radiator MITSUBISHI LANCER 2006 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2006, Model line: LANCER, Model: MITSUBISHI LANCER 2006Pages: 800, PDF Size: 45.03 MB
Page 15 of 800
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . .14-2
SERVICE SPECIFICATIONS . . . . . . .14-2
LUBRICANT . . . . . . . . . . . . . . . . . . . .14-3
SEALANTS . . . . . . . . . . . . . . . . . . . .14-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .14-3
TROUBLESHOOTING . . . . . . . . . . . .14-5
INSPECTION CHART FOR TROUBLE
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 14-5
INSPECTION PROCEDURE FOR
TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 14-6
ON-VEHICLE SERVICE . . . . . . . . . . .14-21
ENGINE COOLANT LEAK CHECK . . . . . . 14-21
RADIATOR CAP VALVE OPENING
PRESSURE CHECK . . . . . . . . . . . . . . . . . . 14-21
ENGINE COOLANT REPLACEMENT . . . . 14-21
CONCENTRATION MEASUREMENT . . . . 14-22
COOLING FAN MOTOR DRIVE
CONTROL UNIT CHECK . . . . . . . . . . . . . . 14-22
FAN CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
COOLING FAN MOTOR CHECK . . . . . . . . 14-24
THERMOSTAT . . . . . . . . . . . . . . . . . .14-24
REMOVAL AND INSTALLATION . . . . . . . . 14-24
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-26
WATER PUMP . . . . . . . . . . . . . . . . . .14-27
REMOVAL AND INSTALLATION <4G1> . . 14-27
REMOVAL AND INSTALLATION <4G6> . . 14-28
WATER HOSE AND WATER PIPE . .14-29
REMOVAL AND INSTALLATION <4G1> . . 14-29
REMOVAL AND INSTALLATION <4G6> . . 14-31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-32
RADIATOR . . . . . . . . . . . . . . . . . . . . .14-33
REMOVAL AND INSTALLATION <4G1> . . 14-33
REMOVAL AND INSTALLATION <4G6> . . 14-35
Page 16 of 800
GENERAL INFORMATION
ENGINE COOLING14-2
GENERAL INFORMATION
M1141000100371
The cooling system is designed to keep every part of
the engine at appropriate temperature in whatever
condition the engine may be operated. The cooling
method is of the water-cooled, pressure forced circu
-
lation type in which the water pump pressurizes cool-
ant and circulates it throughout the engine. If the
coolant temperature exceeds the prescribed temper
-
ature, the thermostat opens to circulate the coolant
through the radiator as well so that the heat
absorbed by the coolant may be radiated into the air.
The water pump is of the centrifugal type and is
driven by the alternator drive belt from the crank
-
shaft. The radiator is the corrugated fin, down flow
type.
ItemSpecification
RadiatorPerformance kJ/h4G13Standard vehicles137,720
Vehicles with capacity up radiator
(option)161,288
4G18Standard vehicles161,288
Vehicles with capacity up radiator
(option)181,800
4G63181,800
A/T oil coolerPerformance kJ/h5,651
SERVICE SPECIFICATIONS
M1141000300687
ItemStandard valueLimit
Fan controller VA/C OFF1 or less-
A/C ONRepeat
8.2 ± 0.7
System voltage ± 2.6
-
High-pressure valve opening pressure of radiator cap kPa93 − 123Minimum 83
Range of coolant antifreeze concentration of radiator %30 − 60-
ThermostatValve opening temperature of
thermostat
°C
4G188 ± 1.5-
4G682 ± 1.5-
Full-opening temperature of
thermostat
°C
4G1100-
4G695-
Valve lift mm8.5 or more-
Page 35 of 800
ON-VEHICLE SERVICE
ENGINE COOLING14-21
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECKM1141001000300
WARNING
When pressure testing the cooling system,
slowly release cooling system pressure to
avoid getting burned by hot coolant.
CAUTION
•Be sure to completely clean away any mois-
ture from the places checked.
•When the tester is taken out, be careful not to
spill any coolant.
•
ACX01844
Cap adapter
Adapter
AC
Be careful when installing and removing the
tester and when testing not to deform the
filler neck of the radiator.
1. Check that the coolant leve l is up to the filler neck.
Install a radiator tester and apply 160 kPa
pressure, and then check for leakage from the
radiator hose or connections.
2. If there is leakage, repair or replace the
appropriate part.
RADIATOR CAP VALVE OPENING
PRESSURE CHECK
M1141001300389
NOTE: Be sure that the cap is clean before test-
ing. Rust or other foreign material on the cap seal
will cause an improper reading.
AC211643AB
Cap adapter
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving.
Minimum limit: 83 kPa
Standard value: 93 − 123 kPa
3. Replace the radiator cap if the reading does not remain at or above the limit.
ENGINE COOLANT REPLACEMENT
M1141001200434
WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the cap and turn the
cap counterclockwise a little to let the pres
-
sure escape through the vinyl tube. After
relieving the steam pres sure, remove the cap
by slowly turning it counterclockwise.
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.
AC208283AC
Cylinder block
drain plug
<4G1>
Inlet side
AC303355
<4G6>
Inlet side
Cylinder block
drain plug
AB
2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain
the coolant.
4. Drain the coolant then clean the path of the coolant by injecting water into the radiator from
the radiator cap area.
Page 36 of 800
AC200625
Cylinder block
drain plug
AC
ON-VEHICLE SER VICE
ENGINE COOLING14-22
5.App l y the designa ted sealant to t he scre w area of
th e cylin der block drain plu g , and then tighten to
th e st and ard torq ue.
Sp e c ified s ealant: 3 M Nut Loc king Part
No. 4171 o r e quivale n t
Ti ghtenin g torque:
40 ± 5 N⋅m <4G1>
44 ± 5 N⋅m <4G6>
6.Securely tighten t he drain plug of t he radiator .
7.Reinst all the ra diato r con denser t ank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium compo
-
nents.
AC303612AB
MB991871
AIR HOSE
8. By referring to the section on coolant, select an
appropriate concentration for safe operating
temperature within the range of 30 to 60%. Use
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50% water and
50% antifreeze solution (freezing point:
−31°C).
Recommended antifreeze: DIAQUEEN SUPER LONG LIFE COOLANT or equivalent
Quantity:
5.0 L <4G1>
7.0 L <4G6>
NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.
9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the thermostat opens.
11.After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
Do not overfill the radiator condenser tank.
13.Add coolant to the radiator condenser tank between the "F" and "L" mark if necessary.
CONCENTRATION MEASUREMENT
M1141001100352
Measure the temperature and specific gravity of the
engine coolant to check the antifreeze concentration.
Standard value: 30 − 60% (allowable concentra-
tion range)
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
CAUTION
If the concentration of the anti-freeze is below
30%, the anti-corrosion property will be
adversely affected. In addition, if the concentra
-
tion is above 60%, both the anti-freezing and
engine cooling properties will decrease, affecting
the engine adversely. For these reasons, be sure
to maintain the concentration level within the
specified range.
COOLING FAN MOTOR DRIVE CONTROL
UNIT CHECK
M1141006100250
1. Remove the cooling fan motor drive control unit connector.
AC103195
Y1716AU
1
23
AC
Cooling fan motor
drive control unit
2. Turn the ignition switch to the "ON" position, and
measure the voltage between terminal 1 and 3 at
the harness side connector.
Standard value: system voltage
Page 39 of 800
AC301429
1
2 36
7
13 ± 2 N·m
AD
5
<4G6>
Removal steps
1.Water temperature gauge unit
connector <4G6>
2.Water temperature sensor unit
connector <4G6>
<>>B<<3.Radiator lower hose connection
4.Engine control oxygen sensor
connector and connector bracket
<4G1>
5.Control wiring harness clip <4G6>
6.Cooling water inlet hose fitting
>>A<<7.Thermostat
THERMOST
A T
ENGINE COOLING14-25
REMOV A L SER V ICE POINT
<> RADIAT OR LOW E R HOSE DIS-
CONNECTION
AC200641AC
Mating marks
Make mating marks on the rad i ator lower ho se an d
the hose clamp. Disconn
ect t he radiator lower hose.
INSTALLA T ION SER VICE POINTS
>>A<< THERMOSTA T INST ALLA TION
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.
AC000279
Jiggle valve
Rubber ring
AB
Install the thermostat so that the jiggle valve is facing
straight up. Be careful not to fold or scratch the rub
-
ber ring.
Page 40 of 800
THERMOSTAT
ENGINE COOLING14-26
>>B<< RADIATOR LOWER HOSE
CONNECTION
AC200642
Mating marks
Projection
Cooling water inlet
hose fitting
AH
1.In sert ra diato r lower h o se a s fa r as th e projection
of the Cooling wa ter inlet ho se fitting .
2.Align the mating marks on the radiator lower hose
an d hose clamp, and then connect the radia t or
lower hose.
INSPECTION
M1 141 0025 0042 7
THERMOSTA T CHECK
ACX00400
AB
1.Imme rse th e thermost at in water , and h eat the
wate r wh ile stirring. Ch eck the th ermost a t va lve
o penin g temperatu r e.
St andard va lue:
88 ± 1.5°C <4G1 >
82 ± 1.5°C <4G6 >
ACX00401 AC
Valve lift
2.
Check t hat the amo unt of valve lif t is at the
st a ndard valu e when th e water is at the
fu ll-o penin g temperatu r e.
NOTE: Meas ure the valve height when the the r-
mostat is fu lly closed , and use t h is measurement
to
comp are the valve h e ight wh en the thermost at
is fully open.
St andard va lue:
100°C <4G1>
95°C <4G6>
Amou nt of val ve lif t: 8 . 5 mm or more
Page 43 of 800
WATER HOSE AND WATER PIPE
ENGINE COOLING14-29
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.14-21).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-24).
AC203411
1
2 3
4
5
6
7
8
10
9
13 ± 2 N·m
23 ± 4 N·m
13 ± 2 N·m
N
N
AC
1112
13
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 assembly
7.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-ring
REMOV
A L SER VICE POINT
<> RADIAT OR UPPER HOSE DISCON-
NECTION
AC200641AC
Mating marks
After making matin g ma rks on the radia t or upp er
hose
and h o se clamp, disconnect the radia t or upp er
hose
.
Page 44 of 800
WATER HOSE AND WATER PIPE
ENGINE COOLING14-30
INSTALLATION SERVICE POINTS
>>A<< COOLING WATER LINE O-RING
INSTALLATION
AC200644 AD
Cooling water
line O-ring
Water pump inlet pipe Water pump or thermostat case
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
AC200642
Mating marks
Projection
Thermostat case assemblyAI
Radiator upper
hose
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.
Page 45 of 800
WATER HOSE AND WATER PIPE
ENGINE COOLING14-31
REMOVAL AND INSTALLATION <4G6>
M1141003300426
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).
•Thermostat Removal and Installation (Refer to P.14-24).
AC303471
1
2
3
4
5 6
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 equivalent
Ø3 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 connection
7.Control wiring harness clamp
8.Water pump inlet pipe
>>A<<9.Cooling water line O-ring
Removal steps (Continued)
Page 46 of 800
