Cooling - Lancer Evolution: Other Mitsubishi Lancer X

COOLANT

COOLANT SPECIFICATION

SEALANT

SEALANT SPECIFICATION

ENGINE COOLANT LEAK CHECK

1. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa (23 psi) 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 OPENING PRESSURE CHECK

Note. Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an improper reading.

Scheme 20

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 (12 psi) Standard value: 93 - 123 kPa (14 - 18 psi)
3. Replace the radiator cap if the reading does not remain at or above the limit.

ENGINE COOLANT CHANGE

Required Special Tool

1. MB991871: LLC changer

Scheme 21

1. Remove the engine room under cover front A (RH). (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) ) 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.
2. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.
3. Remove the engine room under cover front B. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) )
4. Remove the air cleaner intake hose. (Refer to «AIR CLEANER»(ref-289375-S31240850732008063000000) )
5. Remove the turbocharger compressor bracket. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-289375-S31455216472008063000000) )
6. Disconnect the turbocharger water return hose and drain the coolant in the water jacket.
7. Remove the radiator condenser tank and drain the coolant.
8. Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area.
9. Connect the turbocharger water return hose.
10. Securely tighten the drain plug of the radiator.
11. 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 aluminum components.
12. 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 MB991871 to refill the engine coolant up to the top of the radiator port. A convenient mixture is a 50% water and 50% antifreeze solution [freezing point: --31°C (--23.8 °F)]. Recommended antifreeze: Long Life Antifreeze Coolant or an equivalent Quantity: 7.5 dm 3 (7.9 quarts) NOTE: For how to use special tool (MB991871), refer to its manufacturer's instructions.
13. Tighten the radiator cap securely.
14. Remove the radiator condenser tank cap, and add the engine coolant up to the "FULL" line.
15. Turn the A/C switch to OFF position to start the engine and warm up until the cooling fan operates. NOTE: This step opens the thermostat fully.
16. Rev the engine several times and then stop it. Check that there are no coolant leaks.
17. Remove the radiator cap with the engine cool, and then refill the engine coolant up to the top of the radiator port.
18. Tighten the radiator cap securely. CAUTION: Do not overfill the radiator condenser tank.
19. Remove the radiator condenser tank cap, and add the engine coolant up to the "FULL" line.
20. Install the turbocharger compressor bracket. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-289375-S31455216472008063000000) )
21. Install the air cleaner intake hose. (Refer to «AIR CLEANER»(ref-289375-S31240850732008063000000) )
22. Remove the engine room under cover front B and engine room under cover front A (RH). (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) )

WATER PUMP COOLANT LEAK CHECK

If a residue of the coolant draining is found on the drain hole, the vapor hole and the installation surface, check the water pump leakage by following method.

1. Wipe off the residue of the coolant draining on the water pump. WARNING: Make sure that the coolant is cold when removing the radiator cap.
2. Remove the radiator cap. CAUTION: Do not pressures 100 kPa (15 psi) or more.
3. Install the radiator tester and pressures at 100 kPa (15 psi).
4. Hold the pressurized state for 20 minutes, and check that the water leakage from the drain hole, the vapor hole or the installation surface of the water pump.
5. Remove the radiator tester, and install the radiator cap.
6. Warm up the engine, let it idle for 20 minutes and stop it.
7. After stopping the engine, and check that the water leakage from the drain hole, the vapor hole or the installation surface of the water pump.
8. If the water leakage is found in step 4 or 7 , replace the water pump. (Refer to «WATER PUMP»(ref-289378-S25704052812008063000000) .)

RADIATOR FAN RELAY CHECK

BATTERY VOLTAGE CONTINUITY CHART

Scheme 22

CONDENSER FAN RELAY CHECK

BATTERY VOLTAGE CONTINUITY CHART

Scheme 23

FAN CONTROL RELAY CHECK

BATTERY VOLTAGE CONTINUITY CHART

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Scheme 27

1. Disconnect the fan motor connector.
2. Check that the fan motor runs when a positive battery terminal is connected to the fan motor-side connector terminal No.1, and terminal No.2 is grounded. Also check to see that there is no abnormal sound emitted from the fan motor at this time.
3. If the fan motor is defective, replace it (Refer to «RADIATOR»(ref-289378-S01895578722008063000000) ).

Scheme 28

<< A >> RADIATOR LOWER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

Scheme 29

>> B << RADIATOR LOWER HOSE CONNECTION

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.

Scheme 30

Scheme 31

1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: Valve opening temperature: 76.5 ± 1.5°C (170 ± 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: 90°C (194°F) Amount of valve lift: 8.5 mm (0.33 inch) or more

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Required Special Tool

1. MB992042: Water Temp Sensor Wrench

<< A >> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

Scheme 34

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Scheme 36

1. Follow the steps below to unlock the fuel high-pressure hose connector. Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04inch) thick] into the retainer of the fuel high-pressure hose connector. CAUTION: When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel high-pressure hose connector.
2. Remove the fuel high-pressure hose.

>> B << FUEL HIGH-PRESSURE HOSE CONNECTION

Scheme 37

1. Securely insert the fuel rail stopper into the fuel high-pressure hose connector groove to install the fuel high-pressure hose to the fuel rail.
2. Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel rail.

WATER PIPE AND HOSE CHECK

Check the water pipe and hose for cracks, damage and clogs. Replace them if necessary.

Scheme 38