relay MITSUBISHI 380 2005 Workshop Manual

00E-1
GROUP 00E
GENERAL

CONTENTS
HARNESS CONNECTOR
INSPECTION . . . . . . . . . . . . . . . . . . .00E-2
HOW TO DIAGNOSE . . . . . . . . . . . . .00E-2
HOW TO DIAGNOSE . . . . . . . . . . . . . . . . . 00E-2
TROUBLESHOOTING STEPS . . . . . . . . . . 00E-3
INFORMATION FOR DIAGNOSIS . . . . . . . 00E-3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 00E-4INSPECTION INSTRUMENTS . . . . . . . . . . 00E-5
CHECKING FUSES . . . . . . . . . . . . . . . . . . . 00E-6
CHECKING SWITCHES . . . . . . . . . . . . . . . 00E-7
CHECKING RELAYS . . . . . . . . . . . . . . . . . 00E-8
CABLES AND WIRES CHECK . . . . . . . . . . 00E-9
BATTERY HANDLING . . . . . . . . . . . . . . . . 00E-9
GENERAL ELECTRICAL SYSTEM CHECK00E-9

HOW TO DIAGNOSE
GENERAL 00E-4
INSPECTIONM1001004600139
1. Sight and sound checks
Check relay operation, blower motor rotation, light
illumination, etc. Listen for a "click" when some relay covers
are pushed down.
2. Simple checks
For example, if a headlight does not come on and a faulty
fuse or poor grounding is suspected, replace the fuse with a
new one. Or use a jumper wire to ground the light to the
body. Determine which part(s) is/are responsible for the
problem.
3. Checking with instruments
Use an appropriate instrument in an adequate range and
read the indication correctly.

HOW TO DIAGNOSE
GENERAL 00E-8
CHECKING RELAYSM1001004900152
1. By using a relay, a heavy current can be turned on and off by
a switch using much less current. For example, in the circuit
shown here, when the switch is turned on (closed), current
flows to the coil of the relay. Then, its contact is turned on
(closed) and the light comes on. The current flowing through
the switch is much less than that for the light.
2. When current flows through the coil of a relay, its core is
magnetized to attract the iron piece, closing (ON) the
contact at the tip of the iron piece. When the coil current is
turned off, the iron piece returns to its original position by a
spring, opening the contact (OFF).
3. Relays may be classified as the normally open-type or the
normally closed-type, depending on their contact
construction.
NOTE: The deenergised state means that no current is flow-
ing through the coil. The energised state means that current
is flowing through the coil.
(1) The normally open-type
When a normally open relay as illustrated here is
checked, there should be no continuity between terminals
3 and 4 when the relay is deenergised. There should be
continuity between terminals 3 and 4 when battery
voltage and ground are applied to terminals 1 and 2. The
relay condition is determined by this check.
NOTE: Check the relay in both situation which is
energised and is not energised.
(2) The normally closed-type
When a normally closed relay as illustrated here is
checked, there should be continuity between terminals 3
and 4 when the relay is deenergised. There should be no
continuity between terminals 3 and 4 when battery
voltage and ground are applied to terminals 1 and 2. The
relay condition is determined by this check.
NOTE: Check the relay in both situation which is
energised and is not energised.

HOW TO DIAGNOSE
GENERAL 00E-9
CABLES AND WIRES CHECKM1001005100041
1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks, and
wear.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with
sharp edges and corners or hot parts (exhaust manifold,
pipe, etc.).
9. Check that harnesses are secured firmly to provide enough
clearance from the fan pulley, fan belt, and other rotating or
moving parts.
10.Check that the harnesses between fixed parts (such as the
vehicle body) and vibrating parts (such as the engine) are
long enough to allow for vibration and movement.
BATTERY HANDLINGM1001005200048
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When checking or servicing does not require power from the
vehicle battery, be sure to disconnect the cable from the battery
(
) terminal. This will prevent problems that could be caused by
a short circuit. Disconnect the (
) battery terminal first and
reconnect it last.
GENERAL ELECTRICAL SYSTEM CHECKM1001005300045
A circuit consists of the power supply, switch, relay, load,
ground, etc. There are various methods to check a circuit
including an overall check, voltage check, short-circuit check,
and continuity check. Each of the methods briefly described
below applies only to circuits similar to the illustration.

14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .14-2
SPECIAL TOOL . . . . . . . . . . . . . . . . .14-2
ENGINE COOLING DIAGNOSIS . . . .14-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 14-2
TROUBLESHOOTING STRATEGY . . . . . . 14-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 14-3
SYMPTOM PROCEDURES . . . . . . . . . . . . 14-3
ON-VEHICLE SERVICE . . . . . . . . . . .14-26
ENGINE COOLANT LEAK CHECK . . . . . . 14-26
RADIATOR CAP PRESSURE CHECK . . . . 14-27
ENGINE COOLANT REPLACEMENT . . . . 14-27
ENGINE COOLANT CONCENTRATION TEST14-29
FAN CONTROLLER CHECK . . . . . . . . . . . 14-29
FAN CONTROL RELAY CONTINUITY CHECK14-31
RADIATOR . . . . . . . . . . . . . . . . . . . . .14-32
REMOVAL AND INSTALLATION . . . . . . . . 14-32
THERMOSTAT . . . . . . . . . . . . . . . . . .14-35
REMOVAL AND INSTALLATION . . . . . . . . 14-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-38
WATER PUMP . . . . . . . . . . . . . . . . . .14-39
REMOVAL AND INSTALLATION . . . . . . . . 14-39
WATER HOSE AND WATER PIPE . .14-40
REMOVAL AND INSTALLATION . . . . . . . . 14-40
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-41
SPECIFICATIONS . . . . . . . . . . . . . . .14-42
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 14-42
SERVICE SPECIFICATION . . . . . . . . . . . . 14-43
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 14-43
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 14-43

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-5
INSPECTION PROCEDURE 3: Radiator Fan and Condenser Fan do not Operate
.
CIRCUIT OPERATION
The fan controller is powered from fusible link
No.2.
The engine-ECU uses input signals from the A/C
switch, the water temperature sensor unit and the
vehicle speed sensor or the output shaft
speed sensor to control the speed of the
radiator fan motor and the condenser fan motor.
The engine-ECU controls the fan controller to
activate the radiator fan motor and the condenser
fan motor.
.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the fan con-
troller power supply or earth circuit.
If the communication line wiring harness between
the fan controller and the engine-ECU is
short-circuited to earth, the radiator fan motor
and the condenser fan motor will not rotate.
The cause could also be a malfunction of input
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor
or the output shaft speed sensor to the
engine-ECU.
The cause could also be a malfunction of the fan
controller or the engine-ECU.

.
TROUBLESHOOTING HINTS
Malfunction of fusible link No.2
Malfunction of fan control relay
Malfunction of cooling fan motor and fan control-
ler
Malfunction of engine-ECU.
Damaged wiring harness or connector
Refer to component locations GROUP-1
Refer to configuration diagrams GROUP-1
Refer to circuit diagrams GROUP-1

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-7
STEP 3. Check the fusible link No.2.
Q: Is the fusible link No.2 in good condition?
YES : Go to Step 4.
NO : Replace the fusible link No.2. Then go to Step 24.
STEP 4. Measure the power supply voltage at fan control
relay connector A-10X.
(1) Disconnect fan control relay connector A-10X (remove the
fan control relay) and measure relay box side connector.
(2) Turn the ignition switch to the "ON" position.
(3) Measure the voltage between fan control relay connector
A-10X terminal 4 and body earth.
The voltage should measure system voltage.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
(5) Connect fan control relay connector A-10X (install the fan
control relay).
Q: Is the measured voltage system voltage?
YES : Go to Step 7.
NO : Go to Step 5.

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-8
STEP 5. Check the fan control relay connector A-10X.
Q: Is the connector in good condition?
YES : Go to Step 6.
NO : Repair the connector or replace the relay box. Then
go to Step 24.
STEP 6. Check the harness wire between fusible link No.2
and fan control relay connector A-10X terminal 4.
Q: Is the harness wire in good condition?
YES : An intermittent malfunction is suspected (Refer to
GROUP 00 - How to use troubleshooting 00-7).
NO : Repair the damaged harness wire. Then go to Step
24.
STEP 7. Check the fan control relay.
Refer to 14-31.
Q: Is the fan control relay in good condition?
YES : Go to Step 8.
NO : Replace the fan control relay. Then go to Step 24.

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-9
STEP 8. Check the fan control relay connector A-10X.
Q: Is the connector in good condition?
YES : Go to Step 9.
NO : Repair the connector or replace the relay box. Then
go to Step 24.
STEP 9. Check the harness wire between fan control relay
connector A-10X terminal 2 and fan controller connector
A-24 terminal 3.
Q: Is the harness wire in good condition?
YES : Go to Step 10.
NO : Repair the damaged harness wire. Then go to Step
24.

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-10
STEP 10. Measure the terminal voltage at fan control relay
connector A-10X.
(1) Disconnect fan control relay connector A-10X (remove the
fan control relay) and measure relay box side connector.
(2) Turn the ignition switch to the "ON" position.
(3) Measure the voltage between fan control relay connector
A-10X terminal 3 and body earth.
The voltage should measure system voltage.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
(5) Connect fan control relay connector A-10X (install the fan
control relay).
Q: Is the measured voltage system voltage?
YES : Go to Step 13.
NO : Go to Step 11.