2005 MITSUBISHI LANCER service

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

SERVICE SPECIFICATIONS
HEATER, AIR CONDITIONER AND VENTILATION55-3
SERVICE SPECIFICATIONS
M1552000300292
LUBRICANTS
M1552000400299
ItemStandard value
Idle speed r/min 750 ± 100
Idle-up speed r/min 850 ± 100
Resistor (for blower motor) ΩLO 2.54
ML 1.24
MH 0.6
Air gap (magnetic clutch) mm 0.3 − 0.5
Item Specified lubricant Quantity
Compressor refrigerant unit lubricant SUN PAG 56 1300, 1600 140 mL
2000 120 mL
Each connection of refrigerant line SUN PAG 56 As required
Refrigerant R134a (HFC-134a) 480 − 520 g

TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-5
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOWM1552009600364
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points P.00-5.
SYMPTOM CHARTM1552009900611
NOTE: Refer to GROUP 14, Troubleshooting P.14-5
for the condenser fan.
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the Ignition Switch is "ON" the A/C does not Operate.
COMMENTS ON TROUBLE SYMPTOM
The blower system or the compressor system may
be defective if there is no cool air coming from the
spit hole.
TROUBLESHOOTING HINTS
•Malfunction of blower motor
•Malfunction of A/C compressor
DIAGNOSIS
Check that the blower motor operation when the
blower switch is moved to the "HI" position.
(1) Turn the ignition switch to the "ON" position.
(2) Turn the blower switch to the "HI" position.
Q: Does the blower motor operate when the blower
switch is moved to the "HI" position?
YES :
Refer to Inspection procedure 3
"When the A/C is operating, temperature
inside the passenger compartment does not
decrease (cool air is not emitted).
P.55-11."
YES : Refer to Inspection procedure 4
"When the A/C is operating, temperature
inside the passenger compartment does not
decrease (cool air is not emitted).
P.55-20."
NO : Refer to Inspection procedure 5 "Blower fan
and motor do not turn P.55-29." Symptom Inspection
ProcedureReference
Page
When the ignition switch is "ON" the A/C does not operate. 1
P.55-5
Inside/outside air selection is not possible. 2
P.55-6
When the A/C is operating, temperature inside the passenger
compartment does not decrease (cool air is not emitted). 3
P.55-11
When the A/C is operating, temperature inside the passenger
compartment does not decrease (cool air is not emitted). 4
P.55-20
Blower fan and motor do not turn. 5
P.55-29
Blower air amount cannot be changed. 6
P.55-39
Rear window defogger function does not operate. 7
P.55-42
Rear window defogger Timer function does not operate. 8
P.55-52
Malfunction of the A/C-ECU power supply system. 9
P.55-53
Malfunction of the A/C-ECU power supply system. 10
P.55-56
A/C compressor power supply system. 11
P.55-59
Condenser Fan does not operate. 12 Refer to
GROUP 14
P.14-5

TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-28
STEP 19. Check the magnetic clutch operation.
Refer to P.55-93.
Q: Can the sound of the magnetic clutch (click) be
heard?
YES :
Go to Step 20.
NO : Replace the compressor magnet clutch.
STEP 20. Check the refrigerant temperature
switch.
Refer to P.55-95.
Q: Is the refrigerant temperature switch operating
properly?
YES :
Go to Step 21.
NO : Replace the refrigerant temperature switch.
STEP 21. Check the air thermo sensor.
Refer to P.55-90.
Q: Is the air thermo sensor in good condition?
YES :
Go to Step 22.
NO : Replace the air thermo sensor.
STEP 22. Check the refrigerant level.
Refer to P.55-69.
Q: Is the refrigerant level correct?
YES :
Go to Step 23.
NO : Correct the refrigerant level (Refer to
On-vehicle Service P.55-70).
STEP 23. Replace the A/C-ECU.
Check that the air conditioner works normally.
Q: Is the check result normal?
YES :
This diagnosis is complete.
NO : Replace the engine-ECU or the
engine-A/T-ECU .

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-69
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL
TEST
M1552008400378
1. Start the engine.
2. Operate the air-conditioner, and then set the
temperature to maximum cooling.
3. Hold the engine speed at 1500 r/min.
4. Check the refrigerant level (bubble state) through
the sight glass.
CAUTION
Use the low-pressure service valve.
NOTE: Use the refrigerant recovery station to
charge the specified refrigerant because you can
not calculate the amount of the refrigerant
properly with the sight glass.
MAGNETIC CLUTCH TESTM1552008500405
1. Disconnect the magnetic clutch connector to the
magnetic clutch.
2. Connect positive battery voltage directly to the
connector for the magnetic clutch.3. If the magnetic clutch is normal, there will be a
"click." If the pulley and armature do not make
contact ("click"), there is a malfunction.
COMPRESSOR DRIVE BELT
ADJUSTMENT
M1552001000335
<1300, 1600>
Refer to GROUP 11A, On-vehicle Service − Drive
Belt Tension Check P.11A-7.
<2000>
Refer to GROUP 11C, On-vehicle Service − Drive
Belt Tension Check P.11C-7.
DUAL PRESSURE SWITCH CHECKM1552010400320
1. Remove the dual pressure switch connector and
connect the high/low pressure side terminals
located on the harness side as shown in the
illustration..
2. Install a gauge manifold to the high-pressure side
service valve of the refrigerant line. (Refer to
P.55-98, P.55-99.)
3. When the high/low pressure sides of the dual
pressure switch are at operation pressure (ON)
the resistance should less than two ohms
between the terminals. If open circuit, replace the
switch. Items State
Insufficient Many bubbles are seen.
If refrigerant is extremely
low, it appears white.
Sufficient or excess
refrigerantNo bubbles are seen.
AC005963
Bubbles Insufficient
refrigerantSufficient or excess
refrigerant
AC
AC005671
Magnetic clutch connector
AC
AC001368AD High/Low
Pressure Side
Low-pressure side
High-pressure side
ON
OFFON
OFF
2650 ± 200 2060 ± 200230 ± 20 210 ± 25
(kPa)

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-70
CHARGING M1552001200362
1. With the handles turned back all the way (valve
closed), install the adaptor valve to the
low-pressure side of the gauge manifold.
2. Connect the charging hose (blue) to the adaptor
valve.
3. Connect the quick joint (for low-pressure) to the
charging hose (blue).
CAUTION
•Use tools that are suited to R134a.
•To install the quick joint, press section when
connecting, run your hand along the hose
while pressing to ensure that there are no
bends in the hose.
4. Connect the quick joint (for low-pressure) to the
low- pressure service valve.
NOTE: The low-pressure service valve should be
connected to the flexible suction hose.5. Close the high and low-pressure valves of the
gauge manifold.
CAUTION
Be sure to connect the power plug of the vacuum
pump to the vacuum pump adapter, and then
connect the power plug of the adapter to a 100-V
outlet.
6. Install the vacuum pump adaptor to the vacuum
pump.
7. Connect the charging hose (yellow) to the R-134a
connection port of the vacuum pump adaptor.
8. Tighten the adaptor valve handle (valve open).
9. Open the low-pressure valve of the gauge
manifold.
10.Turn the power switch of the vacuum pump to the
ON position.
NOTE: Even if the vacuum pump power switch is
turned ON, the vacuum pump will not operate
because of the power supply connection in step
(6).
CAUTION
Do not operate the compressor for evacuation.
11.Turn the vacuum pump adaptor switch to the
R134a side to start the vacuum pump.
12.Evacuate to a vacuum reading of 100 kPa or
higher (takes approx. 10 minutes).
AC212526
AB
A
Sleeve Low-pressure
service valve Quick
joint
(for low
pressure)
SwitchVacuum
pump
Power supply
plug Vacuum
pump
adaptor R-12
connection
portCharging hose
(blue)
Adapter
valveCharging hose
(yellow)Gauge manifold
Switch
R-134a
connection
port Low-pressure
valveHigh-pressure
valve
AC212535
Vacuum
pump Low-pressure
service valve
AB
Vacuum pump
adaptor switch

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-71
CAUTION
Do not operate the compressor in the vacuum
condition; damage may occur.
13.Loosen the valve of the adapter valve fully (valve
closed), and turn off the vacuum pump adapter
switch. Then leave it for five minutes.
14.Check the system for proper sealing (negative
pressure should not decrease).
15.Connect the service can valve to the service can
with the handle loosened fully (valve closed).
16.Turn the handle of the adaptor valve back all the
way (valve closed), remove it from the gauge
manifold and install the service can.
17.Tighten the handle of the charging valve (valve
closed) to puncture the service can.
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.
18.Turn the handle of the charging valve back (valve
open) and tighten the handle of the adaptor valve
(valve open) to charge the system with refrigerant.
19.If the refrigerant is not drawn in, turn the handle of
the adaptor valve back all the way (valve closed).
20.Check for gas leaks using a leak detector. If a gas
leak is detected, re-tighten the connections, and
then repeat the charging procedure from
evacuation in step (11).
CAUTION
The leak detector for R-134a 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.
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.
24.Tighten the handle of the adaptor valve (valve
open) to charge the required volume of
refrigerant.
AC212536
Valve open
Valve close
Charging valve
Service can Adaptor valve
AB
AC212537
Charging valve
Service can
(Refrigerant container)
Low-pressure
service valve
AB

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