Mitsubishi Lancer Evolution IX 2006 Gebrauchsanweisung

14-1

GROUP 14

ENGINE COOLING

CONTENTS

GENERAL INFORMATION . . . . . . . . 14-2

SERVICE SPECIFICATIONS. . . . . . . 14-2

LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2

SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-2

SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-3

TROUBLESHOOTING . . . . . . . . . . . . 14-3

ON-VEHICLE SERVICE. . . . . . . . . . . 14-15

ENGINE COOLANT LEAK CHECK . . . . . . 14-15

RADIATOR CAP PRESSURE CHECK. . . . 14-15

ENGINE COOLANT REPLACEMENT . . . . 14-15

CONCENTRATION MEASUREMENT . . . . 14-16

FAN CONTROLLER CHECK . . . . . . . . . . . 14-16

FAN CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17

COOLING FAN MOTOR CHECK . . . . . . . . 14-17

THERMOSTAT . . . . . . . . . . . . . . . . . . 14-18

REMOVAL AND INSTALLATION . . . . . . . . 14-18

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-19

WATER PUMP . . . . . . . . . . . . . . . . . . 14-20

REMOVAL AND INSTALLATION . . . . . . . . 14-20

WATER HOSE AND WATER PIPE . . 14-22

REMOVAL AND INSTALLATION . . . . . . . . 14-22

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-23

RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-24

REMOVAL AND INSTALLATION . . . . . . . . 14-24

GENERAL INFORMATION

ENGINE COOLING

14-2

GENERAL INFORMATION

M1141000100456

The cooling system is designed to keep every part of

the engine at appropriate temperature in whatever

condition the engine may be operated. The cooling

method is of the water-cooled, pressure forced circu-

lation type in which the water pump pressurizes cool-

ant and circulates it throughout the engine. If the

engine coolant temperature exceeds the prescribed

temperature, the thermostat opens to circulate the

coolant through the radiator as well so that the heat

absorbed by the coolant may be radiated into the air.

The water pump is of the centrifugal type and is

driven by the drive belt from the crankshaft. The radi-

ator is the corrugated fin, down flow type. The cool-

ing fan is controlled by the fan controller and

engine-ECU depend on driving conditions.

Item Specification

Radiator Performance kJ/h 216,700

SERVICE SPECIFICATIONS

M1141000300483

Item Standard value Limit

Radiator cap pressure kPa 93 −123 Minimum 83

Range of coolant antifreeze concentration of radiator % 30 −60 -

Fan controller input voltage V Ignition switch: "ON" Battery positive voltage -

Fan controller output voltage V A/C switch: "OFF" 1 or less -

A/C switch: "ON" Repeat steps 1) and 2).

1) 8.2 ±2.6

2) Battery positive voltage

±2.6

Thermostat Valve opening temperature of thermostat °C80 ±1.5 -

Full-opening temperature of thermostat °C 93 -

Valve lift mm 9.5 or more -

LUBRICANT

M1141000400424

Item Specified lubricant Quantity L

Engine coolant (including

reserve tank)

DIA QUEEN SUPER LONG LIFE COOLANT or equivalent 6.0

SEALANT

M1141000500658

Item Specified sealant Remark

Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent Drying sealant

SPECIAL TOOLS

ENGINE COOLING 14-3

SPECIAL TOOLS

M1141000600592

Tool Number Name Use

MB991223

DO NOT USE

MB991223

A: MB991219

B: MB991220

C: MB991221

D: MB991222

Harness set

A: Check harness

B: LED harness

C: LED harness

adapter

D: Probe

Making voltage and

resistance measurement

during troubleshooting

A: Connector pin contact

pressure inspection

B: Power circuit inspection

C: Power circuit inspection

D: Commercial tester

connection

MB992006

MB992006 Extra fine probe Making voltage and

resistance measurement

during troubleshooting

MB991871

MB991871 LLC changer Coolant refilling

TROUBLESHOOTING

INSPECTION CHART FOR TROUBLE

SYMPTOMS

M1141005600434

Trouble symptom Inspection

procedure No.

Reference page

Cooling fan does not operate 1P.14-4

Cooling fan does not change speed or does not stop 2P.14-10

TROUBLESHOOTING

ENGINE COOLING

14-4

INSPECTION PROCEDURE FOR

TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1: Cooling fan does not operate

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

INPUT SIGNAL

· A/C SWITCH

· ENGINE

COOLANT

TEMPERATURE

SENSOR

· VEHICLE SPEED

SENSOR

ENGINE-

ECU

ENGINE

CONTROL

RELAY

SMOOTHING

CIRCUIT

FIELD EFFECT

TRANSISTOR

CIRCUIT

INPUT SIGNAL

PROCESSING

DRIVE

CIRCUIT

TEMPERATURE

DETECTION

CURRENT

DETECTION

RADIATOR

FAN

MOTOR

FAN CONTROLLER

ENGINE

CONTROL

SYSTEM

FUSIBLE

LINK 2

FAN

CONTROL

RELAY

AC505138

Cooling fan drive circuit <L.H. drive vehicles>

Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

INPUT SIGNAL

· A/C SWITCH

· ENGINE

COOLANT

TEMPERATURE

SENSOR

· VEHICLE SPEED

SENSOR

ENGINE-

ECU

ENGINE

CONTROL

RELAY

SMOOTHING

CIRCUIT

FIELD EFFECT

TRANSISTOR

CIRCUIT

INPUT SIGNAL

PROCESSING

DRIVE

CIRCUIT

TEMPERATURE

DETECTION

CURRENT

DETECTION

RADIATOR

FAN

MOTOR

FAN CONTROLLER

ENGINE

CONTROL

SYSTEM

FUSIBLE

LINK 2

FAN

CONTROL

RELAY

AC505139

Cooling fan drive circuit <R.H. drive vehicles>

TROUBLESHOOTING

ENGINE COOLING 14-5

CIRCUIT OPERATION

•The fan controller is powered from fusible link

No.2.

•The engine-ECU judges the required revolution

speed of cooling fan motor using the input signals

transmitted from A/C switch, vehicle speed sen-

sor and engine coolant temperature sensor. The

engine-ECU activates the fan controller to drive

the cooling fan motor.

TROUBLESHOOTING

ENGINE COOLING

14-6

TECHNICAL DESCRIPTION

•The cause could be a malfunction of the fan con-

troller power supply or earth circuit.

•The cause could also be a malfunction of the fan

controller or the engine-ECU.

TROUBLESHOOTING HINTS

•Malfunction of fusible link

•Malfunction of fan control relay

•Malfunction of cooling fan motor

•Malfunction of fan controller

•Malfunction of engine-ECU

•Damaged wiring harness or connector

DIAGNOSIS

STEP 1. Check the circuit at fan controller

connector A-17 terminal 3.

AC210859

Connector: A-17

A-17 (GR)

Fan controller

Component side

(1) Disconnect fan controller connector A-17, and

measure at the harness side connector.

(2) Measure the voltage between terminal No.3 and

earth.

•When the ignition switch is turned to the "ON"

position, voltage should measure battery pos-

itive voltage.

Q: Is the voltage battery positive voltage when the

ignition switch is turned to the "ON" position?

YES : Go to Step 7.

NO : Go to Step 2.

STEP 2. Check the fan control relay.

Refer to P.14-17.

Q: Is the fan control relay in good condition?

YES : Go to Step 3.

NO : Replace it, then go to Step 1.

STEP 3. Check for harness damage between

fusible link No.2 and fan control relay connector

A-09X terminal 4.

AC310900AC

Fusible link (2)

Fusible link (2) And

Connector: A-09X

A-09X

Relay box

side

Q: Are the harness wires between fusible link No.2

and fan control relay connector A-09X damaged?

YES : Repair or replace them, then go to Step 13.

NO : Go to Step 4.

STEP 4. Check for harness damage between fan

control relay connector A-09X terminal 2 and fan

controller connector A-17 terminal 3.

AC310900AB

Connector: A-09X

A-09X

Relay box

side

AC210859

Connector: A-17

A-17 (GR)

Fan controller

Component side

Q: Are the harness wires between fan control relay

connector A-09X terminal 2 and fan controller

connector A-17 terminal 3 damaged?

YES : Repair or replace them, then go to Step 13.

NO : Go to Step 5.

TROUBLESHOOTING

ENGINE COOLING 14-7

STEP 5. Check for harness damage between J/C

(6) C-105 and fan control relay connector A-09X.

NOTE:

AC210877AC

Connector: A-13 <LHD>

A-13 (B)

AC310903AB

Connector: C-31 <RHD>

C-31

AC310901AB

Connector: C-105 <LHD>

C-105

AC310902AB

Connector: C-105 <RHD>

C-105

After inspecting intermediate connector A-13 <LHD>

terminal 3, intermediate connector C-31 <RHD> ter-

minal 12 and J/C (6) C-105 terminal 28, 33 inspect

the wires. If intermediate connector A-13 <LHD>,

C-31<RHD> and J/C (6) C-105 are damaged, repair

or replace them. Refer to GROUP 00, How to Use

Troubleshooting/Inspection Service Points P.00-5.

AC310900AB

Connector: A-09X

A-09X

Relay box

side

AC310901AB

Connector: C-105 <LHD>

C-105

AC310902AB

Connector: C-105 <RHD>

C-105

Q: Are the harness wires between J/C (6) C-105

terminal 28 and fan control relay connector A-09X

terminal 1 damaged?

YES : Repair or replace them, then go to Step 13.

NO : Go to Step 6.

STEP 6. Check for harness damage between fan

control relay connector A-09X terminal 3 and

earth.

AC310900AB

Connector: A-09X

A-09X

Relay box

side

TROUBLESHOOTING

ENGINE COOLING

14-8

Q: Are the harness wires between fan control relay

connector A-09X terminal 3 and earth damaged?

YES : Repair or replace them, then go to Step 13.

NO : Go to Step 7.

STEP 7. Check the cooling fan motor.

Refer to P.14-17.

Q: Is the cooling fan motor in good condition?

YES : Go to Step 8.

NO : Replace it, then go to Step 13.

STEP 8. Check the circuit at fan controller

connector A-17 terminal 1.

AC210859

Connector: A-17

A-17 (GR)

Fan controller

Component side

(1) Disconnect fan controller connector A-17, and

measure at the harness side connector.

(2) Measure the resistance between terminal No.1

and earth.

•The resistance should measure less than 2

ohms.

Q: Is the resistance less than 2 ohms?

YES : Go to Step 10.

NO : Go to Step 9.

STEP 9. Check the harness wire between fan

controller connector A-17 and earth.

AC210859

Connector: A-17

A-17 (GR)

Fan controller

Component side

Q: Are the harness wires between fan controller

connector A-17 and earth damaged?

YES : Repair or replace them, then go to Step 13.

NO : Go to Step 10.

STEP 10. Measure the output circuit voltage at

engine-ECU connector C-121 terminal 18 by

backprobing.

AC505254

2829

1415

3031

1718

3332

19 21

JAE

Connector: C-121 <LHD>

Harness side

C-121 (GR)

Engine-ECU

AC505255

2829

1415

3031

1718

3332

19 21

JAE

Connector: C-121 <RHD>

Harness side

C-121 (GR)

Engine-ECU

(1) Do not disconnect engine-ECU connector C-121.

(2) Start the engine and allow it to idle.

(3) Turn the A/C switch to the "ON" position.

(4) Measure the voltage between terminal No.18 and

earth by backprobing.

•The voltage should measure 0.7 volt or more

when the cooling fan is operating.

Q: Is the voltage 0.7 volt or more when the cooling fan

is operating?

YES : Go to Step 12.

NO : Go to Step 11.

TROUBLESHOOTING

ENGINE COOLING 14-9

STEP 11. Check the harness wire between

engine-ECU connector C-121 and fan controller

connector A-17.

NOTE:

AC210877AC

Connector: A-13 <LHD>

A-13 (B)

AC310903AB

Connector: C-31 <RHD>

C-31

If intermediate connector A-13 <LHD> terminal 2 and

intermediate connector C-31 <RHD> terminal 14 is

damaged, repair or replace it. Refer to GROUP 00,

How to Use Troubleshooting/Inspection Service

Points P.00-5.

AC505254 AC

Connector: C-121 <LHD>

C-121 (GR)

Engine-ECU

222123

3534

161819 1720

3233 30

11 10121314

262827 25

JAE

Component side

AC505255 AC

Connector: C-121 <RHD>

C-121 (GR)

Engine-ECU

222123

3534

161819 1720

3233 30

11 10121314

262827 25

JAE

Component side

AC210859

Connector: A-17

A-17 (GR)

Fan controller

Component side

Q: Are the harness wires between engine-ECU

connector C-121 terminal 18 and fan controller

connector A-17 terminal 2 damaged?

YES : Repair or replace them, then go to Step 13.

NO : Go to Step 12.

TROUBLESHOOTING

ENGINE COOLING

14-10

STEP 12. Check the fan controller at engine-ECU

connector C-121.

AC505254

2829

1415

3031

1718

3332

19 21

JAE

Connector: C-121 <LHD>

Harness side

C-121 (GR)

Engine-ECU

AC505255

2829

1415

3031

1718

3332

19 21

JAE

Connector: C-121 <RHD>

Harness side

C-121 (GR)

Engine-ECU

(1) Do not disconnect engine-ECU connector C-121.

(2) Pull out terminal No.18.

(3) Turn the ignition switch to the "ON" position.

Q: Does the cooling fan motor operate?

YES : Replace the engine-ECU. Then go to Step

13.

NO : Replace the fan controller. Then go to Step

13.

STEP 13. Check the symptoms.

Q: Does the cooling fan operate correctly?

YES : The procedure is complete.

NO : Return to Step 1.

INSPECTION PROCEDURE 2: Cooling fan does not change speed or does not stop

NOTE: If the engine coolant temperature reaches 110

C or higher, the cooling fan control runs the cooling fan

for up to 5 minutes even after the ignition switch is turned to the "LOCK" (OFF) position (the fan stops its rota-

tion when the engine coolant temperature decreases to 110

C or lower).

COOLING FAN DRIVE CIRCUIT

Refer to P.14-4.

CIRCUIT OPERATION

•The fan controller is powered from fusible link

No.2.

•The engine-ECU judges the required revolution

speed of cooling fan motor using the input signals

transmitted from A/C switch, vehicle speed sen-

sor and engine coolant temperature sensor. The

engine-ECU activates the fan controller to drive

the cooling fan motor.

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