2005 MITSUBISHI LANCER 001

GENERAL INFORMATION
ENGINE LUBRICATION12-2
GENERAL INFORMATION
M1121000100357
The lubrication method is a fully force-fed, full-flow
filtration type. The engine oil pump is a trochoid type
which is driven by the crankshaft <4G1>.The engine
oil pump is a gear type which is driven by the
crankshaft via the balancer timing belt <4G6>.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them. Other precautions:
•Avoid prolonged and repeated contact with oils,
particularly used engine oils.
•Wear protective clothing, including impervious
gloves where practicable.•Avoid contaminating clothes, particularly
underpants, with oil.
•Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
•Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.
•Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
•Obtain first aid treatment immediately for open
cuts and wounds.
•Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
•Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
•Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
•If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300232
LUBRICANT
M1121000400433
Item Standard value
Oil pressure kPa at idle 29 or more
at 3,500 r/min 294 − 686
Item Specification
Engine oil ACEA classification A1, A2 or A3
Engine oil API classification SG or higher
Engine oil quantity L 4G1 Oil filter 0.3
To t a l 3 . 3
4G6 Oil filter 0.3
To t a l 4 . 3

ON-VEHICLE SERVICE
ENGINE LUBRICATION12-4
ON-VEHICLE SERVICE
ENGINE OIL CHECKM1121000900342
1. Pull out the engine oil level gauge slowly and
check that the oil level is in the illustrated range.
2. Check that the oil is not excessively dirty, that
there is no coolant or petrol mixed in, and that it
has sufficient viscosity.
ENGINE OIL REPLACEMENTM1121001000416
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80 °C to 90
°C.
2. Remove the engine oil filler cap.
CAUTION
Use care as engine oil could be hot.
3. Remove the engine oil pan drain plug to drain
engine oil.4. Install a new engine oil pan drain plug gasket so
that it faces in the direction shown in the
illustration, and then tighten the engine oil pan
drain plug to the specified torque.
Tightening torque: 39 ± 5 N⋅m
NOTE: Install the engine oil pan drain plug gasket
so it faces in the direction shown in the illustration.
5. Refill with specified quantity of engine oil.
Specified Engine Oil (ACEA and API
classification): ACEA A1, A2 or A3/API SG or
higher
Total quantity (Includes volume inside engine
oil filter):
3.3 L <4G1>
4.3 L <4G6>
6. Install the engine oil filler cap.
7. Check engine oil level.
ENGINE OIL FILTER REPLACEMENTM1121001100383
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80 °C to 90
°C.
2. Remove the engine oil filler cap.
CAUTION
Use care as engine oil could be hot.
3. Remove the engine oil pan drain plug to drain
engine oil.
4. Remove the under cover.
ACX00892 AC
Good
MaximumMinimum
<4G1>
AC205268
Maximum MinimumGood
AC
<4G6>
AC208299
Engine oil pan
AC
Engine oip pan
drain plug
Engine oip pan
drain plug
Engine oil
pan side
AC301513

GENERAL INFORMATION
ENGINE COOLING14-2
GENERAL INFORMATION
M1141000100371The 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
circulation type in which the water pump pressurizes
coolant and circulates it throughout the engine. If the
coolant temperature exceeds the prescribed temperature, 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
crankshaft. The radiator is the corrugated fin, down
flow type.
SERVICE SPECIFICATIONS
M1141000300416
LUBRICANT
M1141000400338
ItemSpecification
Radiator Performance kJ/h 4G13 Standard vehicles 137,720
Vehicles with capacity up radiator
(option)161,288
4G18 Standard vehicles 161,288
Vehicles with capacity up radiator
(option)181,800
4G63 181,800
A/T oil cooler Performance kJ/h 5,651
Item Standard value Limit
High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Thermostat Valve opening temperature of
thermostat °C4G1 88 ± 1.5 -
4G6 82 ± 1.5 -
Full-opening temperature of
thermostat °C4G1 100 -
4G6 95 -
Valve lift mm 8.5 or more -
Item Specified coolant Quantity L
Engine coolant (including
condense tank)DIAQUEEN SUPER LONG LIFE COOLANT
or an equivalent4G1 5.0
4G6 7.0

ON-VEHICLE SERVICE
ENGINE COOLING14-22
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
moisture from the places checked.
•When the tester is taken out, be careful not to
spill any coolant.
•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 level 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
testing. Rust or other foreign material on the cap
seal will cause an improper reading.
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 REPLACEMENTM1141001200434
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
pressure escape through the vinyl tube.
After relieving the steam pressure, 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.
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.
ACX01844
Cap adapter
Adapter
AC
AC211643AB
Cap adapter
AC208283AC
Cylinder block
drain plug
<4G1>
Inlet side
AC303355
<4G6>
Inlet side
Cylinder block
drain plug
AB

ON-VEHICLE SERVICE
ENGINE COOLING14-23
5. Apply the designated sealant to the screw area of
the cylinder block drain plug, and then tighten to
the standard torque.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent
Tightening torque:
40 ± 5 N⋅m <4G1>
44 ± 5 N⋅m <4G6>
6. Securely tighten the drain plug of the radiator.
7. Reinstall the radiator condenser tank.
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
components.
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 MEASUREMENTM1141001100352
Measure the temperature and specific gravity of the
engine coolant to check the antifreeze concentration.
Standard value: 30 − 60% (allowable
concentration 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
concentration 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
M1141006100216
1. Remove the cooling fan motor drive control unit
connector.
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
AC200625
Cylinder block
drain plug
AC
AC303612AB
MB991871
AIR HOSE
AC103195
Y1716AU
1 23
AC
Cooling fan motor
drive control unit

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

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 EXHAUST15-6
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)