Mitsubishi Engine cooling, Workshop Manual

Page 1: ...OOL 3 TROUBLESHOOTING 3 ON VEHICLE SERVICE 9 Engine Coolant Leak Checking 9 Radiator Cap Opening Pressure Check 9 Engine Coolant Replacement 10 Concentration Measurement 11 Fan Controller Check 12 Fan Control Relay Continuity Check 12 THERMOSTAT 13 WATER PUMP 4G6 15 6A1 16 4D6 18 WATER HOSE AND WATER PIPE 19 RADIATOR 24 ...

Page 2: ...pe and is cooled by the electrical radiator fan The cooling fans are controlled by a fan controller and the engine ECU depending on driving conditions Items Specifications Radiator Performance kJ h 4G6 175 800 6A1 200 900 4D6 213 500 A T oil cooler Performance kJ h 4G6 5 700 6A1 4D6 7 100 SERVICE SPECIFICATIONS 14100030091 Items Standard value Limit Radiator cap opening pressure kPa 74 103 64 Rang...

Page 3: ...cles without A C 1 14 3 Radiator fan and condenser fan do not change speed or stop Vehicles with A C Radiator fan does not change speed or stop Vehicles without A C 2 14 6 Radiator fan does not operate Vehicles with A C 3 14 8 Condenser fan does not operate Vehicles with A C 4 14 8 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Radiator fan and condenser fan do not operate Vehicl...

Page 4: ...inal voltage check Refer to GROUP 13A Trou bleshooting OK Measure at the engine ECU connectors C 34 1 C 33 2 C 53 3 D Connect the connector Except 4D6 D Voltage between 21 and body earth Engine idling A C switch ON OK 0 7 V or more When A C compressor is operating 4D6 D Voltage between 18 and body earth Engine idling A C switch ON OK 0 7 V or more When A C compressor is operating NG Check the harn...

Page 5: ...ition switch ON OK The radiator fan motor operates 4D6 D Pull out the terminal No 18 to disconnect it Ignition switch ON OK The radiator fan motor operates OK Measure at the engine ECU connectors C 34 1 C 33 2 C 53 3 D Connect the connector Except 4D6 D Voltage between 21 and body earth Engine idling OK 0 7 V or more When radiator fan is operating 4D6 D Voltage between 18 and body earth Engine idl...

Page 6: ... to the body earth Ignition switch ON OK The radiator fan motor and condenser fan motor stop 4D6 D Pull out the terminal No 18 to disconnect it Ignition switch ON OK The radiator fan motor and condenser fan motor operate D Connect the terminal No 18 to the body earth Ignition switch ON OK The radiator fan motor and condenser fan motor stop OK Fan controller check Refer to P 14 12 NG Replace the ra...

Page 7: ...o the body earth Ignition switch ON OK The radiator fan motor stops OK Fan controller check Refer to P 14 12 NG Replace the radiator fan motor and fan controller assembly OK Measure at the engine ECU connectors C 34 1 C 33 2 C 53 3 D Connect the connector Except 4D6 D Voltage between 21 and body earth Engine idling engine coolant temperature 80_C or less OK 0 0 3 V Engine idling OK 0 7 V or more W...

Page 8: ...place the radiator fan motor and fan controller assembly Inspection Procedure 4 Condenser fan does not operate Vehicles with A C Probable cause The cause could be a malfunction of the condenser fan motor or of the fan controller D Malfunction of condenser fan motor D Malfunction of fan controller D Malfunction of wiring harness or connector OK Replace the radiator fan motor and fan controller asse...

Page 9: ... 3 Be careful when installing and removing the tester and when testing not to deform the filler neck of the radiator 2 If there is leakage repair or replace the appropriate part RADIATOR CAP OPENING PRESSURE CHECK 14100130159 1 Use a cap adapter to attach the cap to the tester 2 Increase the pressure until the indicator of the gauge stops moving Limit 64 kPa Standard value 74 103 kPa 3 Replace the...

Page 10: ...G6 4D6 6A1 Front bank 6A1 Rear bank 3 Remove the reserve tank to drain the engine coolant 4 When the engine coolant has drained pour in water from the radiator cap to clean the engine coolant line 5 Coat the thread of the cylinder block drain plug with the specified sealant and tighten to the specified torque Specified sealant 3M Nut Locking Part No 4171 or equivalent 6 Securely tighten the radiat...

Page 11: ... race the engine several times and then stop the engine 14 Cool down the engine and then pour engine coolant into the reserve tank until the level reaches the FULL line If the level is low repeat the operation from step 11 CONCENTRATION MEASUREMENT 14100110146 Measure the temperature and specific gravity of the engine coolant to check the antifreeze concentration Standard value 30 60 allowable con...

Page 12: ...measuring the voltage between the fan controller side connector terminals check that the value changes repeatedly as indicated by 1 3 below 1 0 V 2 4G6 8 2 2 6 V Except 4G6 6 8 2 6 V 3 Battery voltage 2 6 V 5 If the voltage does not repeatedly change as indicated replace the radiator fan motor and the fan controller assembly FAN CONTROL RELAY CONTINUITY CHECK 14100620014 Battery voltage Terminal N...

Page 13: ...se Assembly Removal and Installation D Air Hose and Air Pipe Assembly Removal and Installation 4D6 Refer to P 14 21 17 20 Nm 4G6 6A1 4D6 13 Nm 12 15 Nm 12 15 Nm 13 Nm 1 2 3 4 5 6 7 4 4 7 6 3 3 6 7 Removal steps 1 Heater hose connection 4D6 2 Water hose connection 4D6 AA BA 3 Radiator lower hose connection 4 Control wiring harness mounting bolt 5 Fuel pipe mounting bolt 4D6 6 Water inlet fitting AA...

Page 14: ...NECTION 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 INSPECTION 14100250275 THERMOSTAT CHECK 1 Immerse the thermostat in water and heat the water while stirring Check the thermostat valve opening temperature Standard value Valve opening temperature 82 1 5_C 2 Check that the amo...

Page 15: ... Nm 24 Nm 8 60 8 22 8 14 20 25 Nm Bolt specifications 8 25 8 22 Screw diameter length mm 1 2 4 3 2 Removal steps 1 Alternator brace 2 Water pump 3 Water pump gasket AA 4 O ring INSTALLATION SERVICE POINT AA O RING INSTALLATION Insert the O ring to the water inlet pipe assembly and coat the outer circumference of the O ring with water or engine coolant Caution Do not allow engine oil or other greas...

Page 16: ... A C Compressor Removal and Installation Refer to GROUP 55 D Timing Belt Removal and Installation Refer to GROUP 11 D Engine Mount Bracket Removal and Installation Refer to GROUP 32 24 Nm 8 30 8 25 Bolt specifications 8 25 Screw diameter length mm 49 Nm 12 Nm 18 Nm 39 Nm 39 Nm Sealant Mitsubishi Genuine Part No MD970389 or equivalent 8 20 8 30 8 25 8 30 1 2 3 4 5 5 5 f3mm Removal steps 1 Pressure ...

Page 17: ...the removed oil pump with rope etc in a place where it will not be in the way when removing and installing the power steering oil pump bracket INSTALLATION SERVICE POINT AA WATER PUMP INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant Specified Sealant Mitsubishi Genuine Part No MD970389 or equivalent ...

Page 18: ... Nm 24 Nm 8 20 8 22 Bolt specifications 8 65 8 22 Screw diameter length mm 1 2 4 3 8 25 24 Nm Removal steps 1 Alternator brace 2 Water pump 3 Water pump gasket AA 4 O ring INSTALLATION SERVICE POINT AA O RING INSTALLATION Insert the O ring to the water inlet pipe assembly and coat the outer circumference of the O ring with water or engine coolant Caution Do not allow engine oil or other greases to...

Page 19: ...Removal and Installation 24 Nm 12 7 8 13 Nm 6 1 5 2 11 3 4 10 9 13 Nm 7 Sealant Mitsubishi Genuine Part No MD970389 or equivalent f3mm Removal steps AA CA 1 Radiator lower hose connection 2 Control wiring harness mounting bolt 3 Water inlet fitting 4 Engine coolant temperature gauge unit connector 5 Water hose 6 Heater hose connection BA 7 Thermostat case assembly AA 8 O ring 9 Heater hose connect...

Page 20: ... 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Removal steps 1 Control wiring harness mounting bolt 2 Spark plug cable clamp mounting bolt AA CA 3 Radiator upper hose connection AA CA 4 Radiator lower hose connection 5 Engine coolant temperature sensor connector 6 Engine coolant temperature gauge unit connector 7 Water hose 8 Water hose 9 Heater hose connection 10 Heater pipe assembly AA 11 O ring 12 ...

Page 21: ...mbly Installation 45 Nm 12 15 Nm 10 12 Nm 12 15 Nm 20 25 Nm 1 2 3 4 5 6 7 8 9 10 11 12 13 10 13 Nm 12 15 Nm 12 15 Nm 10 12 Nm 6 Nm 17 Nm 9 Nm 17 Nm 6 Nm 7 Removal steps 1 Air hose and air pipe assembly AA CA 2 Radiator upper hose connection AA CA 3 Radiator lower hose connection 4 Heater hose connection 5 Turbocharger heat protector 6 Oil return hose and pipe assembly 7 Vacuum hose connection 8 Ai...

Page 22: ...1 22 23 24 Sealant Mitsubishi Genuine Part No MD970389 or equivalent 18 17 f3mm f3mm 14 Water pipe assembly A 15 Water hose 16 Water inlet fitting BA 17 Thermostat case assembly BA 18 Water outlet fitting AA 19 O ring 20 Heater hose connection 21 Water hose 22 Water pipe assembly B 23 Water inlet pipe assembly AA 24 O ring ...

Page 23: ...NG THERMOSTAT CASE ASSEMBLY INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant Specified Sealant Mitsubishi Genuine Parts No MD970389 or equivalent CA RADIATOR LOWER HOSE RADIATOR UPPER HOSE CONNECTION 1 Insert each hose as far as the projection of the water inlet fitting or water outlet fitting 2 Align the mat...

Page 24: ...r removal steps 1 Drain plug 2 Radiator cap 3 Overflow hose 4 Reserve tank 5 Reserve tank bracket AA AA 6 Radiator upper hose AA AA 7 Radiator lower hose 8 Clamp 6A1 A T AB 9 Transmission fluid cooler hose con nection A T 10 Engine oil cooler hose mounting bolt 4D6 11 Upper insulator 12 Radiator assembly 13 Lower insulator 14 Bolt A T AB 15 Transmission fluid cooler hose and pipe assembly A T 16 C...

Page 25: ...E AND PIPE ASSEMBLY REMOVAL After disconnecting the hoses from the radiator and the transmission plug all of the pipes and hoses to prevent dirt and other foreign objects from getting inside INSTALLATION SERVICE POINT AA RADIATOR LOWER HOSE RADIATOR UPPER 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 cl...

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