Mitsubishi Car 1999-05

Removal & Installation

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Fig. Remove the thermostat housing retaining bolts



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Fig. Carefully lift the housing from the engine



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Fig. Remove the thermostat from the thermostat housing, noting the location of the relief valve



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Fig. If reusing the thermostat, always replace the O-ring

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove any necessary components to access the thermostat.
  2.  
  3. Remove the thermostat housing retaining bolts.
  4.  
  5. Lift the housing from the engine.
  6.  
  7. Remove the thermostat taking note of its original position in the housing.
  8.  

To install:


NOTE
In order to prevent leakage, make sure both mating surfaces are clean and free of any old gasket material.

  1. Install the thermostat so its flange seats tightly in the machined groove in the intake manifold or thermostat case. Refer to its location prior to removal. Align the relief valve with the alignment mark on the thermostat housing.
  2.  
  3. Use a new gasket or O-ring and reinstall the thermostat housing. Torque the housing mounting bolts to the following specifications:
  4.  


    1.8L engine: 16 ft. lbs. (22 Nm)
     
    1.5L, 1.6L, 2.0L DOHC, and 1990-92 2.0L SOHC engines: 12-14 ft. lbs. (17-20 Nm)
     
    1993 2.0L SOHC engine: 7-10 ft. lbs. (10-15 Nm)
     
    2.4L engine: 10 ft. lbs. (14 Nm)
     
    3.0L and 3.5L engines: 12-14 ft. lbs. (17-20 Nm)
     

  5. Fill the system with coolant.
  6.  
  7. Install the removed air intake plumbing.
  8.  
  9. Connect the negative battery cable, run the vehicle until the thermostat opens and fill the radiator completely.
  10.  
  11. Once the vehicle has cooled, recheck the coolant level.
  12.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. For the 2.0L turbo engine, disconnect the air hose.
  6.  
  7. Matchmark the position of the upper or lower radiator hose for installation purposes.

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    Fig. Before disconnecting the radiator hose, matchmark for installation purposes-1999 vehicles

  8.  
  9. For the 2.0L non-turbo engine, disconnect the radiator upper hose connection.

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    Fig. Use a pair of pliers to unfasten the upper hose retaining clamp, then disconnect the hose

  10.  
  11. For the 2.0L turbo and 2.4L engines disconnect the radiator lower hose connector.
  12.  
  13. Unfasten the retaining bolt(s), then remove the water outlet or inlet fitting, as applicable.

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    Fig. Unfasten the thermostat housing retaining bolts

  14.  
  15. If equipped, remove gasket, then remove the thermostat from the vehicle.

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    Fig. Pull the fitting away, then remove the thermostat from the vehicle



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    Fig. Exploded view of the thermostat and related components-1999 vehicles

  16.  
  17. Thoroughly clean the gasket mating surfaces.
  18.  

To install:

  1. Install the thermostat so that the jiggle valve is facing straight up and is aligned with the mark on the thermostat case as shown in the accompanying figure.
    NOTE
    Make sure that no oil sticks to the rubber ring of the thermostat. Also, make sure not to fold or scratch the ring when inserting the thermostat.



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    Fig. Position the thermostat in the housing



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    Fig. The thermostat must be installed in the proper position

  2.  
  3. Position the water inlet or outlet fitting, then secure using the retaining bolt(s). For 2.0L non-turbo engines, tighten the bolt to 16 ft. lbs. (22 Nm). Tighten the bolts to 9.4 ft. lbs. (13 Nm) for 2.0L turbo and 2.4L engines.
  4.  
  5. Insert the radiator upper or lower hose as far as the projection of the water outlet or inlet fitting.
  6.  
  7. Align the mating marks on the radiator hose and hose clamp, then connect the radiator hose.

    Click image to see an enlarged view

    Fig. Insert the hose until it reaches the raised projection and align the mating marks

  8.  
  9. For the 2.0L turbo engine, connect the air hose.
  10.  
  11. Fill the cooling system with the proper type and amount of coolant.
  12.  
  13. Connect the negative battery cable, then start the engine and check for leaks. Check the coolant level, and add if necessary.
  14.  

  1. Drain the cooling system.
  2.  
  3. Remove the air intake system.
  4.  
  5. Disconnect the lower radiator hose. Matchmark the hose clamps before removing to ensure proper installation.
  6.  
  7. Unbolt the thermostat housing and remove the thermostat.
  8.  

To install:

  1. Install the thermostat so that the jiggle valve is facing straight up and is aligned with the mark on the thermostat case as shown in the accompanying figure.
    NOTE
    Make sure that no oil sticks to the rubber ring of the thermostat. Also, make sure not to fold or scratch the ring when inserting the thermostat.

  2.  
  3. Position the water inlet or outlet fitting, then secure using the retaining bolt(s). For 2.4L engines, tighten the bolt to 109 inch lbs. (13 Nm). Tighten the bolts to 13 ft. lbs. (19 Nm) for 3.0L engines.
  4.  
  5. Insert the radiator upper or lower hose as far as the projection of the water outlet or inlet fitting.
  6.  
  7. Align the mating marks on the radiator hose and hose clamp, then connect the radiator hose.
  8.  
  9. Install the air intake system.
  10.  
  11. Refill the cooling system to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  



Click image to see an enlarged view

Fig. Remove the thermostat housing retaining bolts



Click image to see an enlarged view

Fig. Carefully lift the housing from the engine



Click image to see an enlarged view

Fig. Remove the thermostat from the thermostat housing, noting the location of the relief valve



Click image to see an enlarged view

Fig. If reusing the thermostat, always replace the O-ring

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  4.  
  5. Remove any necessary components to access the thermostat.
  6.  
  7. Remove the thermostat housing retaining bolts.
  8.  
  9. Lift the housing from the engine.
  10.  
  11. Remove the thermostat taking note of its original position in the housing.
  12.  

To install:

Click image to see an enlarged view

Fig. Thermostat installation positing-3000GT Models



Click image to see an enlarged view

Fig. Exploded view of the thermostat components-3.8L Galant


NOTE
In order to prevent leakage, make sure both mating surfaces are clean and free of any old gasket material.

  1. Install the thermostat so its flange seats tightly in the machined groove in the intake manifold or thermostat case. Refer to its location prior to removal. Align the relief valve with the alignment mark on the thermostat housing.
  2.  
  3. Use a new gasket or O-ring and reinstall the thermostat housing. Torque the housing mounting bolts to the following specifications:

    1.8L engine: 16 ft. lbs. (22 Nm)
     
    1.5L and 2.0L DOHC: 12-14 ft. lbs. (17-20 Nm)
     
    2.4L engine: 10 ft. lbs. (14 Nm)
     
    3.0L and 3.5L engines: 12-14 ft. lbs. (17-20 Nm)
     
    3.8L engines: 14 ft. lbs. (19 Nm)
     

  4.  
  5. Fill the system with coolant.
  6.  
  7. Install the removed air intake plumbing.
  8.  
  9. Connect the negative battery cable, run the vehicle until the thermostat opens and fill the radiator completely.
  10.  
  11. Once the vehicle has cooled, recheck the coolant level.
  12.  

 
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