Group 80 MITSUBISHI LANCER 2005 User Guide

TROUBLESHOOTING
ENGINE COOLING14-13
STEP 18. Check the cooling fan motor drive
control unit connector A-18.
Q: Is the connector in good condition?
YES :
Go to Step 19 .
NO : Repair or replace the connector. Then go to
Step 24 .
STEP 19. Check the harness wire between
cooling fan motor drive control unit connector
A-18 terminal 1 and body earth.
Q: Is the harness wire in good condition?
YES :
An intermittent malfunction is suspected
(Refer to GROUP 00 - How to use
troubleshooting P.00-5).
NO : Repair the damaged harness wire. Then go
to Step 24 .
STEP 20. Check the cooling fan motor drive
control unit connector A-18, intermediate
connector A-13 <L.H. drive vehicles> or C-111
<R.H. drive vehicles> and engine-ECU connector
C-123 <M/T> or engine-A/T-ECU connector C-122
<A/T>.
AC100293
A-18
321
Connector: A-18
AD
AC100293
A-18
321
Connector: A-18
AD
AC100293
A-18
321
Connector: A-18
AD
AC303526
Connector: A-13 <L.H. drive vehicles>
AB
A-13
A-13
AC303527
Connector: C-111 <R.H. drive vehicles>
AB
C-111
C-111
615
121179
810234

TROUBLESHOOTING
ENGINE COOLING14-15
STEP 22. Check the cooling fan motor drive
control unit.
(1) Disconnect engine-ECU connector C-123 <M/T>
or engine-A/T-ECU connector C-122 <A/T>.
(2) Pull out connector terminal pin 21 <M/T> or 18
<A/T> to disconnect connector.
(3) Reconnect the connector with connector terminal
pin still removed.
(4) Turn the ignition switch to the "ON" position.(5) Check for the cooling fan operation.
•The cooling fan rotates. (with connector
terminal pin 21 <M/T> or 18 <A/T>
disconnected)
•The cooling fan stops. (When connector
terminal pin 21 <M/T> or 18 <A/T> is
connected to the body earth.)
(6) Turn the ignition switch to the "OFF" position.
(7) Disconnect engine-ECU connector C-123 <M/T>
or engine-A/T-ECU connector C-122 <A/T>, and
push in connector terminal pin 21 <M/T> or 18
<A/T> to disconnect connector.
(8) Reconnect the connector with connector terminal
pin still installed.
Q: Does the cooling fan rotate? And when the
connector terminal pin is connected to the body
earth, does the cooling fan stop?
YES :
Go to Step 23 .
NO : Replace the cooling fan motor drive control
unit (Refer to P.14-35). Then go to Step 24 .
STEP 23. MUT-II/III self-diag code
Check if an MPI system self-diag code is set. (Refer
to GROUP 13A - Trouble shooting P.13A-9) <4G1>
or (Refer to GROUP 13B - Trouble shooting
P.13B-9) <4G6>.
Q: Diagnosis code set?
YES :
Inspection chart for diagnosis code (Refer
to GROUP 13A - Trouble shooting
P.13A-15) <4G1> or Inspection chart for
diagnosis code (Refer to GROUP 13B -
Trouble shooting P.13B-15) <4G6>.
NO : Replace the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (Refer to GROUP
13A P.13A-401). Then go to Step 24 .
STEP 24. Check the symptoms.
Q: Does the cooling fan motor (L.H.) and the cooling
fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C
condenser fan motor <4G6> operate correctly?
YES :
This symptoms is complete.
NO : Return to Step 1 .
AC303555AB
Connector: C-123 <M/T>, C-122 <A/T>
C-123 <M/T>
or
C-122 <A/T>
C-123 <M/T>
Engine-ECU <M/T> or
engine-A/T-ECU <A/T>
C-122 <A/T>
AC303559
C-122 connector <A/T>
(Harness side connector: ECU side view)
AB
C-123 connector <M/T>
(Harness side connector: ECU side view)

TROUBLESHOOTING
ENGINE COOLING14-19
STEP 6. Check the cooling fan motor drive
control unit.
(1) Disconnect engine-ECU connector C-123 <M/T>
or engine-A/T-ECU connector C-122 <A/T>.
(2) Pull out connector terminal pin 21 <M/T> or 18
<A/T> to disconnect connector.
(3) Reconnect the connector with connector terminal
pin still removed.
(4) Turn the ignition switch to the "ON" position.(5) Check for the cooling fan operation.
•The cooling fan rotates. (with connector
terminal pin 21 <M/T> or 18 <A/T>
disconnected)
•The cooling fan stops. (When connector
terminal pin 21 <M/T> or 18 <A/T> is
connected to the body earth.)
(6) Turn the ignition switch to the "OFF" position.
(7) Disconnect engine-ECU connector C-123 <M/T>
or engine-A/T-ECU connector C-122 <A/T>, and
push in connector terminal pin 21 <M/T> or 18
<A/T> to disconnect connector.
(8) Reconnect the connector with connector terminal
pin still installed.
Q: Does the cooling fan rotate? And when the
connector terminal pin is connected to the body
earth, does the cooling fan stop?
YES :
Go to Step 7 .
NO : Replace the cooling fan motor drive control
unit (Refer to P.14-35). Then go to Step 8 .
STEP 7. MUT-II/III self-diag code
Check if an MPI system self-diag code is set. (Refer
to GROUP 13A - Trouble shooting P.13A-9) <4G1>
or (Refer to GROUP 13B - Trouble shooting
P.13B-9) <4G6>.
Q: Diagnosis code set?
YES :
Inspection chart for diagnosis code (Refer
to GROUP 13A - Trouble shooting
P.13A-15) <4G1> or Inspection chart for
diagnosis code (Refer to GROUP 13B -
Trouble shooting P.13B-15) <4G6>.
NO : Replace the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (Refer to GROUP
13A P.13A-401). Then go to Step 8 .
STEP 8. Check the symptoms.
Q: Does the cooling fan motor (L.H.) and the cooling
fan motor (R.H.) <4G1 (Vehicles with A/C)> or A/C
condenser fan motor <4G6> operate correctly?
YES :
This symptoms is complete.
NO : Return to Step 1 .
AC303555AB
Connector: C-123 <M/T>, C-122 <A/T>
C-123 <M/T>
or
C-122 <A/T>
C-123 <M/T>
Engine-ECU <M/T> or
engine-A/T-ECU <A/T>
C-122 <A/T>
AC303559
C-122 connector <A/T>
(Harness side connector: ECU side view)
AB
C-123 connector <M/T>
(Harness side connector: ECU side view)

TROUBLESHOOTING
ENGINE COOLING14-21
INSPECTION PROCEDURE 4: Cooling Fan (R.H.) <4G1> or A/C Condenser Fan <4G6> does not
Operate {When Cooling Fan (L.H.) Operate} <Vehicles with A/C>
COOLING FAN (L.H.) AND COOLING FAN
(R.H.) OR A/C CONDENSER FAN DRIVE
CIRCUIT
Refer to P.14-6.
CIRCUIT OPERATION
Refer to P.14-6.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the cooling fan
motor (R.H.) <4G1> or A/C condenser fan motor
<4G6> or cooling fan motor drive control unit.
TROUBLESHOOTING HINTS
•Malfunction of cooling fan motor (R.H.) <4G1> or
A/C condenser fan motor <4G6>
•Malfunction of cooling fan motor drive control unit
DIAGNOSIS
STEP 1. Check the cooling fan motor (R.H.)
<4G1> or A/C condenser fan motor <4G6>.
Cooling fan motor (R.H.) check. (Refer to P.14-25)
<4G1>.
A/C condenser fan motor check. (Refer to GROUP
55 P.55-97) <4G6>.
Q: Is the cooling fan motor (R.H.) <4G1> or A/C
condenser fan motor <4G6> in good condition?
YES :
Go to Step 2 .
NO : Replace the cooling fan motor (R.H.) (Refer
to P.14-35) <4G1> or A/C condenser fan
motor (Refer to GROUP 55 P.55-96)
<4G6>. Then go to Step 3 .
STEP 2. Check the cooling fan motor drive
control unit.
Refer to P.14-23.
Q: Is the cooling fan motor drive control unit in good
condition?
YES :
Go to Step 3 .
NO : Replace the cooling fan motor drive control
unit (Refer to P.14-35). Then go to Step 3 .
STEP 3. Check the symptoms.
Q: Do the cooling fan (R.H.) <4G1> or A/C condenser
fan <4G6> operate (when the cooling fan (L.H.)
operate)?
YES :
This symptoms is complete.
NO : Return to Step 1 .

THERMOSTAT
ENGINE COOLING14-26
THERMOSTAT
REMOVAL AND INSTALLATIONM1141002400442
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Refilling (Refer to P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Battery Removal and Installation
AC203409AC
4
3 6 7
22 ± 4 N·m
<4G1>
AC301429
1
2
36 7
13 ± 2 N·m
AD
5
<4G6>

WAT ER P U M P
ENGINE COOLING14-29
WAT E R P U M P
REMOVAL AND INSTALLATION <4G1>M1141002700421
INSTALLATION SERVICE POINT
>>A<< WATER PUMP ASSEMBLY
INSTALLATION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
mounting surface.2. Apply a bead of the specified sealant.
Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent
3. With the sealant still wet (within 15 minutes after
the sealant is applied), install the water pump
assembly. Do not apply the sealant in an area
more than the required.
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Refilling (Refer to P.14-22).
•Valve Timing Belt Removal and Installation (Refer to
GROUP 11A P.11A-33).
AC303372
24 ± 3 N·m 23 ± 2 N·m
14 ± 1 N·m
1
2
Bolt specifications
Screw diameter × length mm 8 × 50
8 × 308 × 25
AB
2
2
Sealant: Mitsubishi Genuine Part
No. MD970389 or equivalent
Removal steps
1. Alternator adjusting brace
>>A<<2. Water pump assembly

WAT E R P U M P
ENGINE COOLING14-30
REMOVAL AND INSTALLATION <4G6>M1141002700432
INSTALLATION SERVICE POINT
>>A<< COOLING WATER LINE O-RING
INSTALLATIONFit the cooling water line O-ring to the groove in the
water pump inlet pipe. Then lubricate the cooling
water line O-ring and the inside of the water pump
assembly with water, and then insert the water pump
inlet pipe to the water pump assembly.
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Refilling (Refer to P.14-22).
•Valve Timing Belt and Balancer Timing Belt Removal and
Installation (Refer to GROUP 11C P.11C-35).
AC301467
22 ± 4 N·m
23 ± 3 N·m
14 ± 1 N·m
12
3 4
N
N
Bolt specifications
Screw diameter × length mm
8 × 708 × 22
8 × 14
8 × 22 8 × 25
2
AB
Removal steps
1. Alternator adjusting brace
2. Water pump assembly3. Water pump gasket
>>A<<4. Cooling water line O-ringRemoval steps (Continued)
AC103005
Water pump assembly
Cooling water
line O-ring
Water pump inlet pipe
AF

WATER HOSE AND WATER PIPE
ENGINE COOLING14-31
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATION <4G1>M1141003300415
Pre-removal and Post-installation Operation
•Under Cover Removal and Installation
•Engine Coolant Draining and Supplying (Refer to
P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-26).
AC203411
1 234
5 67
8
10 9
13 ± 2 N·m 23 ± 4 N·m
13 ± 2 N·m
N
N
AC
111213
N
Removal steps
1. Water temperature sensor unit
connector
2. Water temperature gauge unit
connector
3. Control wiring harness and harness
bracket
<<A>> >>B<<4. Radiator upper hose connection
5. Throttle body water feed hose
6. Thermostat case assembly7. Thermostat case gasket
>>A<<8. Cooling water line O-ring
9. Control wiring harness clamp
10. Throttle body water return hose
11. Heater water hose connection
12. Water pump inlet pipe
>>A<<13. Cooling water line O-ringRemoval steps (Continued)

WATER HOSE AND WATER PIPE
ENGINE COOLING14-33
REMOVAL AND INSTALLATION <4G6>M1141003300426
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to
P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-26).
AC303471
1 23 4
56
7 8 9
9
13 ± 2 N·m
23 ± 4 N·m 13 ± 2 N·m
N
N
AB
2
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalentØ3 mm
Ø3 mm
5
Removal steps
<<A>> >>C<<1. Radiator upper hose connection
>>B<<2. Cooling water outlet hose fitting
3. Throttle body water return hose
4. Throttle body water feed hose
>>B<<5. Thermostat case assembly
6. Heater water hose connection7. Control wiring harness clamp
8. Water pump inlet pipe
>>A<<9. Cooling water line O-ringRemoval steps (Continued)

RADIATOR
ENGINE COOLING14-35
RADIATOR
REMOVAL AND INSTALLATIONM1141001500468
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to
P.14-22).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
AC303472
18
17 1520 12 9
14
5 2
9
3
4
1
10
6 10
AB
12 ± 2 N·m
12 ± 2 N·m<4G1 (Vehicles without A/C)>
7