2005 MITSUBISHI LANCER belt

DOOR
BODY42-39
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP
REMOVAL AND INSTALLATIONM1423003100290

AC304409AB
Section A – A

Sealant: 3M ATD Part No.8633 or equivalentDoor
: Sectional view of
clip position
: Sectional view of
clip position
6 2
1
4
365
A A
1
Waterproof film removal steps
•Door trim assembly, speaker (Refer to
GROUP 52A, Trims P.52A-11).
1. Waterproof film
Door inner opening weatherstrip
removal steps
•Scuff plate, centre pillar lower trim
and cowl side trim (Refer to GROUP
52A, Trims P.52A-11.)
2. Door inner opening weatherstrip
(Body side)
Door outer opening weatherstrip
removal steps
•Front door check mounting bolt (Door
side) (Refer to P.42-31.)
<> >>A<<3. Door outer opening weatherstripDoor window glass runchannel
removal
4. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Front door trim(Refer to GROUP 52A,
Door trim P.52A-15.)
5. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door mirror assembly (Refer to
GROUP 51, Door mirror P.51-45.)
•Door window glass (Refer to
P.42-32.)
6. Door beltline moulding

DOOR
BODY42-40

AC304418AB
Section A – A
Door
: Sectional view of
clip position
: Sectional view of
clip position
6 2 4
5
7
A A
3
Section B – B
Door
6
3
6
BB
Sealant: 3M ATD Part No.8633 or equivalent
1
1
Waterproof film removal steps
•Door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
1. Waterproof film
Door inner opening weatherstrip
removal steps
•Scuff plate, centre pillar lower trim
and cowl side trim (Refer to GROUP
52A, Trims P.52A-11.)
2. Door inner opening weatherstrip
(Body side)
Door outer opening weatherstrip
removal steps
•Rear door check mounting bolt (Door
side) (Refer to P.42-31.)
3. Retainer weatherstrip
<> >>A<<4. Door outer opening weatherstripDoor window glass runchannel
removal
5. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Rear door trim (Refer to GROUP 52A,
Door trim P.52A-15.)
•Centre sash upper (Refer to P.42-32.)
6. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door window glass (Refer to
P.42-32.)
•Stationary glass (Refer to P.42-32.)
7. Door beltline moulding

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 VENTILATION55-69
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 VENTILATION55-74
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.

COMPRESSOR ASSEMBLY AND TENSION PULLEY
HEATER, AIR CONDITIONER AND VENTILATION55-91
COMPRESSOR ASSEMBLY AND TENSION PULLEY
REMOVAL AND INSTALLATIONM1552004100472
Pre-removal Operation
•Refrigerant Discharging (Refer to P.55-72).Post-installation Operation
•Drive Belt Tension Adjustment (1300, 1600: Refer to
GROUP 11A, On-vehicles Service − Drive Belt Tension
Check P.11A-7, 2000: Refer to GROUP 11C, On-vehicles
Service − Drive Belt Tension Check P.11C-7).
•Refrigerant Charging (Refer to P.55-70).
AC304850
1, 2
A/C compressor oil:
SUN PAG 56-Pipe coupling
O ring
12 ± 2 N·m
N
12 3 5
AB
7
54
7
<1300, 1600>
<1300, 1600><2000>
<2000>
Removal steps
<>1. Flexible suction hose connection
<>2. Flexible discharge hose connection
3. O ring
<>4. Drive belt <1300, 1600>
<>5. Drive belt <2000>
<> >>A<<6. A/C compressor
7. A/C compressor bracketRemoval steps (Continued)