2006 MITSUBISHI LANCER Workshop Manual

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

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 pre-
cautions.
•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>

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 duct
6.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 bracket
AIR CLEA NER
INTAKE AN D EXHAU ST15-4
Removal 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-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)