wiring MITSUBISHI LANCER 2006 Workshop Manual

TROUBLESHOOTING
ENGINE COOLING14-7
•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.14-24.
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.14-33) <4G1> (Refer to P.14-35)
<4G6>. Then go to Step 24 .
STEP 2. Measure the power supply voltage at
cooling fan motor drive control unit connector
A-18.
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 .
(2)T urn t he ig nition switch t o the "ON" positio n.
AC000246AF
A-18 Connector
(Component side)
(3)M easu r e the volt age between cooling fan motor
drive control unit con nect o r A-18 te rmin al 3 a nd
bod y ea rth.
•The voltage shou ld measu r e syste m volt age.
(4)T urn t he ig nition switch t o the "L OCK" (OF F )
position.
(5)C onne ct cooling fa n mot o r drive control unit
connector A-18.
Q:Is t h e mea s ure d volt a g e sy ste m v o lt ag e?
YES : Go to S t ep 1 7 .
NO : Go to S t ep 3 .

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 COOLING14-16
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.14-23.
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.
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 3 .
NO : Repa ir th e con nect o r or rep l ace the re lay
box. Then
go to S t ep 8
.
STEP 3 . Check the harness wire be twee n 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

AC301429
1
2 36
7
13 ± 2 N·m
AD
5
<4G6>
Removal steps
1.Water temperature gauge unit
connector <4G6>
2.Water temperature sensor unit
connector <4G6>
<>>B<<3.Radiator lower hose connection
4.Engine control oxygen sensor
connector and connector bracket
<4G1>
5.Control wiring harness clip <4G6>
6.Cooling water inlet hose fitting
>>A<<7.Thermostat
THERMOST
A T
ENGINE COOLING14-25
REMOV A L SER V ICE POINT
<> RADIAT OR LOW E R HOSE DIS-
CONNECTION
AC200641AC
Mating marks
Make mating marks on the rad i ator lower ho se an d
the hose clamp. Disconn
ect t he radiator lower hose.
INSTALLA T ION SER VICE POINTS
>>A<< THERMOSTA T INST ALLA TION
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.
AC000279
Jiggle valve
Rubber ring
AB
Install the thermostat so that the jiggle valve is facing
straight up. Be careful not to fold or scratch the rub
-
ber ring.

WATER HOSE AND WATER PIPE
ENGINE COOLING14-29
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.14-21).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-24).
AC203411
1
2 3
4
5
6
7
8
10
9
13 ± 2 N·m
23 ± 4 N·m
13 ± 2 N·m
N
N
AC
1112
13
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 assembly
7.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-ring
REMOV
A L SER VICE POINT
<> RADIAT OR UPPER HOSE DISCON-
NECTION
AC200641AC
Mating marks
After making matin g ma rks on the radia t or upp er
hose
and h o se clamp, disconnect the radia t or upp er
hose
.

WATER HOSE AND WATER PIPE
ENGINE COOLING14-31
REMOVAL AND INSTALLATION <4G6>
M1141003300426
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to P.14-21).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Thermostat Removal and Installation (Refer to P.14-24).
AC303471
1
2
3
4
5 6
7
8
9
9
13 ± 2 N·m
23 ± 4 N·m
13 ± 2 N·m
N
N
AB
2
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent
Ø3 mm
Ø3 mm
5
Removal steps
<>>>C<<1.Radiator upper hose connection
>>B<<2.Cooling water outlet hose fitting
3.Throttle body water return hose
4.Throttle body water feed hose
>>B<<5.Thermostat case assembly
6.Heater water hose connection
7.Control wiring harness clamp
8.Water pump inlet pipe
>>A<<9.Cooling water line O-ring
Removal 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-372).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13A
P.13A-383).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A
P.13A-381).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A
P.13A-381).
•Throttle Body Assembly Inst allation (Refer to GROUP
13A
P.13A-383).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service
P.17-2).
•Fuel Leak Check
AC303642AB
15
36
5
4 12
10
7
1
2
11
9 13
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m 18 ± 2 N·m
5.0 ± 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 connection
8.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)

CHARGING SYSTEM
ENGINE ELECTRICAL16-3
SERVICE SPECIFICATIONS
M1161000300258
ItemStandard valueLimit
Alternator output line voltage drop (at 30 A) V−maximum 0.3
Regulated voltage ambient
temperature at voltage regulator V−20°C14.2 − 15.4−
20°C13.9 − 14.9−
60°C13.4 − 14.6−
80°C13.1 − 14.5−
Output current−70 % of normal output current
SPECIAL TOOLM1161000600163
ToolNumberNameUse
MB991519Alterna t or test harn e ssChec king th e alt e rnator
("S" te rminal volt age )
ON-VEHICLE SERV ICE
ALTERNA T O R OUTPUT LINE VOL T AGE DROP TEST
M1161 0009 0034 6
AK203361AD
Alternator Ammeter (clamp-type)
Voltmeter (digital-type)
"B" terminal Battery
This test
determine s whethe r the wiring fro m th e
altern
ator "B" termina l to t he batt e ry (+) terminal
(including the
fusible line ) is in a good condition or
not.
1.Always b e su re to check the following b e fore th e
te st.
•Alternator inst allatio n
•Drive belt tension
(Ref er to GROUP 1 1 A − On-veh icle Service <4G1>
P.11A-7 or GROUP 1 1 C − On-vehicle Service
<4G6> P.11C-7.)
•Fusible link
•Abnormal noise from the altern ator while the
eng
ine is ru nning

CHARGING SYSTEM
ENGINE ELECTRICAL16-4
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
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 pos
-
sibly 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 digital-type voltmeter between the
alternator "B" terminal and the battery (+)
terminal. [Connect the (+) lead of the voltmeter to
the "B" terminal and the connect the (-) lead of the
voltmeter to the battery (+) cable].
6. Reconnect the negative battery cable.
7. Connect a tachometer or the M.U.T.-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. Leave the hood open.
9. Start the engine.
10.With the engine running at 2,500 r/min, turn the
headlamps and other lamps on and off to adjust
the alternator load so that the value displayed on
the ammeter is slightly above 30 A.
Adjust the engine speed by gradually decreasing
it until the value displayed on the ammeter is 30
A. Take a reading of the value displayed on the
voltmeter at this time.
Limit: maximum 0.3 V
NOTE: When the alternator output is high and the
value displayed on the ammeter does not
decrease until 30 A, set the value to 40 A. Read
the value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is maxi
-
mum 0.4 V.
11.If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction in
the alternator output wire, so check the wiring
between the alternator "B" terminal and the
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
12.After the test, run the engine at idle.
13.Turn off all lamps and the ignition switch.
14.Remove the tachometer or the M.U.T.-II/III.
15.Disconnect the negative battery cable.
16.Disconnect the ammeter and voltmeter.
17.Connect the negative battery cable.

AC303827
65
84
9
7
22 ± 4 N·m
23 ± 3 N·m
8.8 ± 1.0 N·m 44 ± 10 N·m
AB
13 ± 3 N·m
Removal steps
4.Battery wiring harness clamp
5.Engine oil pressure switch
connection
6.Alternator connector and terminal
<>7.Alternator assembly
8.Water pump pulley
9.Alternator brace
CHARGING SYSTEM
ENGINE ELECTRICAL16-14
REMOV
A L SER V ICE POINT
<> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBL
Y REMOV A L
Remove the shift cable bracket inst allation bolt with
the shif
t ca ble inst alled o n the shif t cable bracket,
and remove
the shif t cable and shif t cable bracket
assembly fro
m the transmission.
<> ALTERNA T O R ASSEMBL Y
REMOV
A L
AC302930 AB
Alternator
assemnly
Af
ter re moving the alternato r assembly inst allation
bolt
s a nd nu t, move the alte rnator a sse mbly to the
transmission side an
d remove the alternato r assem
-
bly upward the engine roo m thr ough th e clearan ce
between t
he tran smission and the inlet ma nifold.