2007 MITSUBISHI LANCER EVOLUTION Leak

STEERING - Power Steering Gear Box and Linkage37A-26
"HALOWER OIL SEAL INSTALLATION
Using the special tool, press the oil seal into the valve housing.
The upper surface of the oil seal must project outwards about
1 mm from the housing end surface.
Caution
When the oil seal is flush with or lower than the housing
edge, reassemble the components. Otherwise, oil leaks
will result.
"IAEND PLUG INSTALLATION
1. Apply specified sealant to the threaded section of the
end plug, and then install the end plug to the gear housing.
Specified fluid:
3M ATD Part No.8661, 8663 or equivalent
2. Use a punch to bend over the two tabs on the sides
of the end plug to stop the end plug from turning.
"JARACK SUPPORT COVER/LOCKING NUT
INSTALLATION
1. Apply specified sealant to the rack support cover thread.
Specified fluid:
3M ATD Part No.8661, 8663 or equivalent
2. Using the special tool, tighten the rack support cover
to 23±2 N·m.
3. Return the rack support cover by about 30_.
4. Tighten the locking nut to the specified torque, using
the special tool to prevent the rack support cover from
spinning.
"KAPINION TOTAL ROTATION TORQUE ADJUSTMENT
1. Using the special tool, measure total rotation torque by
turning the pinion gear at a speed of one rotation per
4 to 6 seconds.
Standard value:
Total rotation torque: 0.8-1.8 Nm
Torque fluctuation: 0.49 Nm or lessMB990941 Approx. 1 mmOil
seal
Housing
End plugEnd plug
MB991204
MB991006

BODY -Window Glass42-10
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the direct
rays of the sun. Do not place any heavy article on the sealant
nor press it, otherwise it will become deformed. Avoid storing
the sealant for more than 6 months, because it will lose its
sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove old
adhesive completely. If the flange requires painting, bake
it after painting is completed.
WORKING PROCESS
Window glass installation procedure
Body side
Cleaning of adhesion surface
Cut off the residual adhesive until the
thickness is less than 2 mm. Clean
the adhesion surface with isopropyl al-
cohol, and let dry for 3 minutes or more.
Attaching of clip, spacer and dual
lock fastener
Attach the clip, spacer and dual lock
fastener to set the positions for the glass
to be installed.
Application of primer
Apply to the adhesion surface of the
body and let dry for 3 minutes or more.
Window glass side
Reusing the glassReplacing the glass
Cleaning of adhesion surface
Completely cut off all of the residual
adhesive. Clean the adhesion
surface with isopropyl alcohol, and
let dry for 3 minutes or more.Cleaning of adhesion surface
Clean off any dirt adhering to the adhe-
sion surface with isopropyl alcohol, and
let dry for 3 minutes or more.
Gluing of window spacer, glass stoppers and dual lock fastener
Glue the window spacer, glass stoppers and dual lock fastener along the standard position
on the glass outer circumference.
Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass
After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, etc., clean off with isopropyl alcohol.
Checking for water leaks
Carry out a shower test to check that no water will leak through.

BODY -Window Glass42-15
6. Install the windshield molding.
7. Within thirty minutes after the primer application, fill a
sealant gun with the adhesive, and then apply the
adhesive evenly around the windshield.
NOTE
Cut the tip of the sealant gun nozzle into a V shape
to simplify adhesive application.
8. After applying adhesive, align the mating marks on the
windshield and the body, and then lightly press the
windshield evenly so that it adheres completely.
9. After removing any adhesive that is sticking out or adhering
to the windshield or body with spatula, etc., clean with
isopropyl alcohol. Install the windshield molding before
the adhesive sets. After the windshield is installed, wait
until the adhesive sets.
10. Adhere the windshield to the body, and install the roof
drip molding (Refer to GROUP 51.) promptly before the
adhesive sets.
11. After adhering the windshield to the body, wait 30 minutes
or more, and then test for water leakage.
Caution
(1) Move the vehicle carefully.
(2) When testing for water leakage, do not pinch the
end of the hose to spray the water.
10 mm
15 mm

CHASSIS ELECTRICAL -BatteryCHASSIS ELECTRICAL -Battery54A-4
BATTERY
SERVICE SPECIFICATION
ItemSpecification
Specific gravity of the battery fluid1.220 - 1.290 [20_C]
ON-VEHICLE SERVICE
FLUID LEVEL AND SPECIFIC GRAVITY CHECK
1. Inspect whether or not the battery fluid is between the
UPPER LEVEL and LOWER LEVEL marks.
Caution
(1) If the battery fluid is below the LOWER LEVEL,
the battery could explode in using.
(2) If the battery fluid is over the UPPER LEVEL,
leakage could result.
2. Use a hydrometer and thermometer to check the specific
gravity of the battery fluid.
Standard value: 1.220 - 1.290 [20_C]
The specific gravity of the battery fluid varies with the
temperature, so use the following formula to calculate
the specific gravity for 20_C. Use the calculated value
to determine whether or not the specific gravity is
satisfactory.
D20 = (t - 20)×0.0007 + Dt
D20: Specific gravity of the battery fluid calculated
for 20_C.
Dt: Actually measured specific gravity
t: Actually measured temperature
CHARGING
1. Remove the battery from the vehicle.
2. The normal charging current is a value in amperes which is 1/10th of the battery capacity. If the
battery needs to be charged rapidly because of reasons such as time limitations, the maximum charging
current for rapid charging is the battery capacity expressed as an ampere value.
Battery typeCapacity (5-hour rate)Normal charging currentRapid charging current
44B2034 A3.4 A34 A
3. Determine when charging is finished.
DWhen the specific gravity of the battery electrolyte is constantly within 1.250 - 1.290 for a
continuous period of one hour or more
DWhen the voltage per cell during charging is 2.5 - 2.8 V constantly for a continuous period
of one hour or more
Thermometer
HydrometerGood

55-1
HEATER, AIR
CONDITIONER AND
VENTILATION
CONTENTS
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
SPECIAL TOOLS 2...........................
TROUBLESHOOTING 3.......................
ON-VEHICLE SERVICE 14....................
Refrigerant Level Test through Performance Test 14.
Magnetic Clutch Test 14.........................
Receiver Drier Test 14..........................
Compressor Drive Belt Adjustment 15.............
Dual Pressure Switch Check 15..................
Charging 16...................................
Correcting Low Refrigerant Level in case the Service
can used 18...................................
Discharging System 19..........................
Refilling of Oil in the A/C System 19...............
Performance Test 20............................
Refrigerant Leak Repair 21......................
Blower Relay Continuity Check 22................
A/C Compressor Relay Continuity Check 22........Condenser Fan Relay (LO) Check 23.............
Condenser Fan Relay (HI) Check 23..............
Idle-up Operation Check 24.....................
HEATER CONTROL ASSEMBLY (A/C-ECU)
AND A/C SWITCH 25........................
HEATER UNIT AND BLOWER ASSEMBLY 28.
REGISTOR, BLOWER MOTOR AND
INSIDE/OUTSIDE AIR CHANGE OVER
DAMPER MOTOR 32.........................
EVAPORATOR AND AIR THERMO SENSOR
34 ...........................................
COMPRESSOR 36............................
CONDENSER ASSEMBLY AND CONDENSER
FAN ASSEMBLY 40...........................
REFRIGERANT LINES 42.....................
DUCTS 44...................................
VENTILATION 45.............................

HEATER, AIR CONDITIONER AND VENTILATION-Troubleshooting55-7
Inspection procedure 5
Cold air not coming out from the air outlet
Probable cause
If cold air does not come out from the air outlet, the amount of refrigerant may
be inappropriate or the compressor circuit system may be defective.DRefrigerant line fault
DAmount of refrigerant fault
DCompressor fault
DCompressor relay fault
DDual pressure switch fault
DEngine-ECUfault
DA/C-ECU fault
OK
NG
Repair
NG
Check the harness between the A/C compressor relay and the
ignition switch (IG2), and repair if necessary.
OK
Check the trouble
symptoms.
Check the following connectors:
C-12X, C-130, C-102, C-209, C-210
C-12X, C-128, D-102, C-209, C-210NG
Repair
Check the following connectors:
C-12X, A-13, A-47.
C-12X, A-136, A-47.
OK
OK
Check the trouble
symptoms.
NG
OK
NG
Replace
OK
OK
OK
NG
Check the harness between the battery and the A/C
compressor relay., and repair if necessary.
OK
Check the trouble
symptoms.
Check the following connectors:
B-12X, A-43
B-12X, C-136.(1) NG
RepairNG
(2) NG
OK
Check the dual pressure switch.
OK
NG
Repair
Check the harness between the A/Compressor relay and the
A/Compressor.
NG
Repair
Check the following connectors:B-12X, C-126.
OK
Check the trouble
symptoms.
NG
OKNG
Repair
Check the harness between the A/Compressor relay and the
Engine-ECU.
To the next page
Check refrigerant for leakage.
NG
Replace
NG
Replace
NG
NG
Replace
Check the amount of refrigerant.
Check the compressor relay.
Check the compressor magnetic clutch.
Check the refrigerant temperature switch.
Measure at the compressor relay B-12X.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
(1) Voltage between terminal 1 and body earth.
OK :Battery voltage
(2) Continuity between terminal 2 and body earth.
OK :Battery voltage
Refer to Inspection procedure 6 magnet clutch not working
normally.

HEATER, AIR CONDITIONER AND VENTILATION–On-vehicle Service55-17
12. Turn the vacuum pump adaptor switch to the R134a side
to start the vacuum pump.
Caution
Do not operate the compressor for evacuation.
13. Evacuate to a vacuum reading of 100 kPa or higher (takes
approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow
to stand it for 5 minutes.
Caution
Do not operate the compressor in the vacuum
condition; damage may occur.
15. Carry out a leak test. (Good if the negative pressure
does not drop.)
Caution
If the negative pressure drops, increase the tightness
of the connections, and then repeat the evacuation
procedure from step (12).
16. With the handle turned back all the way (valve open),
install the charging valve to the service can.
17. Turn the handle of the adaptor valve back all the way
(valve closed), remove it from the gauge manifold and
install the service can.
18. Tighten the handle of the charging valve (valve closed)
to puncture the service can.
19. 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.
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.
20. If the refrigerant is not drawn in, turn the handle of the
adaptor valve back all the way (valve closed).
21. 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 (12).
Caution
The leak detector for R-134a should be used.
22. Start the engine.
23. Operate the A/C and set to the lowest temperature (MAX.
COOL).
Low-pressure
service valveVacuum pump
Adaptor valveValve open
Valve close
Charging
valve
Service can
Charging valve
Service can
(Refrigerant container)
Low-pressure
service valve

HEATER, AIR CONDITIONER AND VENTILATION–On-vehicle Service55-21
REFRIGERANT LEAK REPAIR
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system. (See procedure.)
2. Charge the system with approximately one
pound of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
6. Replace receiver drier.
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 reassembly to avoid keeping
the system open any longer than necessary.
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.
Unified plumbing connections with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE
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
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure),
restrict air flow through condenser. Install
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. (See “Charging
System”.)
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.