Mitsubishi Lancer Evolution IX 2006 Instruction manual

14-1
GROUP 14
ENGINE COOLING
CONTENTS
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

GENERAL INFORMATION
ENGINE COOLING
14-2
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 cool-
ant and circulates it throughout the engine. If the
engine 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 drive belt from the crankshaft. The radi-
ator is the corrugated fin, down flow type. The cool-
ing fan is controlled by the fan controller and
engine-ECU depend on driving conditions.
Item Specification
Radiator Performance kJ/h 216,700
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 °C80 ±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

SPECIAL TOOLS
ENGINE COOLING 14-3
SPECIAL TOOLS
M1141000600592
Tool Number Name Use
MB991223
A
D
C
B
AZ
DO NOT USE
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
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
pressure inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection
MB992006
MB992006 Extra fine probe Making voltage and
resistance measurement
during troubleshooting
MB991871
MB991871 LLC changer Coolant refilling
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE
SYMPTOMS
M1141005600434
Trouble symptom Inspection
procedure No.
Reference page
Cooling fan does not operate 1P.14-4
Cooling fan does not change speed or does not stop 2P.14-10

TROUBLESHOOTING
ENGINE COOLING
14-4
INSPECTION PROCEDURE FOR
TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1: Cooling fan does 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 : Grey R : Red P : Pink V : Violet PU : Purple
INPUT SIGNAL
· A/C SWITCH
· ENGINE
COOLANT
TEMPERATURE
SENSOR
· VEHICLE SPEED
SENSOR
ENGINE-
ECU
ENGINE
CONTROL
RELAY
SMOOTHING
CIRCUIT
FIELD EFFECT
TRANSISTOR
CIRCUIT
INPUT SIGNAL
PROCESSING
DRIVE
CIRCUIT
TEMPERATURE
DETECTION
CURRENT
DETECTION
RADIATOR
FAN
MOTOR
FAN CONTROLLER
ENGINE
CONTROL
SYSTEM
FUSIBLE
LINK 2
FAN
CONTROL
RELAY
AC505138
Cooling fan drive circuit <L.H. drive vehicles>
AB

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
INPUT SIGNAL
· A/C SWITCH
· ENGINE
COOLANT
TEMPERATURE
SENSOR
· VEHICLE SPEED
SENSOR
ENGINE-
ECU
ENGINE
CONTROL
RELAY
SMOOTHING
CIRCUIT
FIELD EFFECT
TRANSISTOR
CIRCUIT
INPUT SIGNAL
PROCESSING
DRIVE
CIRCUIT
TEMPERATURE
DETECTION
CURRENT
DETECTION
RADIATOR
FAN
MOTOR
FAN CONTROLLER
ENGINE
CONTROL
SYSTEM
FUSIBLE
LINK 2
FAN
CONTROL
RELAY
AC505139
Cooling fan drive circuit <R.H. drive vehicles>
AB
TROUBLESHOOTING
ENGINE COOLING 14-5
CIRCUIT OPERATION
•The fan controller is powered from fusible link
No.2.
•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.

TROUBLESHOOTING
ENGINE COOLING
14-6
TECHNICAL DESCRIPTION
•The cause could be a malfunction of the fan con-
troller 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.
AC210859
Connector: A-17
A-17 (GR)
AD
Fan controller
Component side
(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.
STEP 3. Check for harness damage between
fusible link No.2 and fan control relay connector
A-09X terminal 4.
AC310900AC
Fusible link (2)
Fusible link (2) And
Connector: A-09X
A-09X
3
1
42
Relay box
side
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.
AC310900AB
Connector: A-09X
A-09X
3
1
42
Relay box
side
AC210859
Connector: A-17
A-17 (GR)
AD
Fan controller
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.

TROUBLESHOOTING
ENGINE COOLING 14-7
STEP 5. Check for harness damage between J/C
(6) C-105 and fan control relay connector A-09X.
NOTE:
AC210877AC
Connector: A-13 <LHD>
A-13 (B)
AC310903AB
Connector: C-31 <RHD>
C-31
AC310901AB
Connector: C-105 <LHD>
C-105
AC310902AB
Connector: C-105 <RHD>
C-105
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.
AC310900AB
Connector: A-09X
A-09X
3
1
42
Relay box
side
AC310901AB
Connector: C-105 <LHD>
C-105
AC310902AB
Connector: C-105 <RHD>
C-105
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.
AC310900AB
Connector: A-09X
A-09X
3
1
42
Relay box
side

TROUBLESHOOTING
ENGINE COOLING
14-8
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.
AC210859
Connector: A-17
A-17 (GR)
AD
Fan controller
Component side
(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.
AC210859
Connector: A-17
A-17 (GR)
AD
Fan controller
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.
STEP 10. Measure the output circuit voltage at
engine-ECU connector C-121 terminal 18 by
backprobing.
AC505254
16
25
10
24
1
9
24
27
13
26
11
3
12
2829
1415
3031
1718
3332
6
20
5
19 21
35
34
8
23
7
22
JAE
AB
Connector: C-121 <LHD>
Harness side
C-121 (GR)
Engine-ECU
AC505255
16
25
10
24
1
9
24
27
13
26
11
3
12
2829
1415
3031
1718
3332
6
20
5
19 21
35
34
8
23
7
22
JAE
AB
Connector: C-121 <RHD>
Harness side
C-121 (GR)
Engine-ECU
(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.
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.

TROUBLESHOOTING
ENGINE COOLING 14-9
STEP 11. Check the harness wire between
engine-ECU connector C-121 and fan controller
connector A-17.
NOTE:
AC210877AC
Connector: A-13 <LHD>
A-13 (B)
AC310903AB
Connector: C-31 <RHD>
C-31
If intermediate connector A-13 <LHD> terminal 2 and
intermediate connector C-31 <RHD> terminal 14 is
damaged, repair or replace it. Refer to GROUP 00,
How to Use Troubleshooting/Inspection Service
Points P.00-5.
AC505254 AC
Connector: C-121 <LHD>
C-121 (GR)
Engine-ECU
15
29
222123
3534
78
161819 1720
31
3233 30
56
11 10121314
262827 25
3
42
9
24
1
JAE
Component side
AC505255 AC
Connector: C-121 <RHD>
C-121 (GR)
Engine-ECU
15
29
222123
3534
78
161819 1720
31
3233 30
5
6
11 10121314
262827 25
3
42
9
24
1
JAE
Component side
AC210859
Connector: A-17
A-17 (GR)
AD
Fan controller
Component side
Q: Are the harness wires between engine-ECU
connector C-121 terminal 18 and fan controller
connector A-17 terminal 2 damaged?
YES : Repair or replace them, then go to Step 13.
NO : Go to Step 12.

TROUBLESHOOTING
ENGINE COOLING
14-10
STEP 12. Check the fan controller at engine-ECU
connector C-121.
AC505254
16
25
10
24
1
9
24
27
13
26
11
3
12
2829
1415
3031
1718
3332
6
20
5
19 21
35
34
8
23
7
22
JAE
AB
Connector: C-121 <LHD>
Harness side
C-121 (GR)
Engine-ECU
AC505255
16
25
10
24
1
9
24
27
13
26
11
3
12
2829
1415
3031
1718
3332
6
20
5
19 21
35
34
8
23
7
22
JAE
AB
Connector: C-121 <RHD>
Harness side
C-121 (GR)
Engine-ECU
(1) Do not disconnect engine-ECU connector C-121.
(2) Pull out terminal No.18.
(3) Turn the ignition switch to the "ON" position.
Q: Does the cooling fan motor operate?
YES : Replace the engine-ECU. Then go to Step
13.
NO : Replace the fan controller. Then go to Step
13.
STEP 13. Check the symptoms.
Q: Does the cooling fan operate correctly?
YES : The procedure is complete.
NO : Return to Step 1.
INSPECTION PROCEDURE 2: Cooling fan does not change speed or does not stop
NOTE: If the engine coolant temperature reaches 110 ° C or higher, the cooling fan control runs the cooling fan
for up to 5 minutes even after the ignition switch is turned to the "LOCK" (OFF) position (the fan stops its rota-
tion when the engine coolant temperature decreases to 110 ° C or lower).
COOLING FAN DRIVE CIRCUIT
Refer to P.14-4.
CIRCUIT OPERATION
•The fan controller is powered from fusible link
No.2.
•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.