Mitsubishi Lancer Evolution IX 2006 Workshop Manual

GROUP 14

ENGINE COOLING

CONTENTS

14-1

GENERAL INFORMATION . . . . . . . . 14-2

SERVICE SPECIFICATIONS. . . . . . . 14-2

LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2

SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-2

SPECIAL TOOLS. . . . . . . . . . . . . . . . 14-3

TROUBLESHOOTING . . . . . . . . . . . . 14-3

ON-VEHICLE SERVICE. . . . . . . . . . . 14-15

ENGINE COOLANT LEAK CHECK . . . . . . 14-15

RADIATOR CAP PRESSURE CHECK. . . . 14-15

ENGINE COOLANT REPLACEMENT . . . . 14-15

CONCENTRATION MEASUREMENT . . . . 14-16

FAN CONTROLLER CHECK . . . . . . . . . . . 14-16

FAN CONTROL RELAY CONTINUITY

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17

COOLING FAN MOTOR CHECK . . . . . . . . 14-17

THERMOSTAT . . . . . . . . . . . . . . . . . . 14-18

REMOVAL AND INSTALLATION . . . . . . . . 14-18

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-19

WATER PUMP . . . . . . . . . . . . . . . . . . 14-20

REMOVAL AND INSTALLATION . . . . . . . . 14-20

WATER HOSE AND WATER PIPE . . 14-22

REMOVAL AND INSTALLATION . . . . . . . . 14-22

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-23

RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-24

REMOVAL AND INSTALLATION . . . . . . . . 14-24

14-2

ENGINE COOLING

GENERAL INFORMATION

GENERAL INFORMATION

M1141000100456

The 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 circu
lation type in which the water pump pressurizes cool­ant and circulates it throughout the engine. If the
engine coolant temperature exceeds the prescribed
temperature, the thermostat opens to circulate the

Item Specification

Radiator Performance kJ/h 216,700

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 drive belt from the crankshaft. The radi
ator is the corrugated fin, down flow type. The cool­ing fan is controlled by the fan controller and
engine-ECU depend on driving conditions.

SERVICE SPECIFICATIONS

M1141000300483

Item Standard value Limit

Radiator cap pressure kPa 93 − 123 Minimum 83

Range of coolant antifreeze concentration of radiator % 30 − 60 -

Fan controller input voltage V Ignition switch: "ON" Battery positive voltage -

-

Fan controller output voltage V A/C switch: "OFF" 1 or less -

A/C switch: "ON" Repeat steps 1) and 2).

1) 8.2 ± 2.6

2) Battery positive voltage
± 2.6

Thermostat Valve opening temperature of thermostat °C 80 ± 1.5 -

Full-opening temperature of thermostat °C 93 -

Valve lift mm 9.5 or more -

-

LUBRICANT

M1141000400424

Item Specified lubricant Quantity L

Engine coolant (including
reserve tank)

DIA QUEEN SUPER LONG LIFE COOLANT or equivalent 6.0

SEALANT

M1141000500658

Item Specified sealant Remark

Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent Drying sealant

ENGINE COOLING

SPECIAL TOOLS

SPECIAL TOOLS

Tool Number Name Use

A

MB991223

A: MB991219
B: MB991220
C: MB991221
D: MB991222

B

C

Harness set

A: Check harness
B: LED harness
C: LED harness

adapter

D: Probe

Making voltage and
resistance measurement
during troubleshooting

A: Connector pin contact

B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester

14-3

M1141000600592

pressure inspection

connection

D

DO NOT USE

MB991223

AZ

MB992006 Extra fine probe Making voltage and

MB992006

MB991871 LLC changer Coolant refilling

MB991871

TROUBLESHOOTING

INSPECTION CHART FOR TROUBLE
SYMPTOMS

Trouble symptom Inspection

Cooling fan does not operate 1

Cooling fan does not change speed or does not stop 2

M1141005600434

procedure No.

resistance measurement
during troubleshooting

Reference page

P.14-4

P.14-10

14-4

ENGINE COOLING

TROUBLESHOOTING

INSPECTION PROCEDURE FOR
TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1: Cooling fan does not operate

Cooling fan drive circuit <L.H. drive vehicles>

INPUT SIGNAL

· A/C SWITCH

· ENGINE
COOLANT
TEMPERATURE
SENSOR

· VEHICLE SPEED
SENSOR

ENGINE­ECU

FUSIBLE

2

LINK

SMOOTHING
CIRCUIT

ENGINE
CONTROL
SYSTEM

ENGINE
CONTROL
RELAY

FAN
CONTROL
RELAY

INPUT SIGNAL
PROCESSING

TEMPERATURE
DETECTION

CURRENT
DETECTION

FAN CONTROLLER

Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

DRIVE
CIRCUIT

FIELD EFFECT
TRANSISTOR
CIRCUIT

RADIATOR
FAN
MOTOR

AC505138

AB

ENGINE COOLING

TROUBLESHOOTING

Cooling fan drive circuit <R.H. drive vehicles>

14-5

INPUT SIGNAL

· A/C SWITCH

· ENGINE
COOLANT
TEMPERATURE
SENSOR

· VEHICLE SPEED
SENSOR

ENGINE­ECU

FUSIBLE

2

LINK

SMOOTHING
CIRCUIT

ENGINE
CONTROL
SYSTEM

ENGINE
CONTROL
RELAY

FAN
CONTROL
RELAY

INPUT SIGNAL
PROCESSING

TEMPERATURE
DETECTION

DRIVE
CIRCUIT

CURRENT
DETECTION

FIELD EFFECT
TRANSISTOR
CIRCUIT

FAN CONTROLLER

Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple

CIRCUIT OPERATION

• The fan controller is powered from fusible link
No.2.

RADIATOR
FAN
MOTOR

AC505139

AB

• The engine-ECU judges the required revolution
speed of cooling fan motor using the input signals
transmitted from A/C switch, vehicle speed sen
sor and engine coolant temperature sensor. The
engine-ECU activates the fan controller to drive
the cooling fan motor.

-

14-6

ENGINE COOLING

TROUBLESHOOTING

TECHNICAL DESCRIPTION

• The cause could be a malfunction of the fan con­troller power supply or earth circuit.

• The cause could also be a malfunction of the fan
controller or the engine-ECU.

TROUBLESHOOTING HINTS

• Malfunction of fusible link

• Malfunction of fan control relay

• Malfunction of cooling fan motor

• Malfunction of fan controller

• Malfunction of engine-ECU

• Damaged wiring harness or connector

DIAGNOSIS

STEP 1. Check the circuit at fan controller
connector A-17 terminal 3.

Connector: A-17

Fan controller

STEP 3. Check for harness damage between
fusible link No.2 and fan control relay connector
A-09X terminal 4.

Fusible link (2) And
Connector: A-09X

A-09X

3

2

4

1

Relay box
side

Fusible link (2)

AC310900

AC

Q: Are the harness wires between fusible link No.2

and fan control relay connector A-09X damaged?
YES : Repair or replace them, then go to Step 13.
NO : Go to Step 4.

STEP 4. Check for harness damage between fan
control relay connector A-09X terminal 2 and fan
controller connector A-17 terminal 3.

A-17 (GR)

Component side

AC210859

AD

(1) Disconnect fan controller connector A-17, and

measure at the harness side connector.

(2) Measure the voltage between terminal No.3 and

earth.

• When the ignition switch is turned to the "ON"
position, voltage should measure battery pos
itive voltage.

Q: Is the voltage battery positive voltage when the

ignition switch is turned to the "ON" position?
YES : Go to Step 7.
NO : Go to Step 2.

STEP 2. Check the fan control relay.

Refer to P.14-17.

Q: Is the fan control relay in good condition?

YES : Go to Step 3.
NO : Replace it, then go to Step 1.

Connector: A-09X

A-09X

3

4

1

Relay box
side

AC310900

Connector: A-17

-

Fan controller

A-17 (GR)

Component side

Q: Are the harness wires between fan control relay

connector A-09X terminal 2 and fan controller
connector A-17 terminal 3 damaged?
YES : Repair or replace them, then go to Step 13.
NO : Go to Step 5.

AC210859

2

AB

AD

ENGINE COOLING

TROUBLESHOOTING

14-7

STEP 5. Check for harness damage between J/C
(6) C-105 and fan control relay connector A-09X.

NOTE:

Connector: A-13 <LHD>

A-13 (B)

AC210877

Connector: C-31 <RHD>

C-31

AC

Connector: A-09X

Connector: C-105 <LHD>

Connector: C-105 <RHD>

A-09X

4

Relay box
side

AC310900

C-105

AC310901

3

2

1

AB

AB

AC310903

AB

Connector: C-105 <LHD>

C-105

AC310901

AB

Connector: C-105 <RHD>

C-105

AC310902

AB

After inspecting intermediate connector A-13 <LHD>
terminal 3, intermediate connector C-31 <RHD> ter

­minal 12 and J/C (6) C-105 terminal 28, 33 inspect
the wires. If intermediate connector A-13 <LHD>,
C-31<RHD> and J/C (6) C-105 are damaged, repair
or replace them. Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points

P.00-5.

C-105

AC310902

AB

Q: Are the harness wires between J/C (6) C-105

terminal 28 and fan control relay connector A-09X
terminal 1 damaged?
YES : Repair or replace them, then go to Step 13.
NO : Go to Step 6.

STEP 6. Check for harness damage between fan
control relay connector A-09X terminal 3 and
earth.

Connector: A-09X

A-09X

3

2

4

1

Relay box
side

AC310900

AB

14-8

ENGINE COOLING

TROUBLESHOOTING

Q: Are the harness wires between fan control relay

connector A-09X terminal 3 and earth damaged?
YES : Repair or replace them, then go to Step 13.
NO : Go to Step 7.

STEP 7. Check the cooling fan motor.

Refer to P.14-17.

Q: Is the cooling fan motor in good condition?

YES : Go to Step 8.
NO : Replace it, then go to Step 13.

STEP 8. Check the circuit at fan controller
connector A-17 terminal 1.

Connector: A-17

Fan controller

A-17 (GR)

STEP 10. Measure the output circuit voltage at
engine-ECU connector C-121 terminal 18 by
backprobing.

Connector: C-121 <LHD>

Engine-ECU

C-121 (GR)

1924

10

11312

24

25

Connector: C-121 <RHD>

JAE

16

13

1415

26

1718

2829

27

3031

Harness side

6205

19 21

3332

8237

22

35

34

AC505254

AB

Component side

AC210859

AD

(1) Disconnect fan controller connector A-17, and

measure at the harness side connector.

(2) Measure the resistance between terminal No.1

and earth.

• The resistance should measure less than 2
ohms.

Q: Is the resistance less than 2 ohms?

YES : Go to Step 10.
NO : Go to Step 9.

STEP 9. Check the harness wire between fan
controller connector A-17 and earth.

Connector: A-17

Fan controller

A-17 (GR)

Engine-ECU

C-121 (GR)

1924

10

11312

24

25

JAE

16

13

1415

26

2829

27

1718
3031

6205

19 21

3332

8237

22

35

34

Harness side

AC505255

AB

(1) Do not disconnect engine-ECU connector C-121.
(2) Start the engine and allow it to idle.
(3) Turn the A/C switch to the "ON" position.
(4) Measure the voltage between terminal No.18 and

earth by backprobing.

• The voltage should measure 0.7 volt or more
when the cooling fan is operating.

Component side

Q: Are the harness wires between fan controller

connector A-17 and earth damaged?
YES : Repair or replace them, then go to Step 13.
NO : Go to Step 10.

AC210859

AD

Q: Is the voltage 0.7 volt or more when the cooling fan

is operating?
YES : Go to Step 12.
NO : Go to Step 11.