2005 MITSUBISHI LANCER clutch

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-73
PERFORMANCE TEST M1552001400355
1. The vehicles to be tested should be in a place that
is not in direct sunlight.
2. Close the high and low-pressure valve of the
gauge manifold.
3. Connect the charging hose (blue) to the
low-pressure valve and connect the charging
hose (red) to the high-pressure valve of the gauge
manifold.
CAUTION
•To connect the quick joint, press section A
firmly against the service valve until a click is
heard.
•When connecting, run your hand along the
hose while pressing to ensure that there are
no bends in the hose.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).NOTE: The high-pressure service valve is on the
A/C pipe and the low-pressure service valve is on
the suction hose.
5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick
joint (for high-pressure) to the high-pressure
service valve.
6. Start the engine.
7. Set the A/C controls as follows:
•A/C switch: A/C − ON position
•Mode selection: FACE position
•Temperature control: MAXIMUM COOLING
position
•Air selection: RECIRCULATION position
•Blower switch: "4" (Fast) position
8. Keep engine speed to idling speed with A/C clutch
engaged.
9. Engine should be warmed up with doors and all
windows opened.
10.Insert a thermometer in the centre air outlet and
operate the engine for 20 minutes.
NOTE: If the clutch cycles, take the reading before
the clutch disengages.
11.Note the discharge air temperature.
Performance Temperature Chart
AC001388
Low-pressure
valveHigh-pressure
valve
Gauge manifold
Charging
hose (red)
A
Sleeve Charging
hose (blue)
Adaptor valve
(for low-
pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
AB
Adaptor valve
(for high-
pressure)
AC304576
Thermometer
AB
Garage ambient temperature °C20 25 30 35
Discharge air temperature °C8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
Compressor high pressure kPa 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
Compressor low pressure kPa 150 − 190 190 − 240 240 − 300 300 − 375

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 VENTILATION55-93
INSTALLATION SERVICE POINT
>>A<< A/C COMPRESSOR
INSTALLATION
If a new compressor is installed, first adjust the
amount of oil according to the procedures described
below, and then install the compressor.
1. Measure the amount (X mL) of oil within the
removed compressor.
2. Drain (from the new compressor) the amount of
oil calculated according to the following formula,
and then install the new compressor.
New compressor oil amount = 140mL <1300,
1600>, 120 mL <2000>
140 mL−X mL = Y mL <1300, 1600>
120 mL−X mL = Y mL <2000>
NOTE: Y mL indicates the amount of oil in the
refrigerant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the
same times as the compressor, subtract the rated oil
amount of the each part from Y mL and discharge
from the new compressor.
Quantity:
•Evaporator: 60 mL
•Condenser: 15 mL
•Suction hose: 10 mL
•Receiver: 10 mL
INSPECTIONM1552014300949
COMPRESSOR MAGNETIC CLUTCH
OPERATION CHECK
Connect the compressor connector terminal to the
battery positive (+) terminal and earth the battery’s
negative (−) terminal to the compressor unit. At that
time, the magnetic clutch should make a definite
operating sound.
AC005671
Magnetic clutch connector
AC

COMPRESSOR ASSEMBLY AND TENSION PULLEY
HEATER, AIR CONDITIONER AND VENTILATION55-94
DISASSEMBLY AND REASSEMBLYM1552004600660
DISASSEMBLY SERVICE POINT
<> SELF-LOCKING NUT REMOVAL
Use the special tools to remove the self-locking nut.
•Special spanner (MB991367)
•Pin (MB991386)
REASSEMBLY SERVICE POINTS
>>A<< FIELD CORE ATTACHMENT
Line up the pin hole on the compressor unit with the
field core projection and attach.
AC100630
N
N
16 ± 1 N·m
10
46789
512
AB
3
11
Cooling temperature switch
disassembly steps
1. Snap ring
2. Refrigerant temperature switch
3. O ring
Magnetic clutch disassembly
>>D<<•Air gap adjustment
<> >>C<<4. Self-locking nut5. Armature
>>B<<6. Snap ring
7. Rotor
8. Snap ring
>>A<<9. Field core
10. Shim
11. A/C compressorMagnetic clutch disassembly
AC100633AB
MB991386
MB991367
AC100634AB
Field core projection
Compressor
unit pin hole

COMPRESSOR ASSEMBLY AND TENSION PULLEY
HEATER, AIR CONDITIONER AND VENTILATION55-95
>>B<< SNAP RING INSTALLATION
Using snap ring pliers, fit the snap ring so that the
snap ring’s tapered part is on the outside.
>>C<< SELF-LOCKING NUT
INSTALLATION
Use the special tools to install the self-locking nut.
•Special spanner (MB991367)
•Pin (MB991386)
>>D<< AIR GAP ADJUSTMENT
Check that the clutch air gap is inside the standard
value. If outside the standard value, use a shim to
adjust the gap.
Standard value: 0.3 − 0.5 mm
INSPECTIONM1552014300950
REFRIGERANT TEMPERATURE SWITCH
CAUTION
Do not heat more than necessary.
1. Dip the metal part of the cooling temperature
switch into engine oil and increase the oil
temperature using a gas burner or similar.
2. When the oil temperature reaches the standard
value, check that voltage is supplied between the
terminals.
Standard value:
NOTE: When the oil temperature is 150
°C or
more and there is no continuity, the resistance will
not be 2
Ω or lower until the oil temperature
reduces to 120
°C or less.
AC001412
Snap ring
RotorClutch coil
Tapered part
AB
AC100633AB
MB991386
MB991367
AC100637AB
Thickness
gauge
Item Temperature
Less than 2
ohmsSlightly below 150°C
No continuity 150°C or more
AC100787
Thermometer
Engine oil
AB
AC100810
Continuity
No continuity
Oil temperature
AD
120˚C150˚C

INVECS-II 4A/T
CIRCUIT DIAGRAMS90-44
INVECS-II 4A/T (CONTINUED)
INVECS-II 4A/T (CONTINUED)
ENGINE-
A/T-ECUFUSE
3()
SHIFT
SWITCH
ASSEMBLYINHIBITOR
SWITCH
SELECT
SWITCH SHIFT
SWITCH
FUSE
2()
FUSE22()J/C (1) J/C (5)
CONTROL CIRCUIT
COMBINATION
METERSHIFT
POSITION
INDICATOR
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet RELAY
BOXFUSE
3() SHIFT
SWITCH
ASSEMBLY TAIL LAMP
RELAY
RHEOSTAT
INHIBITOR
SWITCH FRONT-ECUTAIL LAMP, POSITION
LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER
ENGINE-
A/T-ECU
THROTTLE
BODY
THROTTLE
SENSOR
DIAGNOSIS
CONNECTORFUSIBLE
LINK
ENGINE CONTROL
SYSTEM
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
1A/T
CONTROL
RELAY
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
ENGINE CONTROL
SYSTEM
ENGINE-
A/T-ECU
NOTE
:
:
:
:
: UNDERDRIVE
SOLENOID VALVE
SECOND
SOLENOID VALVE
DAMPER CLUTCH
CONTROL
SOLENOID VALVE OVERDRIVE
SOLENOID VALVE
LOW AND REVERSE
SOLENOID VALVE
A/T FLUID
TEMPERATURE
SENSOR
FRONT
SIDE

INVECS-II 4A/T
CIRCUIT DIAGRAMS90-46
INVECS-II 4A/T (CONTINUED)
INVECS-II 4A/T (CONTINUED)
ENGINE-
A/T-ECUFUSE
3()
SHIFT
SWITCH
ASSEMBLYINHIBITOR
SWITCH
SELECT
SWITCH SHIFT
SWITCH
FUSE
2()
FUSE22()J/C (1)
CONTROL CIRCUIT
COMBINATION
METERSHIFT
POSITION
INDICATOR
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet FUSE
3() SHIFT
SWITCH
ASSEMBLY TAIL LAMP
RELAY
RHEOSTAT
INHIBITOR
SWITCH FRONT-ECUTAIL LAMP, POSITION
LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER
TAIL LAMP, POSITION
LAMP, LICENCE
PLATE LAMP AND
LIGHTING MONITOR
BUZZER
RELAY
BOX
ENGINE-
A/T-ECU
THROTTLE
BODY
THROTTLE
SENSOR
DIAGNOSIS
CONNECTORFUSIBLE
LINK
ENGINE CONTROL
SYSTEM
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet
1
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
NOTE
:
:
:
:
: UNDERDRIVE
SOLENOID VALVE
SECOND
SOLENOID VALVE
DAMPER CLUTCH
CONTROL
SOLENOID VALVE OVERDRIVE
SOLENOID VALVE
LOW AND REVERSE
SOLENOID VALVE
A/T
CONTROL
RELAY
ENGINE CONTROL
SYSTEM
ENGINE-
A/T-ECU
FRONT
SIDE
A/T FLUID
TEMPERATURE
SENSOR

MANUAL AIR CONDITIONER
CIRCUIT DIAGRAMS90-116
MANUAL AIR CONDITIONER (CONTINUED)
FUSIBLE
LINK2ENGINE
CONTROL
RELAY
RADIATOR
FAN RELAY
SMOOTHING
CIRCUIT
INPUT
SIGNAL
PROCESSING
DRIVE
CIRCUIT
TEMPERATURE
DETECTIONCURRENT
DETECTIONRADIATOR
FAN MOTOR COOLING FAN MOTOR
DRIVE CONTROL UNIT
CONDENSER
FAN MOTOR
NOTE
: M/T
: A/T
: EXCEPT 4G6
: 4G6
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
FIELD EFFECT
TRANSISTOR
CIRCUIT BATTERYA/C-ECU
RELAY
BOX
A/C COMPRESSOR
RELAY
A/C COMPRESSOR
A/C
REFRIGERANT
TEMPERATURE
SWITCH
MAGNETIC
CLUTCHLOW-
PRESSURE
SIDE
HIGH-
PRESSURE
SIDE
DUAL
PRESSURE
SWITCH
ENGINE-
ECU
ENGINE-
A/T-ECU
(FUSE )5