2005 MITSUBISHI LANCER low oil pressure

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.

REFRIGERANT LINE
HEATER, AIR CONDITIONER AND VENTILATION55-98
REFRIGERANT LINE
REMOVAL AND INSTALLATION M1552006400402
Pre-removal and Post-installation Operation
•Refrigerant Draining and Refilling (Refer to P.55-70.)
•Air Cleaner Removal and Installation (Refer to GROUP
15, Air cleaner P.15-3.)
•Radiator Grille Removal and Installation (Refer to
GROUP 51, Front bumper P.51-2.)
AC304553
1
2
3
45
6
7
8N
N
N
N
N
8 8
8
8
High-pressure
side service valve
Low-pressure side
service valve
4.9 ± 0.9 N·m 13 ± 1 N·m
4.9 ± 0.9 N·m
12 ± 2 N·m
AB
6
A/C compressor oil: SUN PAG 56 -Pipe coupling
O-ringO-ring
1, 2, 3,
5, 6
Removal steps
<>1. Dual pressure switch
<>2. Liquid pipe A
<>3. Flexible discharge hose
4. Expansion valve cover
<> >>A<<5. Flexible suction hose
<> >>A<<6. Liquid pipe B
7. Expansion valve cover
8. O ringRemoval steps (Continued)

REFRIGERANT LINE
HEATER, AIR CONDITIONER AND VENTILATION55-99
REMOVAL SERVICE POINT
<> HOSE/PIPE DISCONNECTION
CAUTION
As the compressor oil and receiver are highly
moisture absorbent, use a non-porous material
to plug the hose and nipples.
To prevent the entry of other foreign bodies, plug the
condenser, compressor, and expansion valve
nipples.
INSTALLATION SERVICE POINT
>>A<< SUCTION HOSE INSTALLATION
When replacing the suction hose, refill them with a
specified amount of compressor oil, and then install
them.
Compressor oil: SUN PAG 56
Quantity: Suction hose: 10 cm
3
REMOVAL AND INSTALLATION M1552006400413
Pre-removal and Post-installation Operation
•Refrigerant Draining and Refilling (Refer to P.55-70.)
•Air Cleaner Removal and Installation (Refer to GROUP
15, Air cleaner P.15-3.)
•Radiator Grille Removal and Installation (Refer to
GROUP 51, Front bumper P.51-2.)
AC304554
1
2
3
4
5
6
7
8N
8N
8N
N8 8
N
4.9±0.9 N·m
Low-pressure side
service valve 13 ± 1 N·mHigh-pressure
Side Service Valve
12 ± 2 N·m
4.9 ± 0.9 N·m
AB
6
A/C compressor oil: SUN PAG 56 -Pipe coupling
O-ringO-ring
1, 2, 3,
5, 6
Removal steps
<>1. Dual pressure switch
<>2. Liquid pipe A
<>3. Flexible discharge hose
4. Expansion valve cover
<> >>A<<5. Flexible suction hose
<> >>A<<6. Liquid pipe B
7. Expansion valve cover
8. O ringRemoval steps (Continued)

SENSOR
COMPONENT LOCATIONS70-7
AC208762
A
AD
Timing belt front
upper coverTiming belt front
lower coverEngine crank
angle sensor
<4G1>
Engine crank angle
sensor connector
AC302008
A<4G6>
ABHeat protector
Crankshaft
sprocket
Engine crank angle
sensor connectorEngine crank
angle sensor
AC301752
B
AB
Ignition coil 2
<4G1>
Engine control detonation
sensor connector
Engine control
detonation sensor
AC302009
B
AB
Hydraulic unit
<4G6>
Alternator
Engine control detonation
sensor connectorEngine control
detonation sensor
AC208541
C
AE
<4G1>
Throttle body
Throttle body
throttle sensor
Inlet manifold absolute pressure sensor
(incorporating intake air temperature sensor)
AC302479
AB
C
Throttle body
<4G6>
Throttle body
throttle sensor

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 DIAGRAMS80-9
ENGINE AND TRANSMISSION <4G1-MPI (LHD) > (CONTINUED)
NOTE: On A/T only, the standard routing positions
for the corrugated tube and wiring harness are
marked by*.
AC301128
B-118B-101 B-102
B-113
B-114 B-115 B-116B-117
Earth cable
Control wiring
harness
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
-101
thru
-118B
*
AC
9
10
11
13
B-103
B-104B-105
B-107
B-108
Battery wiring
harness
B-109
B-110 B-111
*
B-112
B-101 (2-BR) Emission solenoid valve (EGR system)
B-102 (4-GR) Inlet manifold absolute pressure sensor
B-103 (6-B) Throttle body idle speed control servo
B-104 (3-GR) Ignition coil 1
B-105 (2-B) Emission solenoid valve (Purge control
system)
B-107 (3-B) Camshaft position sensor
B-108 (3-GR) Output shaft speed sensor
B-109 (3-B) Input shaft speed sensor
B-110 (2-B) Back-up lamp switch
B-111 (2-B) Water temperature sensor unit
B-112 (1-B) Water temperature gauge unitB-113 (3-GR) Ignition coil 2
B-114 (1-B) A/C compressor
B-115 (1) Power steering fluid pressure switch
B-116 (3-B) Engine crank angle sensor
B-117 (2-GR) Engine control detonation sensor
B-118 (28-GR) ABS-ECU

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