Mitsubishi Colt Ralliart. Manual - part 111

RADIATOR

ENGINE COOLING

14-26

REMOVAL SERVICE POINT
<<A>> RADIATOR UPPER HOSE/RADIA-
TOR LOWER HOSE/HOSE CLIPS 
REMOVAL

AC209237 AB

Hose clip

Claw (Tip)

Break off the tip of hose clip claw and spread out the 
hose clip, then disconnect the radiator lower hose.
NOTE: If there is a hose clip claw, the hose clip can-
not spread to capacity because the claw contacts the 
hose clip.

INSTALLATION SERVICE POINT
>>A<< HOSE CLIPS/RADIATOR LOWER 
HOSE/RADIATOR UPPWER HOSE 
INSTALLATION

CAUTION

Never reuse the hose clip whose claw is broken 
off to prevent the rusting.
1. Insert a new hose clip into the radiator hose.
2. Insert the radiator hose until the protrusion at both 

radiator and engine side.

3. Remove the hose clip claw and shorten the hose 

clip, then install the radiator hose.

9. Radiator piping clamp

<<

A

>> >>

A

<< 10. Radiator upper hose

<<

A

>> >>

A

<< 11. Hose clips

12. Radiator piping clamp

<<

A

>> >>

A

<< 13. Radiator lower hose

<<

A

>> >>

A

<< 14. Hose clips

15. Headlamp support upper panel
16. Radiator support upper insulators
17. A/C condenser mounting bolts
•

Radiator assembly

18. Radiator support lower insulators
19. Cooling fan, cooling fan motor and 

cooling fan shroud assembly

20. Radiator

Cooling fan, cooling fan motor 
and cooling fan shroud removal 

4. Radiator condenser tank hose
5. Cooling fan motor connector
6. Radiator condenser tank assembly
9. Radiator piping clip
12. Radiator piping clip
15. Headlamp support upper panel
19. Cooling fan, cooling fan motor and 

cooling fan shroud assembly

21. Cooling fan
22. Cooling fan motor
23. Cooling fan shroud

Radiator removal steps 

Main

Index

Group

TOC

GROUP 15

INTAKE AND 

EXHAUST

CONTENTS

GENERAL INFORMATION . . . . . . . .

15-2

SERVICE SPECIFICATIONS. . . . . . .

15-2

SPECIAL TOOL . . . . . . . . . . . . . . . . .

15-2

ON-VEHICLE SERVICE. . . . . . . . . . .

15-3

TURBOCHARGER SUPERCHARGING 

 

PRESSURE CHECK <4G1>. . . . . . . . . . . . 

15-3

SUPERCHARGING PRESSURE 

 

CONTROL SYSTEM CHECK <4G1> . . . . . 

15-3

WASTE GATE ACTUATOR CHECK 

 

<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-4

WASTE GATE SOLENOID VALVE CHECK 

 

<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-4

AIR BY-PASS VALVE CHECK <4G1> . . . . 

15-4

INTAKE MANIFOLD VACUUM CHECK . . . 

15-4

AIR CLEANER . . . . . . . . . . . . . . . . . .

15-5

REMOVAL AND INSTALLATION <4A9> . . 

15-5

REMOVAL AND INSTALLATION <4G1> . . 

15-6

INTERCOOLER  . . . . . . . . . . . . . . . . .

15-8

REMOVAL AND INSTALLATION <4G1> . . 

15-8

INLET MANIFOLD  . . . . . . . . . . . . . . .

15-11

REMOVAL AND INSTALLTION <4A9>. . . . 

15-11

REMOVAL AND INSTALLTION <4G1>  . . . 

15-12

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 

15-13

EXHAUST MANIFOLD . . . . . . . . . . . .

15-14

REMOVAL AND INSTALLATION <4A9>  . . 

15-14

INSPECTION <4A9> . . . . . . . . . . . . . . . . . . 

15-14

EXHAUST MANIFOLD AND 
TURBOCHARGER . . . . . . . . . . . . . . .

15-15

REMOVAL AND INSTALLATION <4G1> . . 

15-15

INSPECTION <4G1>. . . . . . . . . . . . . . . . . . 

15-18

EXHAUST PIPE AND MAIN 

 

MUFFLER . . . . . . . . . . . . . . . . . . . . . .

15-19

REMOVAL AND INSTALLATION <4A9>  . . 

15-19

REMOVAL AND INSTALLATION <4G1> . . 

15-21

Main

Index

GENERAL INFORMATION

INTAKE AND EXHAUST

15-2

GENERAL INFORMATION

M1151000100703

The exhaust pipe is divided into three parts.

SERVICE SPECIFICATIONS

M1151000300848

Item

Standard value

Limit

Turbocharger supercharging pressure (waste gate 
solenoid valve not operating) kPa

39 

− 65

−

Initial activation pressure of waste gate actuator (at the 
stroke of approxim ately 1mm) kPa

60

−

Waste gate solenoid valve coil resistance (at 20

°C) Ω

29 

− 35

−

Initial activation pressure of air by pass valve kPa

Approximately 53

−

Manifold distortion of the installation surface mm

0.15 or less

0.20

SPECIAL TOOL

M1151000600623

Tool

Number

Name

Use

B991953

MB991953

Oxygen sensor 
wrench

Removal and installation of oxygen 
sensor

Main

Index

Group

TOC

ON-VEHICLE SERVICE

INTAKE AND EXHAUST

15-3

ON-VEHICLE SERVICE

TURBOCHARGER SUPERCHARGING 
PRESSURE CHECK <4G1>

M1151001000356

CAUTION

Two persons should be in the vehicle when the 
test is conducted; the person in the passenger 
seat should read the indications shown by the 
pressure meter.

AK402049AC

Plug

Turbocharger waste
gate solenoid valve

1. Disconnect the hose (white paint mark) from the 

turbocharger waste gate solenoid valve, and 
connect the pressure gauge to the hose. Plug the 
nipple of the solenoid valve from which the hose 
(white paint mark) has been disconnected.

2. Drive at full-throttle acceleration in second gear 

and then measure the supercharging pressure 
when the engine speed in about 3,000 r/min.

Standard value: 39 

− 65 kPa

3. If the supercharging pressure deviates from the 

standard value, check the following items for 
possible cause.

• Malfunction of the waste gate actuator

• Leakage of supercharging pressure

• Malfunction of the turbocharger

4. When the indicated supercharging is more than 

standard value, supercharging control may be 
faulty, therefore check the followings.

• Malfunction of the waste gate actuator

• Malfunction of waste gate valve

• Disconnection or cracks of the waste gate actua-

tor rubber hose

SUPERCHARGING PRESSURE 
CONTROL SYSTEM CHECK <4G1>

M1151001100267

AK402050

Three-way joint

AC

Turbocharger waste
gate solenoid valve

1. Disconnect the hose (white paint mark) from the 

turbocharger waste gate solenoid valve and 
connect a three-way joint between the hose and 
the solenoid valve.

2. Connect a hand vacuum pump to the three-way 

joint.

AK402051

Nipple

Boost hose (Red stripe)

AC

3.  Disconnect the hose from the turbocharger waste 

gate actuator control boost nipple and plug the 
nipple.

4. Applying a negative pressure with the hand 

vacuum pump, check tightness both when the 
hose end is closed and when it is open.

Engine state

Hose end

Normal state

Stop
(Ignition switch: ON)

Opened

Negative 
pressure leaks.

Closed

Negative 
pressure is 
maintained.

Idling (after 
warm-up)

Negative 
pressure leaks.

NOTE: If this check indicates an abnormal condi-
tion; the turbocharger waste gate actuator, turbo-
charger waste gate solenoid or hose is broken.

Main

Index

Group

TOC