Engine Cooling - Evolution: Diagnosis Mitsubishi Lancer IX

TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure to find most of the engine cooling faults.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find and repair the malfunction by following the SYMPTOM CHART.
4. Verify that the malfunction is eliminated.

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1. STEP 1. Check for coolant leaks. WARNING: When pressure testing the cooling system, slowly release cooling system pressure to avoid getting burned by hot coolant. CAUTION: Be sure to completely clean away any moisture from the places checked. When the tester is removed, be careful not to spill any coolant. When installing and removing the tester and when testing, be careful not to deform the filler neck of the radiator. Check that the coolant level is up to the filler neck. Install a radiator tester and apply 160 kPa (23 psi) pressure, and then check for leakage from the radiator hose or connections. Q: Is leakage present from the radiator hose or connections? YES: Repair or replace the appropriate part, then go to Step 2. NO: There is no action to be taken.
2. STEP 2. Retest the system. Q: It there still coolant leakage? YES: Return to Step 1. NO: The procedure is complete.

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1. STEP 1. Remove the radiator cap and check for coolant contamination. Q: Is the coolant contaminated with rust and oil? YES: Replace it. Refer to «RADIATOR CAP PRESSURE CHECK»(ref-183212-S06926802592005081200000) . NO: There is no action to be taken. Go to Step 2.
2. STEP 2. Check the radiator cap valve opening pressure. NOTE: Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an improper reading. Use a cap adapter to attach the cap to the tester. Increase the pressure until the gauge indicator stops moving. Minimum limit: 83 kPa (12 psi) Standard value: 93 - 123 kPa (14 - 18 psi) Q: Does the reading remain at or above the minimum limit? YES: Go to Step 3. NO: Replace the radiator cap. Then go to Step 5 .
3. STEP 3. Check thermostat operation. Refer to «>>C<< RADIATOR UPPER HOSE CONNECTION»(ref-183212-S28501068532005081200000) . Q: Does the thermostat operate correctly? YES: Go to Step 4. NO: Replace the thermostat, then go to Step 5 .
4. STEP 4. Check the drive belt for slippage or damage. Refer to «SPECIFICATIONS & DRIVE BELT ROUTING - EVOLUTION»(ref-166725) . Q: Is the drive belt loose or damaged? YES: Replace the drive belt, then go to Step 5. NO: There is no action to be taken.
5. STEP 5. Retest the system. Check the engine coolant temperature. Q: Is the engine coolant temperature abnormally high? YES: Return to Step 2. NO: The procedure is complete.

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TROUBLESHOOTING HINTS

1. Malfunction of fusible link
2. Malfunction of fan control relay
3. Malfunction of cooling fan motor
4. Malfunction of fan control module
5. Malfunction of ECM
6. Damaged wiring harness or connector

DIAGNOSIS

Required Special Tool

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1. STEP 1. Check the circuit at fan control module connector A-17 terminal 3. Disconnect fan control module connector A-17, and measure at the harness side connector. Measure the voltage between terminal number 3 and ground. When the ignition switch is turned to the "ON" position, voltage should measure battery positive voltage. Q: Is the voltage when the ignition switch is turned to the "ON" position? YES: Go to Step 7 . NO: Go to Step 2.
2. STEP 2. Check the fan control relay. Refer to «FAN CONTROL RELAY CONTINUITY CHECK»(ref-183212-S29625615722005081200000) . Q: Is the fan control relay in good condition? YES: Go to Step 3. NO: Replace it, then go to Step 1 .
3. STEP 3. Check for harness damage between fusible link number 2 and fan control relay connector A-09X terminal 4. Q: Are the harness wires between fusible link number 2 and fan control relay connector A-09X damaged? YES: Repair or replace them, then go to Step 13 . NO: Go to Step 4.
4. STEP 4. Check for harness damage between fan control relay connector A-09X terminal 2 and fan control module connector A-17 terminal 3. Q: Are the harness wires between fan control relay connector A-09X terminal 2 and fan control module connector A-17 terminal 3 damaged? YES: Repair or replace them, then go to Step 13 . NO: Go to Step 5.
5. STEP 5. Check for harness damage between joint connector (6) C-105 and fan control relay connector A-09X. NOTE: After inspecting intermediate connector A-13 terminal 3 and joint connector (6) C-105 terminal 28, 33 inspect the wires. If intermediate connector A-13 and joint connector (6) C-105 are damaged, repair or replace them. Q: Are the harness wires between joint connector (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.
6. STEP 6. Check for harness damage between fan control relay connector A-09X terminal 3 and ground damaged? YES: Repair or replace them, then go to Step 13 . NO: Go to Step 7.
7. STEP 7. Check the cooling fan motor. Refer to «FAN CONTROL RELAY CONTINUITY CHECK»(ref-183212-S29625615722005081200000) . Q: Is the cooling fan motor in good condition? YES: Go to Step 8. NO: Replace it, then go to Step 13 .
8. STEP 8. Check the circuit at fan control module connector A-17 terminal 1. Disconnect fan control module connector A-17, and measure at the harness side connector. Measure the resistance between terminal number 1 and ground. 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.
9. STEP 9. Check the harness wire between fan control module connector A-17 and ground. Q: Are the harness wires between fan control module connector A-17 and ground damaged? YES: Repair or replace them, then go to Step 13 . NO: Go to Step 10.
10. STEP 10. Measure the output circuit voltage at ECM connector C-121 terminal 21 by backprobing. Do not disconnect ECM connector C-121. Start the engine and allow it to idle. Turn the A/C switch to the "ON" position. Measure the voltage between terminal number 21 and ground 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.
11. STEP 11. Check the harness wire between ECM connector C-121 and fan control module connector A-17. NOTE: If intermediate connector A-13 terminal 2 is damaged, repair or replace it. Q: Are the harness wires between ECM connector C-121 terminal 21 and fan control module connector A-17 terminal 2 damaged? YES: Repair or replace them, then go to Step 13 . NO: Go to Step 12.
12. STEP 12. Check the fan control module at ECM connector C-121. Do not disconnect ECM connector C-121. Pull out terminal number 21. Turn the ignition switch to the "ON" position. Q: Does the cooling fan motor operate? YES: Replace the ECM. Then go to Step 13. NO: Replace the fan control module. Then go to Step 13.
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 4: Cooling Fan does not Change Speed or does not Stop

Note. If the engine coolant temperature reaches 110°C (230°F) 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 rotation when the engine coolant temperature decreases to 110°C (230°F) or lower.]

Cooling Fan Drive Circuit

Refer to INSPECTION PROCEDURE 3: COOLING FAN DOES NOT OPERATE .

1. Malfunction of fan control relay
2. Malfunction of fan control module
3. Malfunction of ECM

Required Special Tool

1. MB991223: Harness Set

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1. STEP 1. Check the fan control relay. Refer to «FAN CONTROL RELAY CONTINUITY CHECK»(ref-183212-S29625615722005081200000) . Q: Is the fan control relay in good condition? YES: Go to Step 2. NO: Replace the part, then go to Step 8 .
2. STEP 2. Check the harness wire between fan control relay connector A-09X terminal 2 and fan control module connector A-17 terminal 3. Q: Are the harness wire between fan control relay connector A-09X and fan control module connector A-17 damaged? YES: Repair or replace the part, then go to Step 6 . NO: Go to Step 3.
3. STEP 3. Measure the output circuit voltage at ECM connector C-121 terminal 21 by backprobing. Do not disconnect ECM connector C-121. Start the engine and allow it to idle. Measure the voltage between terminal number 21 and ground by backprobing. The voltage should measure less than 0.3 volt when the cooling fan is not operating. Q: Is the voltage less than 0.3 volt when the cooling fan is not operating? YES: Go to Step 6 . NO: Go to Step 4.
4. STEP 4. Measure the output circuit voltage at ECM connector C-121 terminal 21 by backprobing. Do not disconnect ECM connector C-121. Start the engine and allow it to idle. Turn the A/C switch to the "ON" position. Measure the voltage between terminal number 21 and ground 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 6 . NO: Go to Step 5.
5. STEP 5. Check the harness wire between ECM connector C-121 and fan control module connector A-17. NOTE: If intermediate connector A-13 terminal 2 is damaged, repair or replace it. Q: Are the harness wires between ECM connector C-121 terminal 21 and fan control module connector A-17 terminal 2 damaged? YES: Repair or replace them, then go to Step 8 . NO: Go to Step 6.
6. STEP 6. Check the fan control module at ECM connector C-121. Do not disconnect ECM connector C-121. Pull out terminal number 21. Turn the ignition switch to the "ON" position. Q: Does the cooling fan motor operate? YES: Replace the ECM. Then go to Step 8 . NO: Go to Step 7.
7. STEP 7. Check the fan control module at ECM connector C-121. Disconnect ECM connector C-121. Pull out terminal number 21. Connect terminal number 21 to the body ground. Turn the ignition switch to the "ON" position. Q: Does the cooling fan motor stop running? YES: Replace the ECM. Then go to Step 8. NO: Replace the fan control module. Then go to Step 8.
8. STEP 8. Check the symptoms. Q: Does the cooling fan operate correctly? YES: The procedure is complete. NO: Return to Step 1.

ENGINE COOLANT CONCENTRATION TEST

Refer to RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .