2005 MITSUBISHI LANCER oil level

ON-VEHICLE SERVICE
POWER STEERING37-14
CAUTION
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid.
During air bleeding, refill the steering fluid
supply so that the level never falls below the
"MIN" mark on the oil reservoir.
3. Turn the steering wheel all the way to the left and
right five or six times while using the starter motor
to crank the engine intermittently several times
(for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38 or P.16-39).
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until
there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the
level is between "MAX" and "MIN" marks.
8. Confirm that there is very little change in the fluid
level when the steering wheel is turned left and
right.
CAUTION
If the fluid level rises suddenly after the engine is
stopped, the air has not been completely bled. If
air bleeding is not complete, there will be
abnormal noises from the pump and the
flow-control valve, and this condition could
cause reduce the life of the power steering
components.
9. Confirm that the change in the fluid level is no
more than 5 mm when the engine is stopped and
when it is running.
10.If the change of the fluid level is 5 mm or more,
the air has not been completely bled from the
system. The air bleeding procedure must be
repeated.
OIL PUMP PRESSURE TESTM1372002300315
1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
•MB990662: Power Steering Oil Pressure Gauge
•MB991548: Power Steering Oil Pressure Gauge
Adapter (pump side)
•MB991549: Power Steering Oil Pressure Gauge
Adapter (hose side)
2. Bleed air, then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
− 60°C.
3. Start the engine and idle it at 1000 ± 100 r/min.
CAUTION
The pressure gauge shut-off valve must not
remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure
gauge and measure the oil pump relief pressure
to confirm that it is within the standard value
range. Open it again immediately after checking
the pressure.
Standard value: 8.8 − 9.5 MPa
5. If it is not within the standard value, replace the oil
pump.
6. Check whether or not the hydraulic pressure is
the standard value when no-load conditions are
created by fully opening the shut-off valve of the
pressure gauge.
Standard value: 0.2 − 0.7 MPa
ACX01131While engine running While engine stoppedAC
Fluid level change: Within 5 mm
ACX01133
Temperature
gauge
Oil reservoir
Adapter
(MB991548)
Oil
pump
Adapter
(MB991549)
AB
Shut-off valve
(fully closed) Pressure
gauge
(MB990662)

55-2
ON-VEHICLE SERVICE . . . . . . . . . . .55-69
SIGHT GLASS REFRIGERANT
LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . 55-69
MAGNETIC CLUTCH TEST . . . . . . . . . . . . 55-69
COMPRESSOR DRIVE BELT
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 55-69
DUAL PRESSURE SWITCH CHECK . . . . . 55-69
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . 55-70
CORRECTING LOW REFRIGERANT LEVEL
IN CASE THE SERVICE CAN IN USED. . . 55-72
DISCHARGING SYSTEM . . . . . . . . . . . . . . 55-72
REFILLING OF OIL IN THE A/C
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-72
PERFORMANCE TEST . . . . . . . . . . . . . . . 55-73
REFRIGERANT LEAK REPAIR
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-74
COMPRESSOR NOISE CHECK . . . . . . . . 55-74
POWER RELAY CHECK . . . . . . . . . . . . . . 55-75
IDLE-UP OPERATION CHECK . . . . . . . . . 55-76
CLEAN AIR FILTER REPLACEMENT
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-76
HEATER CONTROL ASSEMBLY AND A/C
SWITCH . . . . . . . . . . . . . . . . . . . . . . .55-77
REMOVAL AND INSTALLATION . . . . . . . . 55-77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-79
DISASSEMBLY AND REASSEMBLY . . . . . 55-79
HEATER UNIT, HEATER CORE,
BLOWER ASSEMBLY AND
EVAPORATOR UNIT* . . . . . . . . . . . .55-81
REMOVAL AND INSTALLATION . . . . . . . . 55-81
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 55-82
DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-82
DISASSEMBLY AND ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-83
BLOWER ASSEMBLY . . . . . . . . . . . . . . . . 55-84
DISASSEMBLY AND REASSEMBLY . . . . . 55-84
BLOWERMOTOR, RESISTOR AND
OUTSIDE/INSIDE AIR SELECTION
DAMPER CONTROL MOTOR . . . . . .55-85
REMOVAL AND INSTALLATION . . . . . . . . 55-85
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 55-86
EVAPORATOR ASSEMBLY . . . . . . .55-88
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-88
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-89
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 55-90
COMPRESSOR ASSEMBLY AND
TENSION PULLEY . . . . . . . . . . . . . . .55-91
REMOVAL AND INSTALLATION . . . . . . . . 55-91
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 55-93
DISASSEMBLY AND REASSEMBLY . . . . . 55-94
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 55-95
CONDENSER AND CONDENSER
FAN MOTOR . . . . . . . . . . . . . . . . . . . .55-96
REMOVAL AND INSTALLATION . . . . . . . . 55-96
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 55-97
REFRIGERANT LINE . . . . . . . . . . . . .55-98
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-98
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-99
DUCTS . . . . . . . . . . . . . . . . . . . . . . . .55-101
REMOVAL AND INSTALLATION . . . . . . . . 55-101
VENTILATORS . . . . . . . . . . . . . . . . . .55-102
REMOVAL AND INSTALLATION . . . . . . . . 55-102

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-72
25.After charging with refrigerant, turn the handle of
the adaptor valve back all the way (valve closed).
26.Tighten the charging valve handle (valve closed).
Remove the quick joint (for low-pressure) from the
low-pressure service valve.
27.Remove the service can.
NOTE: If the service can is not emptied
completely, keep the handles of the charging
valve and adaptor valve closed for the next
charging.
CORRECTING LOW REFRIGERANT
LEVEL IN CASE THE SERVICE CAN IN
USED
M1552014600100
1. Install the charge valve with the handle turned all
the way back (valve open) to the service can.
2. Install the adaptor valve with the handle turned all
the way back (valve close) to the charging valve.
3. Connect the charging hose (blue) to the adaptor
valve.
4. Connect the charging hose (blue) to the quick
joint (for low-pressure).
5. Tighten the handle of the charge valve (valve
close), and pierce the service can.
6. Turn the handle of the adaptor valve to bleed the
air.7. Install the quick joint (for low-pressure) to the
low-pressure service valve.
NOTE: The low-pressure service valve should be
connected to the suction hose.
8. Start the engine.
9. Operate the air conditioner and set at the lowest
temperature (MAX. COOL).
10.Fix the engine speed at 1,500 r/min.
11.Tighten the handle of the adaptor valve (valve
open), and replenish refrigerant while checking
the quantity through the sight glass.
12.After replenishing is completed, turn the handle of
the adaptor valve all the way back (valve close),
and remove the quick joint.
NOTE: When there is remainder of refrigerant in
the service can, keep it for next use with the
charge value and the valve of the adaptor valve
being closed.
DISCHARGING SYSTEMM1552013000105
Use the refrigerant recovery unit to discharge
refrigerant gas from the system.
NOTE: Refer to the Refrigerant Recovery and
Recycling Unit instruction Manual for operation of the
unit.
REFILLING OF OIL IN THE A/C SYSTEMM1552020000033
Too little oil will provide inadequate compressor
lubrication and cause a compressor failure. Too
much oil will increase discharge air temperature.
When a compressor is installed at the factory, it
contains 140mL <1300, 1600> or 120 mL <2000> of
compressor oil. While the A/C system is in operation,
the oil is carried through the entire system by the
refrigerant. Some of this oil will be trapped and
retained in various parts of the system.
When the following system components are
changed, it is necessary to add oil to the system to
replace the oil being removed with the component.
Compressor oil: SUN PAG 56
Quantity
Evaporator: 60 mL
Condenser: 15 mL
Flexible suction hose: 10 mL
Receiver: 10 mL
AC300372
AB
Valve open
Valve close
Service can
(Refrigerant
container)Charge valve
Adaptor valve
Charging hose (blue)
Quick joint (for low-pressure)
AC300373
Quick joint
(for low-pressure)
Low-pressure
service valve
AB

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-74
REFRIGERANT LEAK REPAIR
PROCEDURE
M1552001500277
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (Refer to P.55-72).
2. Charge the system with approximately 480 − 520
g of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
CAUTION
Replacement filter-drier units must be sealed
while in storage. The drier used in these units will
saturate water quickly upon exposure to the
atmosphere. When installing a drier, have all
tools and supplies ready for quick assembly to
avoid keeping the system open any longer than
necessary.
6. Replace receiver drier.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the
refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced in
the system when it is operating. Extreme care must
be exercised to make sure that all connections are
pressure tight. Dirt and moisture can enter the
system when it is opened for repair or replacement of
lines or components. The following precautions must
be observed. The system must be completely
discharged before opening any fitting of connection
in the refrigeration system. Open fittings with caution
even after the system has been discharged. If any
pressure is noticed as a fitting is loosened, allow
trapped pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the
correct line for the installation you are servicing. A
good rule for the flexible hose lines is keep the radius
of all bends at least 10 times the diameter of the
hose.Sharper bends will reduce the flow of refrigerant. The
flexible hose lines should be routed so that they are
at least 80 mm from the exhaust manifold. It is good
practice to inspect all flexible hose lines at least once
a year to make sure they are in good condition and
properly routed.
On standard plumbing fittings with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE CHECKM1552008700272
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any
other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory drive belt
tension (power steering or alternator).
Improper accessory drive belt tension can cause a
misleading noise when the compressor is engaged
and little or no noise when the compressor is
disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure), restrict
air flow through the condenser. Install a manifold
gauge set to make sure discharge pressure
doesn't exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt. Check
to assure clutch coil is tight (no rotation or
wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge (Refer to P.55-69).
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.

ENGINE AND TRANSMISSION
CONFIGURATION DIAGRAMS80-8
ENGINE AND TRANSMISSION
ENGINE AND TRANSMISSION <4G1-MPI (LHD) >M1801000400689
NOTE: On A/T only, the standard routing positions
for the corrugated tube and wiring harness are
marked by*.
AC301128
B-02
B-03B-04B-05
B-22
B-23 B-24 B-25 B-26Control wiring
harnessB-01
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow*
Connector
symbol
-01
thru
-26B
Earth cable
AB
9
10
11
13
B-06B-07
B-09
B-10X
B-15X
B-16X
B-17X
B-18
Battery wiring
harness
B-19
B-20
B-21
*
B-01 (5-GR) Windshield wiper motor
B-02 (2-GR) Fuel injector 1
B-03 (2-GR) Fuel injector 2
B-04 (2-GR) Fuel injector 3
B-05 (2-GR) Fuel injector 4
B-06 (3-GR) Throttle body throttle sensor
B-07 (3-B) Vehicle speed sensor
B-09 (2-GR) Brake fluid level indicator switch
B-10X (1) Engine speed detection connector
B-15X (4) A/T control relay
B-16X (4) Engine control relay
B-17X (4) A/C compressor relay
B-18 (6-B) Control wiring harness and battery wiring
harness combination
B-19 (10-GR) A/T control solenoid valve assemblyB-20 (10-B) Inhibitor switch
B-21 (4-B) Engine control oxygen sensor (Front)
B-22 (1) Starter
B-23 (1-B) Starter
B-24 (1-B) Engine oil pressure switch
B-25 (1) Alternator
B-26 (4-GR) Alternator

ENGINE AND TRANSMISSION
CONFIGURATION DIAGRAMS80-10
ENGINE AND TRANSMISSION
<4G1-MPI (RHD) >
M1801000400690
NOTE: On A/T only, the standard routing positions
for the corrugated tube and wiring harness are
marked by*.
AC301131
B-02
B-03B-04 B-05
B-22
B-23 B-24 B-25 B-26Control wiring
harnessB-09
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow*
Connector
symbol
-01
thru
-26B
Earth cable
AB
9
10
11
13
B-06B-07
B-01
B-10X
B-14X
B-15X
B-16X
B-17X
B-18
Battery wiring
harness
B-19
B-20 B-21
*
B-01 (5-GR) Windshield wiper motor
B-02 (2-GR) Fuel injector 1
B-03 (2-GR) Fuel injector 2
B-04 (2-GR) Fuel injector 3
B-05 (2-GR) Fuel injector 4
B-06 (3-GR) Throttle body throttle sensor
B-07 (3-B) Vehicle speed sensor
B-09 (2-GR) Brake fluid level indicator switch
B-10X (1) Engine speed detection connector
B-14X (4) Ignition coil relay
B-15X (4) A/T control relay
B-16X (4) Engine control relay
B-17X (4) A/C compressor relay
B-18 (6-B) Control wiring harness and battery wiring
harness combination
B-19 (10-GR) A/T control solenoid valve assemblyB-20 (10-B) Inhibitor switch
B-21 (4-B) Engine control oxygen sensor (Front)
B-22 (1) Starter
B-23 (1-B) Starter
B-24 (1-B) Engine oil pressure switch
B-25 (1) Alternator
B-26 (4-GR) Alternator

ENGINE AND TRANSMISSION
CONFIGURATION DIAGRAMS80-12
ENGINE AND TRANSMISSION
<4G6-MPI (LHD) >
M1801000400708
AC301134
B-02
B-03B-04
B-25 B-26Control wiring
harnessB-01
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : YellowConnector
symbol
-01
thru
-26B
AB
910
11
13
B-06B-07
B-09
B-10X
B-16X
B-17X
B-18
Battery wiring
harness
B-21 B-22
B-23B-05B-08
B-24
Earth
cable
B-01 (5-GR) Windshield wiper motor
B-02 (2-GR) Fuel injector 1
B-03 (2-GR) Fuel injector 2
B-04 (2-GR) Fuel injector 3
B-05 (2-GR) Fuel injector 4
B-06 (4-B) Throttle body throttle sensor
B-07 (3-B) Vehicle speed sensor
B-08 (7-B) Air cleaner air flow sensor
B-09 (2-GR) Brake fluid level indicator switch
B-10X (1) Engine speed detection connectorB-16X (4) Engine control relay
B-17X (4) A/C compressor relay
B-18 (6-B) Control wiring harness and battery wiring
harness combination
B-21 (4-B) Engine control oxygen sensor (Front)
B-22 (1) Starter
B-23 (1-B) Starter
B-24 (1-B) Engine oil pressure switch
B-25 (1) Alternator
B-26 (4-GR) Alternator

ENGINE AND TRANSMISSION
CONFIGURATION DIAGRAMS80-14
ENGINE AND TRANSMISSION
<4G6-MPI (RHD) >
M1801000400719
AC301137
B-02B-03B-04
B-25 B-26Control wiring
harness
B-09
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
Connector
symbol
-01
thru
-26B
AB
910
11
13
B-05
B-07B-01
B-10X
B-14X
B-16X
B-17X
B-18
Battery wiring
harness
B-22 B-24B-06
B-08
B-23B-21
Earth
cable
B-01 (5-GR) Windshield wiper motor
B-02 (2-GR) Fuel injector 1
B-03 (2-GR) Fuel injector 2
B-04 (2-GR) Fuel injector 3
B-05 (2-GR) Fuel injector 4
B-06 (4-B) Throttle body throttle sensor
B-07 (3-B) Vehicle speed sensor
B-08 (7-B) Air cleaner air flow sensor
B-09 (2-GR) Brake fluid level indicator switch
B-10X (1) Engine speed detection connector
B-14X (4) Ignition coil relayB-16X (4) Engine control relay
B-17X (4) A/C compressor relay
B-18 (6-B) Control wiring harness and battery wiring
harness combination
B-21 (4-B) Engine control oxygen sensor (Front)
B-22 (1) Starter
B-23 (1-B) Starter
B-24 (1-B) Engine oil pressure switch
B-25 (1) Alternator
B-26 (4-GR) Alternator