relay MITSUBISHI LANCER EVOLUTION 2007 Service Owners Manual

MPI -On-vehicle Service13A-138
RESISTOR (FOR INJECTOR) CHECK
1. Disconnect the resistor connector.
2. Measure the resistance between each terminal.
Standard value:
Measurement terminalResistanceΩ
1-35.8 - 6.2 (at 20_C)
4-3
5-3
6-3
IDLE SPEED CONTROL SERVO (STEPPER
MOTOR) CHECK
Checking the Operation Sound
1. Check that the engine coolant temperature is 20_Cor
below.
NOTE
Disconnecting the engine coolant temperature sensor
connector and connecting the harness-side of the
connector to another engine coolant temperature sensor
that is at 20_C or below is also okay.
2. Check that the operation sound of the stepper motor
can be heard after the ignition is switched “ON” position.
(but without starting the engine.)
3. If the operation sound cannot be heard, check the stepper
motor’s activation circuit.
If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engine-ECU.
Resistor
(for injector)
Fuel pump relay 3
1
42
53
6
Equipment
side connector
Idle speed control
servo (stepper motor) 1
42
53
6

MPI -Engine Control Resistor, Relay13A-146
ENGINE CONTROL RESISTOR, RELAY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DHarness Connector Connection
213
4
5.0¶1.0 N·m
5.0±1.0N·m5.0±1.0N·m
2.5±0.5N·m
5.0±1.0N·m
AYC relay
4 2
5.0±1.0N·m
5.0±1.0N·mAYC relay5.0±1.0N·m5.0±1.0N·m
2.5±0.5N·m13


Removal steps
DAYC relay
1. Fuel pump relay
2. Injector resistor
3. Bracket
4. Fuel pump resistor

14-1
ENGINE COOLING
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANT 2...............................
SEALANT 2..................................
SPECIAL TOOLS 3...........................
TROUBLESHOOTING 3.......................
ON-VEHICLE SERVICE 6.....................
Engine Coolant Leak Checking 6................
Radiator Cap Opening Pressure Check 6........Engine Coolant Replacement 6..................
Concentration Measurement 7...................
Radiator Fan Relay Continuity Check 8..........
Radiator Fan Controller Check 8................
Radiator Fan Motor Check 10...................
THERMOSTAT 11............................
WATER PUMP 13............................
WATER HOSE AND WATER PIPE 14..........
RADIATOR 15................................

ENGINE COOLING -Special Tools/Troubleshooting14-3
SPECIAL TOOLS
ToolNumberNameUse
A
B
C
DMB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: ProbeDMeasurement of terminal voltage
DInspection of radiator fan controller
A: Connector pin contact pressure
inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester connection
MB991658Test harnessInspection of radiator fan controller
APS
MB991791Throttle cotrollerInspection of radiator fan controller
[Use the accelerator pedal position sensor
disconnected from harness.]
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomsInspection procedure
No.Reference page
Radiator fan does not operate.114-3
Radiator fan does not change speed or stop.214-5
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
Radiator fan does not operate.
Probable cause
Failure may occur on the power supply of the radiator fan controller and the
earth circuit.
Failure may also occur on the radiator fan controller and engine-ECU.DMalfunction of fusible link
DMalfunction of radiator fan relay
DMalfunction of radiator fan controller
DMalfunction of radiator fan motor
DMalfunction of engine-ECU
DMalfunction of harness, connector

ENGINE COOLING -Troubleshooting14-4
Measure at the engine-ECU connector C-126.
DConnect the connector.
DPull out the teminal No.21 to disconnect it
(Ignition switch: ON)
OK:Radiator fan motor is rotated.
YES
Engine-ECU terminal voltage check
(Refer to GROUP 13A - Troubleshooting.)NO
Replace the radiator fan controller.
NG
Repair
OK
NG
Repair
OK
Check the harness wire between radiator fan controller and
engine-ECU.
Measure at the engine-ECU connector C-126.

DConnect the connector.
DVoltage between terminal 21 and body earth
(Engine: Idling, engine coolant temperature: 95_C or more)
OK:0.7 V or more

DConnect the connector.
DVoltage between terminal 21 and body earth
(Engine: Idling, A/C switch: ON)
OK:0.7 V or more (When A/C compressor is operating)NG
(2) NGCheck the harness wire between radiator fan controller and
body earth, and repair if necessary.
OK
Measure at the radiator fan controller connector A-21.
DDisconnect the connector, and measure at the harness
side.
(1) Voltage between terminal 3 and body earth
(Ignition switch: ON)
OK:Battery voltage
(2) Continuity between terminal 1 and body earth
OK:Continuity(1) NGCheck the harness wire between radiator fan controller and
radiator fan relay, and repair if necessary.
(3) NGCheck the harness wire between radiator fan relay and body
earth, and repair if necessary.
(2) NGCheck the harness wire between radiator fan relay and engine
control relay, and repair if necessary.
OK
Measure at the radiator fan control relay connector A-09X.
DRemove the relay, and measure at the relay box side.
(1) Voltage between terminal 4 and body earth
OK:Battery voltage
(2) Voltage between terminal 1 and body earth
(Ignition switch: ON)
OK:Battery voltage
(3) Continuity between terminal 3 and body earth
OK:Continuity(1) NGCheck the harness wire between radiator fan relay and fusible
link (2), and repair if necessary.
DFusible link (2) check
DRadiator fan relay continuity check
(Refer to P.14-8.)
DRadiator fan motor check (Refer to P.14-10.)NG
Replace
OK
OK
Engine-ECU terminal voltage check
(Refer to GROUP 13A - Troubleshooting.)
Check the following connectors:
C-126, A-13, A-21
C-126, C-136, A-21
NG
Check the trouble symptoms.

ENGINE COOLING -Troubleshooting14-5
Inspection Procedure 2
Radiator fan does not change speed or stop.
Probable cause
Radiator fan controller uses the signal from engine-ECU to control radiator fan
motor in a continously variable mode.DMalfunction of radiator fan relay
DMalfunction of radiator fan controller
DMalfunction of engine-ECU
DMalfunction of harness, connector
Measure at the engine-ECU connector C-126.
DConnect the connector.
DPull out the teminal No.21 to disconnect it
(Ignition switch: ON)
OK:Radiator fan motor is rotated.
DConnect the teminal No.21 to the body earth
(Ignition switch: ON)
OK:Radiator fan motor stop running.
YES
Engine-ECU terminal voltage check
(Refer to GROUP 13A - Troubleshooting.)NO
Replace the radiator fan controller.
OK
Radiator fan controller check (Refer to P.14-8.)NGReplace the radiator fan controller.
OK
Measure at the engine-ECU connector C-126.

DConnect the connector.
DVoltage between terminal 21 and body earth
(Engine: Idling, engine coolant temperature: 80_C or less)
OK:0 - 0.3 V
(Engine: Idling, engine coolant temperature: 95_C or more)
OK:0.7 V or more

DConnect the connector.
DVoltage between terminal 21 and body earth
(Engine: Idling, engine coolant temperature: 80_C or less)
OK:0 - 0.3 V
(Engine: Idling, A/C switch: ON)
OK:0.7 V or more (When A/C compressor is operating)NG
OK
DCheck the harness wire between radiator fan relay and
engine control relay.
DCheck the harness wire between radiator fan relay and
body earth.
DCheck the harness wire between radiator fan relay and
radiator fan controller.NG
Repair
NG
Replace
OK
OK
OK
Check the following connectors:
C-126, A-13, A-21
C-126, C-136, A-21
NG
Engine-ECU terminal voltage check
(Refer to GROUP 13A - Troubleshooting.)
Check the trouble symptoms.
NG
NG
Repair
Repair
Radiator fan relay continuity check (Refer to P.14-8.)
Check the harness wire between radiator fan controller and
engine-ECU.

ENGINE COOLING -On-vehicle Service14-8
RADIATOR FAN RELAY CONTINUITY CHECK
Battery voltageTerminal No.
1234
When current is not
supplied
When current is
supplied
RADIATOR FAN CONTROLLER CHECK

1. Remove the center under cover.
(Refer to GROUP 51 - Front Bumper.)
2. Insert the special tool at the back of the radiator fan
motor connector.
3. Connect the special tool to the circuit tester.
4. Disconnect the engine coolant temperature sensor
connector.
Air cleaner
Radiator fan
controller
MB991222
Circuit tester
Connector
rear view
Water outlet
fitting
Engine coolant
temperature
sensor

ENGINE ELECTRICAL -Charging System16-5
(6) Reconnect the negative battery cable.
(7) Connect a tachometer or the MUT-II.
(Refer to GROUP 11 - On-vehicle Service.)
(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: max. 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 max.
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 MUT-II.
(15)Disconnect the negative battery cable.
(16)Disconnect the ammeter and voltmeter.
(17)Connect the alternator output wire to the
alternator “B” terminal.
(18)Connect the negative battery cable.
OUTPUT CURRENT TEST
Charging warning lampVoltmeter
Ammeter
Ignition switch
Alternator relayLoad
Battery
Engine-ECUAlternatorFR
L
S
G
+ -+-
B

ENGINE AND EMISSION CONTROL -Emission Control System
Vacuum tank
Alternator
Purge control solenoid valve
17-10
EVAPORATIVE EMISSION CONTROL SYSTEM
GENERAL INFORMATION
The evaporative emission control system prevents
fuel vapours generated in the fuel tank from
escaping into the atmosphere.
Fuel vapours from the fuel tank flow through the
fuel tank pressure control valve and vapour
pipe/hose to be stored temporarily in the canister.
When driving the vehicle, fuel vapours stored in
the canister flow through the purge solenoid and
purge port and go into the intake manifold to be
sent to the combustion chamber.When the engine coolant temperature is low or
when the intake air quantity is small (when the
engine is at idle, for example), the engine control
unit turns the purge solenoid off to shut off the
fuel vapour flow to the intake manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also
stabilize the emission level.
SYSTEM DIAGRAM
BatteryIntake air
temperature sensor
Barometric pressure
sensor
Check
valve
Canister
Control
relay
Purge control
solenoid valve
(ON: Open)
Engine-ECUEngine coolant
temperature sensor Air flow sensor
COMPONENT LOCATION

ENGINE AND EMISSION CONTROL -Emission Control System17-13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
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 fromthe 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.DThe engine coolant temperature is low.
DThe engine is at idle.
DThe throttle valve is widely opened.
SYSTEM DIAGRAM
ON Throttle body
EGR control
solenoid valve
Engine
control
relay
Battery EGR valve
Crank angle sensor
Throttle position sensor Engine-ECU
Engine coolant
temperature sensor Air flow sensor