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Old 05-01-2011, 17:22   #1
Stevolution
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ACD lights - Corroded plugs in footwell

After having numerous problems with the ACD system lights all coming on i've put this thread together to show how water has been working its way from outside inside. (behind kick panel)

Issues i've had in the past are: Uncontrollable wipers, Fuel pump failure, AYC pump failure but other members have had Faulty lights,Intercooler spray issues etc etc. All of these due to corroded pins/terminals within the passenger footwell (Plug C135)

Today i traced the wires from the suspect plug through the body and into the wheel arch.



I removed the wheel and inner arch to expose the loom which continues down under the arch and out to the front of the car up to the ECU.

Whilst under the wheel arch i noticed the loom going through a black box?



I peeled back the clips to find the wires are not sealled within the loom and to my suprise they were soaked in water and covered in grit and dirt.



The black box has no water tight seal so water can easily penertrate it and get between the wires causing a capillary effect!

From what i could see the only reason for it being there is to suspend to loom to prevent it hanging down on the inner arch.

The black box is attached by two push clips which go through the inner wing so i popped it off so i could make the loom water tight.



I cleaned and dried the loom then wrapped the exposed wires to seal them in.



There are some other wires in this area one of which is for the side repeater so i wrapped that up within the loom to keep it tidy


I did away with the black box as it would only start to hold water again and suspended the loom using some alternative fixing methods.

To finish off i've smeared silicon grease all over the loom and coated rubber gromet going into the car to aid water protection. Fingers crossed this will keep the water out.
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Last edited by Stevolution; 18-01-2011 at 08:22.. Reason: Update
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Old 05-01-2011, 18:11   #2
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Nice one Steve , Looks like that where the water is coming in ..
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Old 05-01-2011, 19:18   #3
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Nice one, hopefully that is the end of the chase

Nice to meet you toady over at Pauls

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Old 05-01-2011, 20:52   #4
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How hard was it to take the wheel arch linner off?
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Old 05-01-2011, 22:58   #5
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How hard was it to take the wheel arch linner off?
Dead easy mate, It's held on with numerous plastic insert clips and a couple of 10mm bolts. Start at one end and work your way to te other till its loose.
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Old 05-01-2011, 23:01   #6
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Nice one, hopefully that is the end of the chase

Nice to meet you toady over at Pauls

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You too mate, Enjoy your new mods
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Old 06-01-2011, 22:21   #7
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Very good info Steve.

I will check mine now.. Water ingress into those wires will have a capillary effect where it travels down to the plug..

Sealing it off at source where you have pointed it out should stop it but you will still have water from there down to the plug.

It would be worth taking off the electrical tape, drying it all out, then wrapping it all back up again to make it nice and dry.

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Old 06-01-2011, 22:29   #8
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Very good info Steve.

I will check mine now.. Water ingress into those wires will have a capillary effect where it travels down to the plug..

Sealing it off at source where you have pointed it out should stop it but you will still have water from there down to the plug.

It would be worth taking off the electrical tape, drying it all out, then wrapping it all back up again to make it nice and dry.

Yeah you're absolutely right, That did cross my mind but i didn't have enough tape. Doh!

I've had a heater in the car overnight to dry the wires inside the car and have coated the loom/wires in silicon grease to help protect it.
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Old 07-01-2011, 10:02   #9
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Excellent guide!!! This is the cause of many,many Evo problems but Mitsubishi themselves don't seem to know about it.Some people even have to spend £500+ on new ACD pumps thinking their pumps gone but really its the ACD plug in the foot well that's corroded.

This should be made a sticky or at least bumped up every week so everyone see's it. Nice one Steve for taking the time to explain & photograph it all.
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Old 07-01-2011, 13:27   #10
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Definitely should be stickied - also traders should offer this as an additional option at service time, hint, hint.
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Old 08-01-2011, 15:48   #11
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Definitely should be stickied...
Agreed

...Having just had a close call myself

Found this thread linked from here.
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Old 08-01-2011, 17:13   #12
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Good thread
Poor design fault
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Old 09-01-2011, 20:48   #13
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Done mine... now we will see if the error comes back..

https://www.lancerregister.com/showth...=351877&page=4

STEVOLUTION any updates with all this rain we have had!
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Old 09-01-2011, 21:43   #14
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Done mine... now we will see if the error comes back..

https://www.lancerregister.com/showth...=351877&page=4

STEVOLUTION any updates with all this rain we have had!
Fingers crossed you'll be fine from now on mate.
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Old 18-01-2011, 23:44   #15
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Thank god i found this thread as i was away to buy an ayc pump cause of the lights being on!!

but a few months back i had the front seats out of the car and passenger front carpet up and found some dampness but put it down to wet shoes on the carpet but now im thinking this could well be the culprit because i have the front arch liners and wings off and i think the bottom half of my black box is missing thus letting in the water!!!

So i now know what im checking for and will post up my findings tommorow night

Thanks for this info
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