ECU MITSUBISHI LANCER 2005 User Guide

ON-VEHICLE SERVICE
ENGINE COOLING14-23
5. Apply the designated sealant to the screw area of
the cylinder block drain plug, and then tighten to
the standard torque.
Specified sealant: 3M Nut Locking Part
No.4171 or equivalent
Tightening torque:
40 ± 5 N⋅m <4G1>
44 ± 5 N⋅m <4G6>
6. Securely tighten the drain plug of the radiator.
7. Reinstall the radiator condenser tank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium
components.
8. By referring to the section on coolant, select an
appropriate concentration for safe operating
temperature within the range of 30 to 60%. Use
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50% water and
50% antifreeze solution (freezing point: −31°C).
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
Quantity:
5.0 L <4G1>
7.0 L <4G6>
NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the
thermostat opens.
11.After repeatedly revving the engine up to 3,000
r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
Do not overfill the radiator condenser tank.
13.Add coolant to the radiator condenser tank
between the "F" and "L" mark if necessary.
CONCENTRATION MEASUREMENTM1141001100352
Measure the temperature and specific gravity of the
engine coolant to check the antifreeze concentration.
Standard value: 30 − 60% (allowable
concentration range)
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
CAUTION
If the concentration of the anti-freeze is below
30%, the anti-corrosion property will be
adversely affected. In addition, if the
concentration is above 60%, both the
anti-freezing and engine cooling properties will
decrease, affecting the engine adversely. For
these reasons, be sure to maintain the
concentration level within the specified range.
COOLING FAN MOTOR DRIVE CONTROL
UNIT CHECK
M1141006100216
1. Remove the cooling fan motor drive control unit
connector.
2. Turn the ignition switch to the "ON" position, and
measure the voltage between terminal 1 and 3 at
the harness side connector.
Standard value: system voltage
AC200625
Cylinder block
drain plug
AC
AC303612AB
MB991871
AIR HOSE
AC103195
Y1716AU
1 23
AC
Cooling fan motor
drive control unit

AIR CLEANER
INTAKE AND EXHAUST15-3
AIR CLEANER
REMOVAL AND INSTALLATIONM1151002100486
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
•Avoid any shock or load to these parts when removing and installing them.
•When installing, securely set the air cleaner cover clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws.
AC303618
4.0 ± 1.0 N·m 4.0 ± 1.0 N·m
10*9*4
1*5
11
12 ± 1 N·m
9.0 ± 1.0 N·m 9.0 ± 1.0 N·m
AB
12 ± 1 N·m
Clamp
8*
3* <4G1>

CHARGING SYSTEM
ENGINE ELECTRICAL16-2
CHARGING SYSTEM
GENERAL INFORMATIONM1161000100522
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.
OPERATION
Rotation of the excited field coil generates AC
voltage in the stator.
This alternating current is rectified through diodes to
DC voltage having a waveform shown in the
illustration.The average output voltage fluctuates slightly with
the alternator load condition.
When the ignition switch is turned on, current flows in
the field coil and initial excitation of the field coil
occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field
current increases and it falls as the field current
decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
When the battery voltage drops below the regulated
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field
current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.
SYSTEM DIAGRAM
ALTERNATOR SPECIFICATIONS
AKX00183
Voltage
Time
Approximately
14.4 V
AC
AK400308
Alternator
B
Stator coil
Engine-ECU
or
Engine-A/T-ECU

G
S
L
FR <4G1>
Voltage regulatorCharge warning lightIgnition switch
Battery Field coil
+
–
AB
Item 4G1 4G6
Type Battery voltage sensing
Rated output V/A 12/80 12/110
Voltage regulator Electronic built-in type

CHARGING SYSTEM
ENGINE ELECTRICAL16-5
OUTPUT CURRENT TESTM1161001000368
This test determines whether the alternator output
current is normal.
1. Before the test, always be sure to check the
following.
•Alternator installation
•Battery (Refer to GROUP 54A − Battery −
On-vehicle Service P.54A-5).
NOTE: The battery should be slightly discharged.
The load needed by a fully-charged battery is
insufficient for an accurate test.
•Drive belt tension
(Refer to GROUP 11A − On-vehicle Service <4G1>
P.11A-7 or GROUP 11C − On-vehicle Service
<4G6> P.11C-7.)
•Fusible link
•Abnormal noise from the alternator while the
engine is running.
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.CAUTION
Never use clips but tighten bolts and nuts to
connect the line. Otherwise loose connections
(e.g. using clips) will lead to a serious accident
because of high current.
4. Connect a clamp-type DC test ammeter with a
range of 0 − 120 A to the alternator "B" terminal
output wire.
NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is
possibly not found the problem that the output
current is dropping due to the insufficient
connection between terminal "B" and the output
wire.
5. Connect a voltmeter with a range of 0 − 20 V
between the alternator "B" terminal and the earth
[Connect the (+) lead of the voltmeter to the "B"
terminal, and then connect the (-) lead of the
voltmeter to the earth].
6. Connect the negative battery cable.
AK203362
Alternator Ammeter
(clamp-type)
Voltmeter
Battery Inition switch
Engine-ECU
or
Engine-A/T-ECU
Load
B
FR
L
S
G +
AH
–
Charging indicator
Brake warning light

CHARGING SYSTEM
ENGINE ELECTRICAL16-7
REGULATED VOLTAGE TESTM1161001100354
This test determines whether the voltage regulator
correctly controlling the alternator output voltage.
1. Always be sure to check the following before the
test.
•Alternator installation
•Check that the battery installed in the vehicle is
fully charged.
(Refer to GROUP 54A − Battery − On-vehicle
Service − Charging P.54A-4).
•Drive belt tension
(Refer to GROUP 11A − On-vehicle Service <4G1>
P.11A-7 or GROUP 11C − On-vehicle Service
<4G6> P.11C-7.)
•Fusible link
•Abnormal noise from the alternator while the
engine is running
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Use the special tool Alternator test harness
(MB991519) to connect a digital voltmeter
between the alternator "S" terminal and earth
[Connect the (+) lead of the voltmeter to the "S"
terminal, and then connect the (-) lead of the
voltmeter to a secure earth or to the battery (-)
terminal].
5. Connect a clamp-type DC test ammeter with a
range of 0 − 120 A to the alternator "B" terminal
output wire.NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is
possibly not found the problem that the output
current is dropping due to the insufficient
connection between terminal "B" and the output
wire.
6. Reconnect the negative battery cable.
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery (+)
terminal.
9. Turn all lamps and accessories off.
10.Start the engine.
11.Increase the engine speed to 2,500 r/min.
12.Read the value displayed on the voltmeter when
the alternator output current alternator becomes
10 A or less.
13.If the voltage reading conforms to the value in the
voltage regulation, then the voltage regulator is
operating normally.
AK300727AB
BatteryIgnition switch
Engine-ECU
Engine-A/T-ECU Ammeter (clamp-type)Load
Black MB991519
Voltmeter (digital-type) Red
YellowBlueAlternator B
FR
L
S
G

IGNITION SYSTEM
ENGINE ELECTRICAL16-30
IGNITION SYSTEM
GENERAL INFORMATIONM1163000100294
This system is equipped with two ignition coils (A and
B) with built-in power transistors for the No. 1 and
No. 4 cylinders and the No. 2 and No. 3 cylinders
respectively.
Interruption of the primary current flowing in the
primary side of ignition coil A generates a high
voltage in the secondary side of ignition coil A. The
high voltage thus generated is applied to the spark
plugs of No. 1 and No. 4 cylinders to generate
sparks. At the time that the sparks are generated at
both spark plugs, if one cylinder is at the
compression stroke, the other cylinder is at the
exhaust stroke, so that ignition of the compressed
air/fuel mixture occurs only for the cylinder which is
at the compression stroke.
In the same way, when the primary current flowing in
ignition coil B is interrupted, the high voltage thus
generated is applied to the spark plugs of No. 2 and
No. 3 cylinders.The engine-ECU or engine-A/T-ECU
turns the two power transistors inside the ignition
coils alternately on and off. This causes the primary
currents in the ignition coils to be alternately
interrupted and allowed to flow to fire the cylinders in
the order 1-3-4-2.
The engine-ECU or engine-A/T-ECU
determines which ignition coil should be controlled
by means of the signals from the camshaft position
sensor which is incorporated in the camshaft and
from the crank angle sensor which is incorporated in
the crankshaft. It also detects the crankshaft position
in order to provide ignition at the most appropriate
timing in response to the engine operation
conditions. It also detects the crankshaft position in
order to provide ignition at the most appropriate
timing in response to the engine operation
conditions.
When the engine is cold or operated at high
altitudes, the ignition timing is slightly advanced to
provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
AK101074
Air flow sensor
<4G6> MAP sensor <4G1>
Intake air temperatur
sensor
Engine coolant
temperature sensor
Camshaft position
sensor
Crank angle sensor
Barometric pressure
sonsor <4G6>
Detonatoin sensor
Ignition switch-STEngine-A/T-
ECU Engine-ECU
Ignition coil B
Cylinder No.
23 4
AG
1 Spark plugIgnition coil AIgnition
switch
Battery

IGNITION SYSTEM
ENGINE ELECTRICAL16-42
REMOVAL AND INSTALLATION <4G6>M1163003500440
REMOVAL SERVICE POINT
<> POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
Remove the power steering oil pump assembly from
the bracket with the hose attached.
NOTE: Place the removed power steering oil pump
assembly in a place where it will not be a hindrance
when removing and installing and secure it with a
cord or wire.
Pre-removal and Post-installation Operation
•Valve Timing Belt Removal and Installation (Refer to
GROUP 11C P.11C-35).
AC301612
8.8 ± 1.0 N·m
8
8.8 ± 1.0 N·m
9
1
22 ± 4 N·m
4
2
3
49 ± 9 N·m49 ± 9 N·m5
22 ± 4 N·m
3.0 ± 0.5 N·m
6
7
AC
Removal steps
1. Power steering pressure switch
connector
2. A/C compressor connector
3. A/C compressor connector clamp
<>4. Power steering oil pump assembly
5. Power steering oil pump bracket6. Rocker cover centre cover
7. Engine crankshaft position sensor
connector
8. Engine crankshaft position sensor
9. Crankshaft position sensor
connector bracket Removal steps (Continued)

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-8
VACUUM HOSE CHECKM1173007300159
1. Using the piping diagram as a guide, check to be
sure that the vacuum hoses are correctly
connected.
2. Check the connection condition of the vacuum
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.
VACUUM HOSE INSTALLATIONM1173007200107
1. When connecting the vacuum hoses, they should
be securely inserted onto the nipples.
2. Connect the hoses correctly, using the vacuum
hose piping diagram as a guide.
CRANKCASE EMISSION CONTROL
SYSTEM
GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM)
M1173005000237
The crankcase emission control system prevents
blow-by gases from escaping inside the crankcase
into the atmosphere.
Fresh air is sent from the air cleaner into the
crankcase through the breather hose.
The air becomes mixed with the blow-by gases
inside the crankcase.
The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
ventilation (PCV) valve.
The PCV valve lifts the plunger according to the
intake manifold vacuum so as to regulate the flow of
blow-by gas properly.
In other words, the blow-by gas flow is regulated
during low load engine operation to maintain engine
stability, while the flow is increased during high load
operation to improve the ventilation performance.
SYSTEM DIAGRAM
AK204365
Air cleaner
Air
Ventilation hose
Breather hose
PCV valve
AB

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-10
SYSTEM DIAGRAM
COMPONENT LOCATION (EVAPORATIVE
EMISSION CONTROL SYSTEM)
M1173007500216
PURGE CONTROL SYSTEM CHECKM1173001400299
AK204367AC
Throttle body
Canister
From
fuel
tank
OFF
ONPurge
control
solenoid
valveControl
relay
BatteryEngine-ECU <4G1-M/T, 4G6>,
Engine-A/T-ECU <4G1-A/T>
Air flow sensor <4G6>
Engine coolant
temperature sensor
Intake air
temperature sensor
Barometric pressure
sensor <4G6> Manifold absolute pressure
(MAP) sensor <4G1>
AK300769
<4G1>
AB
Purge control
solenoid valve
AK300770
<4G6>
AB
Purge control
solenoid valve
AK300771
<4G1>
AB
Plug
Vacuum hose
AK300772
<4G6>
AB
Plug
Vacuum hose

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-13
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM
GENERAL INFORMATION (EGR SYSTEM)M1173005200327
The exhaust gas recirculation (EGR) system lowers
the nitrogen oxide (NOx) emission level.
When the air/fuel mixture combustion temperature is
high, a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber.
Therefore, this system recirculates part of emission
gas from the exhaust port of the cylinder head to the
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.
OPERATION
The EGR valve is being closed and does not
recirculate exhaust gases under one of the following
conditions.
Otherwise, the EGR valve is opened and recirculates
exhaust gases.
•The engine coolant temperature is low.
•The engine is at idle.
•The throttle valve is widely opened.
SYSTEM DIAGRAM
AK300775
Manifold absolute
pressure (MAP) sensor Engine-ECU ,
Engine-A/T-ECU
Engine coolant
temperature sensor
Crank angle sensor EGR
control
solenoid
valve
EGR valveOFF
ON
Control
relay
Battery
AB
<4G1>