Cooling - Lancer Evolution: Diagnosis Mitsubishi Lancer X

TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy.

If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find an engine cooling faults.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart.
4. Verify that the malfunction is eliminated.

SYMPTOM CHART

SYMPTOM CHART

Scheme 2

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.

Scheme 3

1. STEP 1. Remove the radiator cap and check for coolant contamination. Q: Is the coolant contaminated with rust and oil? YES : Replace the coolant (Refer to «ENGINE COOLANT CHANGE»(ref-289378-S13767163152008063000000) ). Then go to Step 5 . 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 «INSPECTION»(ref-289378-S09443780532008063000000) . Q: Does the thermostat operate correctly? YES : Go to Step 4. NO : Replace the thermostat (Refer to «REMOVAL AND INSTALLATION»(ref-289378-S40441559362008063000000) ). Then go to Step 5 .
4. STEP 4. Check the drive belt for slippage or damage. Refer to «DRIVE BELTS (CHECK CONDITION)»(ref-289379-S31530089682008063000000) . Q: Is the drive belt loose or damaged? YES : Adjust or 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.

Scheme 4

Scheme 5

TROUBLESHOOTING HINTS

1. Malfunction of CAN bus line
2. Malfunction of MFI system
3. Malfunction of ETACS system
4. Damaged wiring harness or connector
5. Malfunction of fusible link number 28
6. Malfunction of fusible link number 29
7. Malfunction of radiator fan relay
8. Malfunction of condenser fan relay
9. Malfunction of fan control relay
10. Malfunction of radiator fan motor
11. Malfunction of condenser fan motor
12. Malfunction of ECM
13. Malfunction of ETACS-ECU

DIAGNOSTIC PROCEDURE

Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V.C.I. MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A
2. MB991223: Harness Set
3. MB992006: Extra Fine Probe

Scheme 6

Scheme 7

1. STEP 1. Using scan tool MB991958, check the CAN bus line diagnostics. Use scan tool to diagnose the CAN bus line (Refer to «EXPLANATION ABOUT THE SCAN TOOL CAN BUS DIAGNOSTICS»(ref-289394-S42115356292008063000000) ). Q: Is the diagnostic trouble code set? YES : Go to Step 2. NO : Repair the CAN bus line (Refer to «CAN BUS DIAGNOSTIC TABLE»(ref-289394-S27719724372008063000000) ). Then go to Step 22 .
2. STEP 2. Using scan tool MB991958, check the MFI system actuator test. Using scan tool to check the MFI system actuator test (Refer to «DIAGNOSTIC FUNCTION»(ref-289380-S06390723722008063000000) ). Item 14: Cooling fan (Refer to «ACTUATOR TEST REFERENCE TABLE»(ref-289380-S16746442482008063000000) ) Q: Is the check result normal? YES : Go to Step 21 . NO : Go to Step 3.
3. STEP 3. Using scan tool MB991958, read the MFI system diagnostic trouble code (DTC). Using scan tool to read the MFI system DTC (Refer to «DIAGNOSTIC FUNCTION»(ref-289380-S06390723722008063000000) ). Q: Is any DTC set? YES : Repair the MFI system (Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-289380-S08258481512008063000000) ). Then go to Step 22 . NO : Go to Step 4.
4. STEP 4. Using scan tool MB991958, read the ETACS system diagnostic trouble code (DTC). Using scan tool to read the ETACS system DTC (Refer to «DIAGNOSTIC FUNCTION»(ref-289392-S39495686092008063000000) ). Q: Is any DTC set? YES : Repair the ETACS system (Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-289392-S29242288832008063000000) ). Then go to Step 22 . NO : Go to Step 5.
5. STEP 5. Measure the voltage at ETACS-ECU connector C-312. Disconnect the ETACS-ECU connector C-312, and measure at front wiring harness connector side. Turn the ignition switch to the "ON" position. Measure the voltage between terminal 2 and ground, between terminal 8 and body ground, and between terminal 9 and body ground. OK: System voltage Turn the ignition switch to the "LOCK" (OFF) position. Connect the ETACS-ECU connector C-312. Q: Is the check result normal? YES : Go to Step 11 . NO : Go to Step 6.
6. STEP 6. Check the radiator fan relay connector A-35X, condenser fan relay connector A-36X, fan control relay connector A-37X, and ETACS-ECU connector C-312, for loose, corroded or damaged terminals, or terminals pushed back in the connector. Refer to «HARNESS CONNECTOR INSPECTION»(ref-289377-S30386868932008063000000) . Q: Is the connectors and terminals in good condition? YES : Go to Step 7. NO : Repair or replace damaged connectors. Then go to Step 22 .
7. STEP 7. Check the harness wire between fusible link number 28 and condenser fan relay connector A-36X terminal number 3, between fusible link number 28 and condenser fan relay connector A-36X terminal number 4, between condenser fan relay connector A-36X terminal number 4 and fan control relay connector A-37X terminal number 1, between fusible link number 29 and radiator fan relay connector A-35X terminal number 3, for damage. Q: Is the harness wires in good condition? YES : Go to Step 8. NO : Repair the damaged harness wire. Then go to Step 22 .
8. STEP 8. Check the harness wire between radiator fan relay connector A-35X terminal number 1 and ETACS-ECU connector C-312 terminal number 2, between condenser fan relay connector A-36X terminal number 1 and ETACS-ECU connector C-312 terminal number 8, between fan control relay connector A-37X terminal number 3 and ETACS-ECU connector C-312 terminal number 9, for damage. Q: Is the harness wires in good condition? YES : Go to Step 9. NO : Repair the damaged harness wire. Then go to Step 22 .
9. STEP 9. Check the radiator fan relay, condenser fan relay and fan control relay. Refer to «COOLING FAN RELAY CONTINUITY CHECK»(ref-289378-S25860327932008063000000) . Q: Is the relay in good condition? YES : Go to Step 10. NO : Replace the damaged relay. Then go to Step 22 .
10. STEP 10. Check the fusible link number 28 and fusible link number 29. Q: Is the fusible link in good condition? YES : An intermittent malfunction is suspected (Refer to «HOW TO COPE WITH INTERMITTENT MALFUNCTION»(ref-289379-S36733983872008063000000) ). NO : Replace the damaged fusible link. Then go to Step 22 .
11. STEP 11. Check the radiator fan relay connector A-35X, condenser fan relay connector A-36X, fan control relay connector A-37X, radiator fan motor connector A-45 and condenser fan motor connector A-47, for loose, corroded or damaged terminals, or terminals pushed back in the connector. Refer to «HARNESS CONNECTOR INSPECTION»(ref-289377-S30386868932008063000000) . Q: Is the connectors and terminals in good condition? YES : Go to Step 12. NO : Repair or replace damaged connectors. Then go to Step 22 .
12. STEP 12. Check the harness wire between fusible link number 28 and condenser fan relay connector A-36X terminal number 4, between fusible link number 29 and radiator fan relay connector A-35X terminal number 4, for damage. Q: Is the harness wires in good condition? YES : Go to Step 13. NO : Repair the damaged harness wire. Then go to Step 22 .
13. STEP 13. Check the harness wire between radiator fan relay connector A-35X terminal number 2 and radiator fan motor connector A-45 terminal number 1, between condenser fan relay connector A-36X terminal number 2 and condenser fan motor connector A-47 terminal number 1, for damage. Q: Is the harness wires in good condition? YES : Go to Step 14. NO : Repair the damaged harness wire. Then go to Step 22 .
14. STEP 14. Check the harness wire between radiator fan motor connector A-45 terminal number 2 and fan control relay connector A-37X terminal number 2, between condenser fan motor connector A-47 terminal number 2 and body ground, for damage. Q: Is the harness wires in good condition? YES : Go to Step 15. NO : Repair the damaged harness wire. Then go to Step 22 .
15. STEP 15. Check the harness wire between fan control relay connector A-37X terminal number 4 and condenser fan motor connector A-47 terminal number 1, between fan control relay connector A-37X terminal number 5 and body ground, for damage. Q: Is the harness wires in good condition? YES : Go to Step 16. NO : Repair the damaged harness wire. Then go to Step 22 .
16. STEP 16. Check the radiator fan relay, condenser fan relay and fan control relay. Refer to «COOLING FAN RELAY CONTINUITY CHECK»(ref-289378-S25860327932008063000000) . Q: Is the relay in good condition? YES : Go to Step 17. NO : Replace the damaged relay. Then go to Step 22 .
17. STEP 17. Check the radiator fan motor and condenser fan motor. Check the output line for short or open circuit. Refer to «COOLING FAN MOTOR CHECK»(ref-289378-S20751646212008063000000) . Q: Is the fan motor in good condition? YES : Go to Step 18. NO : Replace the damaged fan motor (Refer to «RADIATOR»(ref-289378-S01895578722008063000000) ). Then go to Step 22 .
18. STEP 18. Using scan tool MB991958, read the ETACS system diagnostic trouble code (DTC). Using scan tool to read the ETACS system DTC (Refer to «DIAGNOSTIC FUNCTION»(ref-289392-S39495686092008063000000) ). Q: Is any DTC set? YES : Replace the ETACS-ECU (Refer to «ETACS-ECU»(ref-289392-S22124280732008063000000) ). Then go to Step 22 . NO : Go to Step 19.
19. STEP 19. Using scan tool MB991958, check the MFI system actuator test. Using scan tool to check the MFI system actuator test (Refer to «DIAGNOSTIC FUNCTION»(ref-289380-S06390723722008063000000) ). Item 14: Cooling fan (Refer to «ACTUATOR TEST REFERENCE TABLE»(ref-289380-S16746442482008063000000) ) Q: Is the check result normal? YES : Go to Step 21 . NO : Go to Step 20.
20. STEP 20. Using scan tool MB991958, read the MFI system diagnostic trouble code (DTC). Using scan tool to read the MFI system DTC (Refer to «DIAGNOSTIC FUNCTION»(ref-289380-S06390723722008063000000) ). Q: Is any DTC set? YES : Replace the ECM (Refer to «ECM»(ref-289380-S19421569532008063000000) ). Then go to Step 22 . NO : Go to Step 21.
21. STEP 21. Check the symptoms. Q: Does the radiator fan and condenser fan operate normal? YES : An intermittent malfunction is suspected (Refer to «HOW TO COPE WITH INTERMITTENT MALFUNCTION»(ref-289379-S36733983872008063000000) ). NO : Replace the ECM (Refer to «ECM»(ref-289380-S19421569532008063000000) ). Then go to Step 22.
22. STEP 22. Check the symptoms. Q: Does the radiator fan and condenser fan operate normal? YES : The procedure is complete. NO : Return to Step 1 .

ENGINE COOLANT CONCENTRATION TEST

Refer to RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .