1999 MITSUBISHI LANCER EVOLUTION VI check engine

HEATER AND MANUAL AIR CONDITIONER – Troubleshooting55-4
TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES
1. Check air ducts, control rods, etc. for improper connection.
2. Check that the electrical connectors of the relevant components are connected securely and the
fuse is not blown.
3. Perform the troubleshooting as follows; first understand the items to be inspected and the the procedures
comprehensively using Trouble Symptom/Failed Component Cross-Reference Table and then inspect
the appropriate items sequentially.
4. Be sure to perform each component check after disconnecting the relevant connector.
Trouble Symptom/Failed Component Cross-Reference Table
Items to be checked1.
When the igni-
tion switch is
“ON”, the A/C
does not oper-
ate.2.
When the A/C
is operating,
temperature
inside the pas-
senger
compartment
does not
decrease (cool
air is not
emitted).3.
Blower fan
motor does not
turn.4.
Blower fan
motor does not
stop turning.5.
When A/C is
operating,
radiator fan
and condenser
fan do not run.
Fuse111
Harness, connector2212
Amount of refrigerant31
A/C compressor relay4
A/C compressor magnet
clutch5
Dual pressure switch623
A/C switch7
Blower switch832
Blower relay4
Resistor53
Blower motor6
Air thermo-sensor93
Condenser fan relay44
Condenser fan motor55
Radiator fan relay (HI, LO)66
Radiator fan motor77
Refrigerant temperature
switch108
Auto compressor control
unit119
Engine-ECU12108

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-8
12. Evacuate to a vacuum reading of 100 kPa or higher (takes
approx. 10 minutes).
Start evacuation
Approx. for 10 minutes up to
100 kPa
Stop evacuation
Refrigerant charging
(until saturated pressure is reached)
Wait for 5 minutes
Air-tight checkIf faulty
Refrigerant charging
Gas leak check*If faultyRetighten connections
*: If the leaking point cannot be located even after
performing a gas leak check, ask an expert for
checking the system.
13. Return the handle of the adapter valve 1 to the original
position (valve closed), turn off the vacuum pump adapter
switch and leave as it is for 5 minutes.
14. Carry out a leak test. (Good if the negative pressure
does not drop.)
15. With the handle turned back all the way (valve open),
install the charging valve to the service can.
16. Remove the adaptor valve 1 from the gauge manifold
and install the service can.
17. Tighten the handle of the charging valve (valve closed)
and puncture the service can.
18. Turn the handle of the charging valve back (valve open)
and tighten the handle of the adaptor valve 1 (valve open)
to charge the system with refrigerant.
19. If the refrigerant is not drawn in, turn the handle of the
adaptor valve 1 back all the way (valve closed).
20. Check for gas leaks using a leak detector.
Caution
The leak detector for R134a should be used.
21. Start the engine.
22. Operate the A/C and set to the lowest temperature (MAX.
COOL).
23. Fix the engine speed at 1,500 r/min.
24. Tighten the handle of the adaptor valve 1 (valve open)
to charge the required volume of refrigerant.
Caution
If the service can is inverted, liquid refrigerant may
be drawn into the compressor damaging it by liquid
compression. Keep the service can upright to ensure
that refrigerant is charged in gas state.
25. After charging with refrigerant, turn the handle of the
adaptor valve 1 back all the way (valve closed).
26. Tighten the charging valve handle (valve closed).
Charging
valveAdapter valve
(for low pressure)
Charging hose
(blue)
R134a
Service
can
Quick joint
(for low pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-9
27. Remove the quick joint 2 from the low-pressure service
valve.
28. Remove the service can.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve 1 closed
for the next charging.
REFRIGERANT CHARGING AMOUNT CHECK
1. Start the engine.
2. Operate A/C and set the temperature control to MAX
COOL.
3. Fix the engine speed at 1,500 r/min.
4. Check the refrigerant level (bubble generation) through
the sight glass of the receiver.
ItemCondition
Proper levelBubbles are generated some times. No
bubbles appear when the engine speed is
slightly increased.
Level too lowA large amount of air bubbles are generated. If
it looks milky white, the level is excessively
lowered.
Level too highNo air bubbles appear.
5. If the level is too low, add the refrigerant, and if the level
is too high, drain the refrigerant as necessary.
Caution
Be sure to work at the low-pressure side service valve.
Proper level Level too low Level too high
Bubble Bubble

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-10
REPLENISHING SYSTEM
1. Connect the charging hose (blue) to the adapter valve
1 with the handle fully turned back (valve closed).
2. Connect the charging hose (blue) to the quick joint 2
and to the low pressure service valve.
Caution
Never connect to the high-pressure side since
otherwise the refrigerant could flow back.
3. Open and close the valve by operating the handle of
the adapter valve 1 to bleed air from inside the charging
hose.
4. With the handle turned back all the way (valve open),
install the charging valve to the service van.
5. Tighten the handle of the charging valve (valve closed)
and puncture the service can.
6. Install the charging valve to the adapter valve 1 and turn
back the handle all the way (valve open).
7. Start the engine.
8. Operate the A/C and set to the lowest temperature (MAX.
COOL).
9. Fix the engine speed at 1,500 r/min.
10. Tighten the handle of the adapter valve 1 (valve open).
Replenish the system with refrigerant while checking the
level through the sight glass.
After charging with refrigerant, turn the handles of the
charging valve and the adapter valve 1 all the way back
(valve closed), then remove the quick joint 2.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve closed
for the next charging.Charging
valveAdapter valve
(for low pressure)
Charging hose
(blue)
R134a
Service
can
Quick joint
(for low pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-12
Caution
(1) To connect the quick joint, press section “A” firmly
against the service valve until a click is heard.
(2) When connecting, run your hand along the hose
while pressing to ensure that there are no bends
in the hose.
5. Start the engine.
6. Set the blower switch to HI (Fast) position
7. Set the A/C switch to ON position
8. Set the temperature control to Max. cooling position
9. Set the mode selection to Face position
10. Set the air selection to Recirculation position
11. Fix engine speed to 1,500 r/min.
12. Check that the high-pressure side pressure is 1,667 –
1,765 kPa.
NOTE
If the pressure is not within this range, adjust it as follows;
cool down the condenser using a cooling fan if the
pressure is higher, and cover the condenser to protect
it from ventilation air if it is lower.
13. Set a dry-bulb/wet-bulb thermometer at the air inlet, and
set a dry-bulb thermometer at the air outlet.
Caution
(1) Set the dry-bulb thermometer at a position where
the temperature sensing section can be directly
blown with cooled air.
(2) Place the dry-bulb/wet-bulb thermometer at a
position where it is not exposed to cooled air
blown out.
14. After the temperature of the air blown out from the air
outlet has been stabilized (10 – 15 minutes after starting),
read the dry-bulb thermometer set at the air outlet and
the wet-valve thermometer set at the air inlet.
15. The air conditioning system is considered in good
condition if the intersecting point of the measurements
obtained in Step (14) is below the performance evaluation
reference line on the graph.
Caution
Do not remove the quick joint immediately after the
performance test has been completed. Stop the engine
and wait until the high-pressure side pressure of the
gauge manifold has been lowered sufficiently.
Dry-bulb ther-
mometer
Dry-bulb/wet-bulb
thermometer
Reading of wet-bulb thermometer
set at air inlet (°C)
Performance
evaluation
reference line
In order
Not in order
0Reading of dry-bulb
thermometer set at air outlet
(°C)
15 20 25 30 5 10 15 20 25

– Condenser and Condenser Fan HEATER AND MANUAL
AIR CONDITIONER55-29
REMOVAL SERVICE POINTS
AFAN MOTOR AND SHROUD ASSEMBLY
REMOVAL
Remove the clamp bolt of the power steering oil cooler pipe.
Remove the fan motor and shroud assembly while pulling
the power steering oil cooler pipe toward you.
BDISCHARGE HOSE / LIQUID PIPE A
DISCONNECTION
Plug the open end of the disconnected hose and the opening
in the cooling unit not to let foreign matter get into them.
Caution
Seal the hoses completely, otherwise the compressor
oil and receiver will absorb water vapour easily.
CCONDENSER REMOVAL
Move the radiator to the engine side and then lift up the
condenser to remove it.
INSPECTION
CONDENSER FAN MOTOR CHECK
Battery connection terminalCondenser fan operation
12
Rotate
Condenser

FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting55-43
Inspection procedure 2
Air conditioner does not operate.
Probable cause
If the A/C does not operate when the A/C switch is on and the temperature
setting is at 17C, the cause is probably insufficient refrigerant, or a
malfunction of the blower or of the magnet clutch power supply.
Malfunction of blower

Insufficient refrigerant

Malfunction of magnetic clutch

Malfunction of air thermo sensor

Malfunction of A/C compressor relay

Malfunction of refrigerant temperature switch

Malfunction of dual pressure switch

Malfunction of water temperature switch

Malfunction of connector or harness

Malfunction of engine-ECU

Malfunction of A/C-ECU
Does the blower operate?NOInspection procedure 7 (Refer to P.55-45.)
YES
A/C system refrigerant pressure check (Refer to P.55-13.)NGRefill the specified amount of refrigerant. (Refer to P.55-6.)
OK
MUT-II Self-Diag code
Is any of the codes 11, 12, 21 and 22 output?YESINSPECTION CHART FOR DIAGNOSIS CODES (Refer to
P.55-34.)
NO

Magnetic clutch check (Refer to P.55-25.)

A/C compressor relay check (Refer to P.55-14.)

Refrigerant temperature switch check (Refer to P.55-25.)

Dual pressure switch check (Refer to P.55-13.)

Water temperature switch check (Refer to P.55-64.)
<2,000>NG
Replace
OK
Measure at the A/C compressor relay connector A-116X.

Disconnect the connector, and measure at the harness
side connector.
(1) Continuity between terminal (4) and body earth
OK:Continuity
(2) Voltage between terminal (5) and body earth
OK:System voltageOKInspection procedure 13 (Refer to P.55-50.)
(2) NG
Check the following connector:
A-116X
(1) NG
Check the following connectors:
A-116X, A-106NG
Repair
NG
Repair OK
Check the trouble symptom.
NG
Check the harness between the fusible link and the A/C compressor
relay, and repair if necessary.
OK
Check the trouble symptom.
NG
Check the harness between the magnetic clutch and the A/C
compressor relay, and repair if necessary.

FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting55-51
NG
Repair OK
Check the trouble symptom.
NG
Repair
OK
Check the trouble symptom.
NG
Check the harness between the condenser fan motor relay (HI)
and the engine-ECU, and repair if necessary.
Measure at the radiator fan motor relay (HI) connector A-114X.

Disconnect the connector.
(1) Continuity between 4-B-59 and connector terminal (20)
OK:Continuity
(2) Voltage between terminal (2) and body earth (Ignition
switch: ON)
OK:System voltage
(3) Voltage between terminal (1) and body earth
OK:System voltage(1) NGCheck the following connectors:
A-114X, A-28, B-59
From the previous page
NG
Repair
OK
Check the trouble symptom.
NG
Check the harness between the condenser fan motor relay (HI)
and the ignition switch, and repair if necessary.
(2) NG
Check the following connector:
A-114X
NG
Repair
OK
Check the trouble symptom.
NG
Check the harness between the condenser fan motor relay (HI)
and the fusible link 2, and repair if necessary.
(3) NG
Check the following connector:
A-114X
OK
Measure at the condenser fan motor connector A-99.

Disconnect the connector, and measure at the harness
side connector.

Connect the terminal B-59 to the earth.

Voltage between terminal (1) and body earth (Ignition switch:
ON)
OK:System voltageNOCheck the following connector:
A-112X
NG
Check the harness between the condenser fan motor relay (HI)
and the condenser fan motor, and repair if necessary.
Inspection procedure 14
Rear defogger does not operate.
Probable cause
If the rear defogger does not operate when the rear defogger switch is turned
on (timer operates for 20 minutes), the cause is probably a malfunction of the
A/C-ECU power supply system (earth).
Malfunction of connector or harness

Malfunction of A/C-ECU
Can an operating sound be heard when the rear defogger switch
is operated?NOInspection procedure 15 (Refer to P.55-52.)
YES
Replace the A/C-ECU.