cooling MITSUBISHI LANCER 2005 Workshop Manual

GROUP INDEX
00General . . . . . . . . . . . . . . . . . . . . . . . .
11Engine. . . . . . . . . . . . . . . . . . . . . . . . .
12Engine Lubrication . . . . . . . . . . . . . .
13Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
14Engine Cooling . . . . . . . . . . . . . . . . .
15Intake and Exhaust . . . . . . . . . . . . . .
16Engine Electrical . . . . . . . . . . . . . . . .
17Engine and Emission Control . . . . .
21Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
22Manual Transmission . . . . . . . . . . . .
23Automatic Transmission. . . . . . . . . .
26Front Axle . . . . . . . . . . . . . . . . . . . . . .
27Rear Axle . . . . . . . . . . . . . . . . . . . . . .
31Wheel and Tyre . . . . . . . . . . . . . . . . .
32Power Plant Mount . . . . . . . . . . . . . .
33Front Suspension . . . . . . . . . . . . . . .
34Rear Suspension . . . . . . . . . . . . . . . .
35Service Brakes . . . . . . . . . . . . . . . . . .
36Parking Brakes . . . . . . . . . . . . . . . . .
37Power Steering . . . . . . . . . . . . . . . . .
42Body . . . . . . . . . . . . . . . . . . . . . . . . . .
51Exterior . . . . . . . . . . . . . . . . . . . . . . . .
52 . . . . . . . . . .
54Chassis Electrical . . . . . . . . . . . . . . .
55 . . . . . . .
70Component Locations. . . . . . . . . . . .
80Configration Diagrams . . . . . . . . . . .
90Circuit Diagrams . . . . . . . . . . . . . . . .

LANCER /
LANCER WAGON
WORKSHOP MANUAL
FOREWORD
This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.
TECHNICAL INFORMATION MANUAL
PYME0302
PYME0302-A
WORKSHOP MANUAL
CHASSIS GROUP PWME0302
BODY REPAIR MANUAL
PBME0302
PBME0302-A
PARTS CATALOGUE
B606K005A_
All information, illustrations and product descriptions
contained in this manual are current as at the time of
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation.
Mitsubishi Motors Corporation May 2004
Heater, Air Conditioner and
Ventilation Interior and Supplemental
Restraint System (SRS)

14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . .14-2
SERVICE SPECIFICATIONS . . . . . . .14-2
LUBRICANT . . . . . . . . . . . . . . . . . . . .14-2
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 . . . . . . . . . . .14-22
ENGINE COOLANT LEAK CHECK . . . . . . 14-22
RADIATOR CAP VALVE OPENING
PRESSURE CHECK . . . . . . . . . . . . . . . . . . 14-22
ENGINE COOLANT REPLACEMENT . . . . 14-22
CONCENTRATION MEASUREMENT . . . . 14-23COOLING FAN MOTOR DRIVE CONTROL
UNIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . 14-23
FAN CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
COOLING FAN MOTOR CHECK . . . . . . . . 14-25
THERMOSTAT . . . . . . . . . . . . . . . . . .14-26
REMOVAL AND INSTALLATION . . . . . . . . 14-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 14-27
WATER PUMP . . . . . . . . . . . . . . . . . .14-29
REMOVAL AND INSTALLATION <4G1> . . 14-29
REMOVAL AND INSTALLATION <4G6> . . 14-30
WATER HOSE AND WATER PIPE . .14-31
REMOVAL AND INSTALLATION <4G1> . . 14-31
REMOVAL AND INSTALLATION <4G6> . . 14-33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 14-34
RADIATOR . . . . . . . . . . . . . . . . . . . . .14-35
REMOVAL AND INSTALLATION . . . . . . . . 14-35

GENERAL INFORMATION
ENGINE COOLING14-2
GENERAL INFORMATION
M1141000100371The 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
circulation type in which the water pump pressurizes
coolant and circulates it throughout the engine. If the
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 alternator drive belt from the
crankshaft. The radiator is the corrugated fin, down
flow type.
SERVICE SPECIFICATIONS
M1141000300416
LUBRICANT
M1141000400338
ItemSpecification
Radiator Performance kJ/h 4G13 Standard vehicles 137,720
Vehicles with capacity up radiator
(option)161,288
4G18 Standard vehicles 161,288
Vehicles with capacity up radiator
(option)181,800
4G63 181,800
A/T oil cooler Performance kJ/h 5,651
Item Standard value Limit
High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Thermostat Valve opening temperature of
thermostat °C4G1 88 ± 1.5 -
4G6 82 ± 1.5 -
Full-opening temperature of
thermostat °C4G1 100 -
4G6 95 -
Valve lift mm 8.5 or more -
Item Specified coolant Quantity L
Engine coolant (including
condense tank)DIAQUEEN SUPER LONG LIFE COOLANT
or an equivalent4G1 5.0
4G6 7.0

SEALANTS
ENGINE COOLING14-3
SEALANTS
M1141000500324
SPECIAL TOOLS
M1141000600246
Item Specified sealant
Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent
Water pump <4G1>, Thermostat case
<4G6>, Cooling water outlet hose fitting
<4G6>MITSUBISHI GENUINE Part No.MD970389 or equivalent
Tool Number Name Use
MB991502 MUT-II sub assembly Reading diagnosis code
B991502

SPECIAL TOOLS
ENGINE COOLING14-4
MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826MUT-III sub assembly
A: Vehicle
communication
interface (V.C.I.)
B: MUT-III USB cable
C: MUT-III main
harness A (Vehicles
with CAN
communication
system)
D: MUT-III main
harness B (Vehicles
without CAN
communication
system)
E: MUT-III
measurement
adapter
F: MUT-III trigger
harnessChecking the A/T
(Diagnosis display using the
MUT-III) Tool Number Name Use
MB991910
MB991826
MB991955
MB991911
MB991824
MB991827
MB991825
A
B
C
D
E
F
DO NOT USE

TROUBLESHOOTING
ENGINE COOLING14-5
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600360
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222 Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: ProbeMaking voltage and
resistance measurement
during troubleshooting
A: Connector pin contact
pressure inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection
MB991871 LLC changer Coolant refilling Tool Number Name Use
MB991223
A
B
C
D
AC
MB991871
Trouble symptom Inspection
procedure No.Reference page
Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with
A/C)> or A/C condenser fan <4G6> do not operate 1
P.14-6
Cooling fan (L.H.) and Cooling fan (R.H.) <4G1 (Vehicles with
A/C)> or A/C condenser fan <4G6> do not change speed or stop2
P.14-16
Cooling fan (L.H.) does not operate {When cooling fan (R.H.)
<4G1> or A/C condenser fan <4G6> operate} 3
P.14-20
Cooling fan (R.H.) <4G1> or A/C condenser fan <4G6> does not
operate {When cooling fan (L.H.) operate} 4
P.14-21

TROUBLESHOOTING
ENGINE COOLING14-6
INSPECTION PROCEDURE FOR
TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1: Cooling Fan (L.H.) and Cooling Fan (R.H.) <4G1 (Vehicles with A/C)> or
A/C Condenser Fan <4G6> do 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 : Gray
R : Red P : Pink V : Violet
FAN CONTROL
RELAY
A-09XENGINE CONTROL
RELAY
B-16X
AC303577
A-18-1
COOLING FAN
MOTOR (L.H.) COOLING FAN
MOTOR (R.H.)
<4G1 (VEHICLES
WITH A/C>
OR
A/C CONDENSER
FAN MOTOR <4G6>A-18-2 A-18
COOLING FAN
MOTOR DRIVE
CONTROL UNIT1 A-13
12 C-111 ENGINE-ECU OR
ENGINE-A/T-ECU
21 C-123
18 C-122
615
121179
810234
(MU802322) (MU801824)
C-123
(MU803784)C-122
(MU802611)A-13
C-111L
L
2
2211
1B L2
3 4 B-W FUSIBLE
LINK No.2
B3 1 R-Y R-Y
8 A-13
11 C-111
615
121179
810234
(MU802611)
J/C (6)
C-12
C-134 R-Y
3328
A-13
C-111
Cooling Fan (L.H.) and Cooling Fan (R.H.) or A/C Condenser Fan Drive Circut
AB

TROUBLESHOOTING
ENGINE COOLING14-7
CIRCUIT OPERATION
•The cooling fan motor drive control unit is
powered from fusible link (2).
•The engine-ECU or engine-A/T-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 cooling
fan motor (L.H.) and the cooling fan motor (R.H.)
<4G1 (Vehicles with A/C)> or A/C condenser fan
motor <4G6>.
•The engine-ECU or engine-A/T-ECU
controls the cooling fan motor drive control
unit to activate 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>.
TECHNICAL DESCRIPTION
•The cause could be a malfunction of the cooling
fan motor drive control unit power supply or earth
circuit.
•If the communication line wiring harness between
the cooling fan motor drive control unit and the
engine-ECU or engine-A/T-ECU is
short-circuited to earth, the cooling fan motor
(L.H.) and the cooling fan motor (R.H.) <4G1
(Vehicles with A/C)> or the A/C condenser fan
motor <4G6> will not rotate.
•The cause could also be a malfunction of the
cooling fan motor (L.H.).
•The cause could also be a malfunction of imput
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 or engine-A/T-ECU .
•The cause could also be a malfunction of the
cooling fan motor drive control unit or the
engine-ECU or engine-A/T-ECU .
TROUBLESHOOTING HINTS
•Malfunction of fusible link (2)
•Malfunction of fan control relay
•Malfunction of cooling fan motor (L.H.) without A/C>
•Malfunction of cooling fan motor drive control unit
•Malfunction of engine-ECU or
engine-A/T-ECU
•Damaged wiring harness or connector
DIAGNOSIS
STEP 1. Check the cooling fan motor (L.H.).

Refer to P.14-25.
Q: Is the cooling fan motor (L.H.) in good condition?
YES :
Go to Step 2 .
NO : Replace the cooling fan motor (L.H.) (Refer
to P.14-35). Then go to Step 24 .
STEP 2. Measure the power supply voltage at
cooling fan motor drive control unit connector
A-18.
(1) Disconnect cooling fan motor drive control unit
connector A-18 and measure wiring harness side
connector.
(2) Turn the ignition switch to the "ON" position.
(3) Measure the voltage between cooling fan motor
drive control unit connector A-18 terminal 3 and
body earth.
•The voltage should measure system voltage.
(4) Turn the ignition switch to the "LOCK" (OFF)
position.
(5) Connect cooling fan motor drive control unit
connector A-18.
Q: Is the measured voltage system voltage?
YES :
Go to Step 17 .
NO : Go to Step 3 .
AC100293
A-18
321
Connector: A-18
AD
AC000246AF
A-18 Connector
(Component side)

TROUBLESHOOTING
ENGINE COOLING14-8
STEP 3. Check the cooling fan motor drive
control unit connector A-18.
Q: Is the connector in good condition?
YES : .
Go to Step 4 .
NO : . Repair or replace the connector. Then go to
Step 24 .
STEP 4. Check the fusible link No.2.
Q: Is the fusible link No.2 in good condition?
YES : .
Go to Step 5 .
NO : . Replace the fusible link No.2. Then go to
Step 24 .
STEP 5. Measure the power supply voltage at fan
control relay connector A-09X.(1) Disconnect fan control relay connector A-09X
(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-09X 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-09X
(install the fan control relay).
Q: Is the measured voltage system voltage?
YES :
Go to Step 8 .
NO : Go to Step 6 .
STEP 6. Check the fan control relay connector
A-09X.
Q: Is the connector in good condition?
YES :
Go to Step 7 .
NO : Repair the connector or replace the relay
box. Then go to Step 24 .
AC100293
A-18
321
Connector: A-18
AD
AC303509AB
Fusible link
No.2
Relay box
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
AC303511AB
A-09X Connector
(Relay box side)
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X

TROUBLESHOOTING
ENGINE COOLING14-9
STEP 7. Check the harness wire between fusible
link No.2 and fan control relay connector A-09X
terminal 4.
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 8. Check the fan control relay.
Refer to P.14-24.
Q: Is the fan control relay in good condition?
YES :
Go to Step 9 .
NO : Replace the fan control relay. Then go to
Step 24 .
STEP 9. Check the fan control relay connector
A-09X.
Q: Is the connector in good condition?
YES :
Go to Step 10 .
NO : Repair the connector or replace the relay
box. Then go to Step 24 .
STEP 10. Check the harness wire between fan
control relay connector A-09X terminal 2 and
cooling fan motor drive control unit connector
A-18 terminal 3.
Q: Is the harness wire in good condition?
YES :
Go to Step 11 .
NO : Repair the damaged harness wire. Then go
to Step 24 .
STEP 11. Measure the terminal voltage at fan
control relay connector A-09X.
(1) Disconnect fan control relay connector A-09X
(remove the fan control relay) and measure relay
box side connector.
(2) Turn the ignition switch to the "ON" position.
AC303509AB
Fusible link
No.2
Relay box
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X
AC100293
A-18
321
Connector: A-18
AD
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X