15-10
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (FRONT) REMOVAL
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (fro nt).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (FRONT) INSTALLA TION
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (f ront).
INSPECTIONM1151 0034 0054 3
Chec k the fo llowing point s; rep l ace the p a rt if a p r ob-
lem is found.
Exhaust Manifold Check
1.Check f o r damage o r cracking of a n y p a rt.
2.Using a straight e dge an d a fee l er ga uge, check
fo r distortio n of th e cylin der he ad in st allation
surface.
St a ndard val ue: 0.15 mm or les s
Limit: 0.20 mm
EXHAUST PIPE AND MAI N MUFFLER
REMOVA L AND INST ALLA TION
M1151 0087 0096 9
AC303694AC
1
3
50 ± 10 N·m
2
7
N
N
45
8 4
N9
10
59 ± 10 N·m
45 ± 5 N·m
13 ± 2 N·m
45 ± 5 N·m
13 ± 2 N·m
10
<4G1>

EXHAUST PIPE AND MAIN MUFFLER
INTAKE AND EXHAUST15-12
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (REAR) REMOVAL
AC212566AD
MD998770
Engine control
oxygen sensor
(rear)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (re ar).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (REAR) INSTALLA TION
AC212566AD
MD998770
Engine control
oxygen sensor
(rear)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (re ar).