sensor MITSUBISHI LANCER 2005 Workshop Manual

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 COOLING14-16
INSPECTION PROCEDURE 2: 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 Stop
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
•If the communication line wiring harness between
the cooling fan motor drive control unit and the
engine-ECU or the engine-A/T-ECU
is open, 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>
rotate to prevent the engine from overheating.
•If the system voltage is continuously supplied to
the cooling fan motor drive control unit by a fan
motor relay malfunction and a short circuit on the
cooling fan motor drive control unit power supply
wiring harness, 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>
rotate.
•The cause could also be a malfunction of the
cooling fan motor (L.H.).
•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
cooling fan motor drive control unit or the
engine-ECU or engine-A/T-ECU .
TROUBLESHOOTING HINTS
•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 fan control relay.
Refer to P.14-24.
Q: Is the fan control relay in good condition?
YES :
Go to Step 2 .
NO : Replace the fan control relay. Then go to
Step 8 .
STEP 2. Check the fan control relay connector
A-09X.
Q: Is the connector in good condition?
YES :
Go to Step 3 .
NO : Repair the connector or replace the relay
box. Then go to Step 8 .
AC303510AB
Fan control relay
Relay boxConnector: A-09X
A-09X

THERMOSTAT
ENGINE COOLING14-27
REMOVAL SERVICE POINT
<> RADIATOR LOWER HOSE
DISCONNECTION
Make mating marks on the radiator lower hose and
the hose clamp. Disconnect the radiator lower hose.
INSTALLATION SERVICE POINTS
>>A<< THERMOSTAT INSTALLATION
CAUTION
Make absolutely sure that no oil adheres to the
rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
Install the thermostat so that the jiggle valve is facing
straight up. Be careful not to fold or scratch the
rubber ring.
>>B<< RADIATOR LOWER HOSE
CONNECTION
1. Insert radiator lower hose as far as the projection
of the Cooling water inlet hose fitting.
2. Align the mating marks on the radiator lower hose
and hose clamp, and then connect the radiator
lower hose.
INSPECTIONM1141002500427
THERMOSTAT CHECK
1. Immerse the thermostat in water, and heat the
water while stirring. Check the thermostat valve
opening temperature.
Standard value:
88 ± 1.5°C <4G1>
82 ± 1.5°C <4G6>
Removal steps
1. Water temperature gauge unit
connector <4G6>
2. Water temperature sensor unit
connector <4G6>
<> >B<<3. Radiator lower hose connection4. Engine control oxygen sensor
connector and connector bracket
<4G1>
5. Control wiring harness clip <4G6>
6. Cooling water inlet hose fitting>>A<<7. ThermostatRemoval steps (Continued)
AC200641AC
Mating marks
AC000279
Jiggle valve
Rubber ring
AB
AC200642
Mating marks
Projection
Cooling water inlet
hse fitting
AH
ACX00400
AB

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
<> >>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)

GENERAL INFORMATION
INTAKE AND EXHAUST15-2
GENERAL INFORMATION
M1151000100402The exhaust pipe is divided into three parts.
SERVICE SPECIFICATION
M1151000300428
SPECIAL TOOL
M1151000600399
Item Standard value Limit
Manifold distortion of the installation surface mm 0.15 or less 0.20
Tool Number Name Use
MD998770 Oxygen sensor wrench Removal and installation of
engine control oxygen sensor

AIR CLEANER
INTAKE AND EXHAUST15-4
AC303619
4.0 ± 1.0 N·m 4.0 ± 1.0 N·m10*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* <4G6>
6 7
N
2
8.8 ± 1.0 N·m
Removal steps
1. Air cleaner intake duct
2. Air cleaner air flow sensor connector
<4G6>
3. Air cleaner assembly <4G1> or Air
cleaner and air cleaner air flow sensor
assembly <4G6>
4. Rocker cover breather hose
connection
5. Air cleaner to throttle body duct6. Air cleaner air flow sensor <4G6>
7. Air cleaner air flow sensor gasket
<4G6>
8. Air cleaner cover
9. Air cleaner element
10. Air cleaner body assembly
11. Air cleaner bracketRemoval steps (Continued)

INLET MANIFOLD
INTAKE AND EXHAUST15-5
INLET MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003000749
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13A-389).
•Engine Coolant Draining (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Removal (Refer to GROUP 13A
P.13A-400).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A P.13A-398).Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A P.13A-398).
•Throttle Body Assembly Installation (Refer to GROUP
13A P.13A-400).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service P.17-2).
•Fuel Leak Check
AC303642AB
15
3
6
5
412 10 71
2
11
913
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m18 ± 2 N·m5.0 ± 1.0 N·m
31 ± 3 N·m
49 ± 9 N·m
N
N
N
8
Removal steps
1. Inlet manifold absolute pressure
sensor
2. Engine control pressure sensor
O-ring
3. Engine control detonation sensor
connector
4. T/M housing front lower cover stay
(L.H.)
5. Battery wiring harness clamp
connection
6. Inlet manifold stay
7. Brake booster vacuum hose
connection8. Emission control equip hose
connection
9. Fuel vapour control hose
connection
10. Inlet manifold stay
11. Inlet manifold
12. Inlet manifold gasket
13. EGR valve
14. EGR valve gasket
15. Emission vacuum hose & pipe and
emission solenoid valve assembly Removal steps (Continued)

INLET MANIFOLD
INTAKE AND EXHAUST15-6
REMOVAL AND INSTALLATION <4G6>M1151003001236
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13A-389).
•Engine Coolant Draining (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Removal (Refer to GROUP 13B
P.13B-336).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13B P.13B-334).Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13B P.13B-334).
•Throttle Body Assembly Installation (Refer to GROUP
13B P.13B-336).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service P.17-2).
•Fuel Leak Check
AC303657
9.0 ± 1.0 N·m11 ± 1 N·m
20 ± 2 N·m
31 ± 3 N·m 36 ± 6 N·m
20 ± 2 N·m
20 ± 2 N·m
36 ± 6 N·m
36 ± 6 N·m
11
9 10 212
N1413N
AB
5.0 ± 1.0 N·m
3
1
11 ± 1 N·m
4
N
13 ± 1 N·m
5
6
(Engine oil)
7
8
Removal steps
1. Emission control equip hose
connector
2. Brake booster vacuum hose
connection
3. Earth cable connection4. Engine control detonation sensor
connector
5. Engine oil level gauge and guide
assembly
6. Engine oil filler O-ring
7. Emission vacuum hose connectionRemoval steps (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN
SENSOR (FRONT) REMOVAL
Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (front).
INSTALLATION SERVICE POINT
>>A<< ENGINE CONTROL OXYGEN
SENSOR (FRONT) INSTALLATION
Use special tool oxygen sensor wrench (MD998770)
to install the engine control oxygen sensor (front).
Removal steps
1. Front exhaust pipe connection
2. Exhaust pipe gasket
<> >>A<<3. Engine control oxygen sensor (front)
4. Engine oil level gauge and guide
assembly
5. Engine oil filler O-ring6. Exhaust manifold cover
7. Exhaust manifold bracket
8. Exhaust manifold
9. Exhaust manifold gasketRemoval steps (Continued)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-9
REMOVAL AND INSTALLATION <4G6>M1151003300579
Pre-removal and Post-installation Operation
Under cover Removal and Installation
AC30368050 ± 10 N·m 44 ± 5 N·m35 ± 6 N·m14 ± 1 N·m
14 ± 1 N·m
49 ± 5 N·m29 ± 3 N·m
29 ± 3 N·m
N
3
4
12 5
N
8944 ± 5 N·m
AB
1049 ± 5 N·m
6 7
9.0 ± 2.0 N·m49 ± 9 N·m
Removal steps
1. Front exhaust pipe connection
2. Exhaust pipe gasket
<> >>A<<3. Engine control oxygen sensor (front)
4. Exhaust manifold cover
5. Exhaust manifold bracket6. Starter cover
7. Starter cover bracket
8. Engine hanger
9. Exhaust manifold
10. Exhaust manifold gasketRemoval steps (Continued)