Cooling: Removal & Installation Mitsubishi Galant IX facelift 2

ENGINE COOLANT REPLACEMENT

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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 assembly 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.
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™ AAD Part No.8731 or equivalent Tightening torque: < 2.4L Engine > 44 +/- 5 N.m (33 +/- 3 ft-lb) < 3.8L Engine > 39 +/- 5 N.m (29 +/- 3 ft-lb)
6. Securely tighten the radiator drain plug.
7. Assemble the radiator condenser tank assembly. CAUTION: Do not use alcohol or methanol antifreeze or any engine coolants mixed with alcohol or methanol antifreeze. The use of an improper antifreeze can cause corrosion of the aluminum components. If the coolant contact the PremAir® direct ozone reduction (DOR) radiator, wash it with water at once. < Vehicles for California emission regulation > (2.4L Engine)
8. Select an appropriate concentration for safe operating temperature within the range of 30 to 60 %. Use special tool MB991871 to refill the coolant. A convenient mixture is a 50 % water and 50 % antifreeze solution [freezing point: -31°C (-32.8 °F)]. Recommended antifreeze: Long Life Antifreeze Coolant or an equivalent Quantity: < 2.4L Engine > 8.0 dm 3 (8.5 quarts) < 3.8L Engine > 8.7 dm 3 (9.2 quarts) 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, stop the engine.
12. Remove the radiator cap after the engine has cooled, and pour in coolant up to the brim. Reinstall the cap. CAUTION: Do not overfill the radiator condenser tank assembly.
13. Add coolant to the radiator condenser tank assembly between the "FULL" and "LOW" mark if necessary.

<< B >> A/T OIL COOLER HOSE REMOVAL

After removing the hose from the radiator, plug the hose and the radiator nipple to prevent dust or foreign particles from getting in.

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1. Insert each hose as far as the projection of the water inlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

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>> A << THERMOSTAT INSTALLATION

Install the thermostat so that the jiggle valve is facing straight up. Be careful not to fold or scratch the rubber ring.

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1. Insert each hose as far as the projection of the water inlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

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1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: Valve opening temperature: < 2.4L Engine > 82 +/- 1.5°C (180 +/- 3°F) < 3.8L Engine > 88 +/- 1.5°C (190 +/- 3°F)
2. Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to compare the valve height when the thermostat is fully open. Standard value: Full-opening temperature: < 2.4L Engine > 95°C (203°F) < 3.8L Engine > 100°C (212°F) Amount of valve lift: < 2.4L Engine > 8.5 mm (0.33 inch) or more < 3.8L Engine > 9.0 mm (0.35 inch) or more

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>> A << O-RING INSTALLATION

Fit an O-ring into the O-ring groove located at the end of the water inlet pipe and apply water or coolant to the O-ring or the inside of the mounting surface of the water pump for insertion.

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Fit the O-ring into the groove of the water pipe ends, and apply water or coolant to the circumference of the O-ring and the pipe bores to insert the pipe assembly.

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>> A << O-RINGS INSTALLATION

Fit an O-ring into the groove of the water inlet pipe and apply water or coolant to the circumference of the O-ring or the inside of the mounting surface of the water pump or thermostat case for insertion.

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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 sealant to the cylinder head mating surface of the thermostat case as shown. Specified Sealant: 3M™ AAD Part No.8672, 3M™ AAD Part No.8679/8678 or equivalent
3. Apply sealant to the thread of the thermostat case bolts as shown. Specified Sealant: 3M™ AAD Part No.8730, 8731 or equivalent
4. With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case. Do not apply the sealant in an area more than the required.

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1. Insert each hose as far as the projection of the water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

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Insert the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant.

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>> B << ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

Apply the specified sealant to the thread of the engine coolant temperature sensor, and then tighten it to the specified torque.

Specified Sealant: 3M™ AAD Part No. 8731 or equivalent

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1. Insert each hose as far as the projection of the water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.