2005 MITSUBISHI LANCER Workshop Manual

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

NOTES

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . .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> . . 15-5REMOVAL 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 . . . . . . . . . . . . . . . . . . . . . .15-11
REMOVAL AND INSTALLATION . . . . . . . . 15-11

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

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)