group 90 MITSUBISHI LANCER 2006 Workshop Manual

00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00
GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . .00E

11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL <4G1> . . . . . . . . . . . . . . . . . . . . . . . . .11A
ENGINE OVERHAUL <4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . .11B
ENGINE MECHANICAL <4G6> . . . . . . . . . . . . . . . . . . . . . . . . .11C
ENGINE OVERHAUL <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . .11D

12-1
GROUP 12
ENGINE
LUBRIC ATION
CONTENTS
GENERAL INFORMATIO N . . . . . . . .12-2
SERVICE SPECIFICATION . . . . . . . .12-2
LUBRICANT . . . . . . . . . . . . . . . . . . . .12-2
SEALANT . . . . . . . . . . . . . . . . . . . . . .12-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .12-3
ON-VEHICLE SERVICE . . . . . . . . . . .12-4
ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-4
ENGINE OIL REPLACEMENT . . . . . . . . . . 12-4
ENGINE OIL FILTER REPLACEMENT . . . . 12-4
OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-5

13-1
GROUP 13
FUEL
CONTENTS
MULTIPORT FUEL INJECTION (MPI) <4G1> . . . . . . . . . . . . . .13A
MULTIPORT FUEL INJECTION (MPI) <4G6> . . . . . . . . . . . . . .13B
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13C

14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . .14-2
SERVICE SPECIFICATIONS . . . . . . .14-2
LUBRICANT . . . . . . . . . . . . . . . . . . . .14-3
SEALANTS . . . . . . . . . . . . . . . . . . . .14-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .14-3
TROUBLESHOOTING . . . . . . . . . . . .14-5
INSPECTION CHART FOR TROUBLE
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 14-5
INSPECTION PROCEDURE FOR
TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 14-6
ON-VEHICLE SERVICE . . . . . . . . . . .14-21
ENGINE COOLANT LEAK CHECK . . . . . . 14-21
RADIATOR CAP VALVE OPENING
PRESSURE CHECK . . . . . . . . . . . . . . . . . . 14-21
ENGINE COOLANT REPLACEMENT . . . . 14-21
CONCENTRATION MEASUREMENT . . . . 14-22
COOLING FAN MOTOR DRIVE
CONTROL UNIT CHECK . . . . . . . . . . . . . . 14-22
FAN CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
COOLING FAN MOTOR CHECK . . . . . . . . 14-24
THERMOSTAT . . . . . . . . . . . . . . . . . .14-24
REMOVAL AND INSTALLATION . . . . . . . . 14-24
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-26
WATER PUMP . . . . . . . . . . . . . . . . . .14-27
REMOVAL AND INSTALLATION <4G1> . . 14-27
REMOVAL AND INSTALLATION <4G6> . . 14-28
WATER HOSE AND WATER PIPE . .14-29
REMOVAL AND INSTALLATION <4G1> . . 14-29
REMOVAL AND INSTALLATION <4G6> . . 14-31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-32
RADIATOR . . . . . . . . . . . . . . . . . . . . .14-33
REMOVAL AND INSTALLATION <4G1> . . 14-33
REMOVAL AND INSTALLATION <4G6> . . 14-35

TROUBLESHOOTING
ENGINE COOLING14-9
STEP 7. Check the harness wire between fusible
link No.2 and fan control relay connector A-09X
terminal 4.
AC303509AB
Fusible link
No.2
Relay box
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
Q:Is t h e har n es s wire in good c ondition ?
YES : An intermittent malf unction is suspe c ted
(Refer to GROUP 00 - How to use
troub lesh ooting
P.00-5).
NO : Repa ir the dama ged harness wire. Then go
to S
t ep 2 4
.
STEP 8. Ch eck the fan con trol re lay .
Refe r to P.14-23.
Q:Is t h e fa n cont rol relay in go od con d it ion?
YES : Go to S t ep 9 .
NO : Replac e th e fan contro l relay . Then go to
S
t ep 24
.
ST EP 9 . Check the fan con trol re lay co nnector
A-0
9 X.
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
Q:Is t h e con n ec tor in goo d c ond it io n?
YES : Go to S t ep 1 0 .
NO : Repa ir th e con nect o r or rep l ace the re lay
box. Then
go to S t ep 24
.
STEP 1 0 . Check t he harness wire b e twe en fan
control relay
connec tor A-0 9 X terminal 2 and
cooling f
an motor drive control uni t connec tor
A-1
8 terminal 3.
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
AC100293
A-18
321
Connector: A-18
AD
Q:Is t h e har n es s wire in good c ondit i on ?
YES : Go to S t ep 1 1 .
NO : Repa ir the dama ged harness wire. Then go
to S
t ep 2 4
.

AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
TROUBLESHOOTING
ENGINE COOLING14-11
Q: Are t h er e conn ect ors in go od cond it ion?
YES : Go to S t ep 13 .
NO : Repa ir or replace the conne ctor . Th en go to
S
t ep 24
.
STEP 1 3 . Check th e harness wire b e twee n J/C
No.
6 C-12 termina l 33 <L .H. dri ve veh icles> o r
C-1
34 termina l 33 <R.H. drive vehicl es> and fan
control relay
connect or A-09 X terminal 1 .
AC303524
Connector: C-12 <L.H. drive vehicles>
AB
C-12
C-12
AC303525
Connector: C-134 <R.H. drive vehicles>
AB
C-134
C-134
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
Q:Are t h es e har n es s wires in go od cond it ion?
YES : An intermittent malf unction is suspe c ted
(Refer to GROUP 00 - How to use
troub leshooting
P.00-5).
NO : Repa ir the dama ged harness wire. Then go
to S
t ep 2 4
.
STEP 1 4 . Check t he contin uity between fan
control relay
connec tor A-0 9 X and bod y earth.
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
(1)D isconn ect f an control relay co nnector A-09X
(remove the fan control relay) and measure re lay
box side connector .
AC303533AB
A-09X Connector
(Relay box side)
(2) M ea sure th e resi st anc e b e t w e e n f an con t rol re lay
connector A-09X te rmin al 3 and bo dy e a rth.
•Continu i ty exist s .
(3)C onne ct fa n con t rol re lay con necto r A-09X
(inst a ll the fan control relay).
Q:Doe s the cont inuity e x ist s ?
YES : An intermittent malf unction is suspe c ted
(Refer to GROUP 00 - How to use
troub leshooting
P.00-5).
NO : Go to S t ep 15 .

TROUBLESHOOTING
ENGINE COOLING14-12
STEP 15. Check the fan control relay connector
A-09X.
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
Q:Is t h e con n ec tor in goo d c ondit i o n ?
YES : Go to S t ep 16 .
NO : Repa ir the con nect o r or rep l ace the re lay
box. Then
go to S t ep 24
.
STEP 16 . Check th e harness wire b e twee n fan
control relay
connect or A-09 X terminal 3 and
body ea
rth.
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
Q:Is t h e har n es s wire in good c ondition ?
YES : An intermittent malf unction is suspe c ted
(Refer to GROUP 00 - How to use
troub lesh ooting
P.00-5).
NO : Repa ir the dama ged harness wire. Then go
to S
t ep 2 4
.
STEP 1 7 . Check t he contin uity between cooling
fan motor drive
control un it connec tor A-1 8 and
body ea
rth.
AC100293
A-18
321
Connector: A-18
AD
(1)D isconn ect cooling f an motor drive contro l unit
conne ctor A-18 a nd measure wirin g har ness side
connector .
AC303534AB
A-18 Connector
(Wiring harness side)
(2)M easu r e the re sist ance between cooling fan
mot o r d r ive cont rol unit conn ecto r A-1 8 te rmina l 1
and body earth .
•Continu i ty exist s .
(3)C onne ct cooling fa n mot o r drive control unit
connector A-18.
Q:Dos e the cont inuity e x ist s ?
YES : Go to S t ep 2 0 .
NO : Go to S t ep 18 .

TROUBLESHOOTING
ENGINE COOLING14-13
STEP 18. Check the cooling fan motor drive
control unit connector A-18.
AC100293
A-18
321
Connector: A-18
AD
Q:Is t h e con n ec tor in goo d c ondit i o n ?
YES : Go to S t ep 19 .
NO : Repa ir or replace the conne ctor . Th en go to
S
t ep 24
.
STEP 1 9 . Check th e harness wire b e twee n
cooling fa
n motor drive control uni t connec tor
A-1
8 terminal 1 and b ody earth.
AC100293
A-18
321
Connector: A-18
AD
Q:Is t h e har n es s wire in good c ondition ?
YES : An intermittent malf unction is suspe c ted
(Refer to GROUP 00 - How to use
troub lesh ooting
P.00-5).
NO : Repa ir the dama ged harness wire. Then go
to S
t ep 2 4
.
STEP 2 0 . Check t he cooli ng fan m o tor drive
control unit
connecto r A-18 , intermed iate
connecto
r A-13 <L.H. drive v ehicle s > or C-1 1 1
<R.
H . dri ve ve hicles> and en gine-ECU conne ctor
C-1
23 <M/T> or engin e -A/T -ECU connec tor C-122
<A/
T >.
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.
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>
(1) D isconn ect e ngin e -ECU conne ctor C-12 3 <M/T >
or e ngine -A/T -ECU conne ctor C-12 2 <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)
(2)P ull out conne ctor t e rminal p i n 21 <M/T> or 18
<A/T> to discon nect conn ector .
(3)R eco nnect t he con necto r with conn ector ter m in al
pin still removed.
(4)T urn t he ig nition switch to the "ON" positio n.
(5)C heck fo r the cooling fan opera t ion.
•The cooling fan ro t a t e s. (with conne ctor termi-
nal pi n 21 <M/T> or 18 <A/T > disconn ecte d)
•The cooling fan stop s. (When con necto r ter-
minal pi n 21 <M/ T > o r 1 8 <A/ T > is conn ected
to the
body earth.)
(6)T urn t he ig nition switch t o the "OFF" po sit i on.
(7)D isconn ect e ngin e -ECU conne ctor C-12 3 <M/ T >
or e ngine -A/T -ECU conne ctor C-12 2 <A/T>, a nd
push in con nect o r terminal pin 21 <M/T> or 18
<A/T> to discon nect conn ector .
(8)R econnect the con necto r with conn ector te rmin al
pin still inst alled.
Q:Doe s the cooling fa n rot a te ? And wh en th e
c onne ct or te rmin a l p i n is co nnec t e d to t h e bod y
e a rt h, d o es t h e co olin g f a n s t op ?
YES : Go to S t ep 2 3 .
NO : Replac e th e coo lin g fan motor d r ive con t rol
unit (Refer to
P.14-33) <4G1> (Refer to
P.14-35) <4G6>. Then go to S t e p 24 .
STEP 2 3 . M.U.T . -II/III self-dia g code
Check if an MPI system self- d iag code is set. (Ref er
to GROUP
13A - T r ouble shooting
P.13A-9) <4G1>
or (Refer to GROUP 13 B - T r ouble sho o ting
P.13B-9) <4G6>.
Q:Diagn o sis co de se t?
YES : Inspecti on chart fo r dia gnosis code (Re f er
to GROUP 13A - T r ou ble shoot ing
P.13A-15) <4G1 > or Inspection chart for
diagnosis code (Re f er to GROUP 13B -
T
r ouble sh ootin g
P.13B-15) <4G6>.
NO : Replac e th e engine-ECU <M/T> or
engine-A/T
- ECU <A/T> (Refer to GROUP
13A
P.13A- 384). Then go t o S t ep 24 .
STEP 2 4 . Check t he sym ptoms.
Q:Doe s the cooling fa n moto r ( L .H.) and t h e coo l ing
fa n mo to r ( R .H. ) <4G 1 (V ehicles with A/ C)> or A/C
c onde nse r fa n mo tor <4G6> o p era t e c o rre ct ly ?
YES : This symptoms is comple te.
NO : Return to S t ep 1 .