oil MITSUBISHI LANCER 2005 Workshop Manual

TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-12
COMMENTS ON TROUBLE SYMPTOM
If cool air is not distributed when the A/C switch is on,
the air thermo sensor or the A/C compressor relay
system may be defective.
TROUBLESHOOTING HINTS
•Improper amount of refrigerant
•Malfunction of the air thermo sensor
•Malfunction of the dual pressure switch
•Malfunction of the A/C compressor relay
•Malfunction of the A/C refrigerant temperature
switch
•Malfunction of the magnetic clutch
•Malfunction of the manual air conditioner control
panel (A/C-ECU)
•Damaged the wiring harness or connectors
•Malfunction of the engine-ECU <M/T> or the
engine-A/T-ECU <A/T>
DIAGNOSIS
STEP 1. Check the defogger and outside/inside
air selection damper control motor operation.
Q: Do the defogger and outside/inside air selection
damper control motor work normally?
YES :
Go to Step 2.
NO : Refer to Inspection procedure 9
"Malfunction of the A/C-ECU power supply
system <L.H.D.>P.55-53 ."
STEP 2. Check the blower motor operation.
Q: Does the blower motor work normally?
YES :
Go to Step 3.
NO : Refer to Inspection procedure 5 "Blower fan
and motor do not turn P.55-29."
STEP 3. Check the A/C compressor.
Check the A/C compressor for compressor oil leaks.
Q: Is the check result satisfactory?
YES :
Go to Step 4.
NO : Replace the A/C compressor or the
expansion valve.
STEP 4. Connector check: B-114 A/C compressor
connector and C-123 engine-ECU connector
<M/T> or C-122 engine-A/T-ECU connector <A/T>
Q: Is the check result normal?
YES :
Go to Step 5.
NO : Repair the connector.
AC303782
Connector: B-114
<4G1-L.H.D.>
AC
Harness side
B-114 (B)
AC303790
Connector: B-114
<4G6-L.H.D.>
AC
Harness side
B-114 (B)
AC303805
Connectors: C-122 <A/T>, C-123 <M/T>
<L.H.D.>
C-122 (GR)
C-123 (Y)
C-122 Harness side
C-123
AE

TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-21
COMMENTS ON TROUBLE SYMPTOM
If cool air is not distributed when the A/C switch is on,
the air thermo sensor or the A/C compressor relay
system may be defective.
TROUBLESHOOTING HINTS
•Improper amount of refrigerant
•Malfunction of the air thermo sensor
•Malfunction of the dual pressure switch
•Malfunction of the A/C compressor relay
•Malfunction of the A/C refrigerant temperature
switch
•Malfunction of the magnetic clutch
•Malfunction of the manual air conditioner control
panel (A/C-ECU)
•Damaged the wiring harness or connectors
•Malfunction of the engine-ECU <M/T> or the
engine-A/T-ECU <A/T>
DIAGNOSIS
STEP 1. Check the defogger and outside/inside
air selection damper control motor operation.
Q: Do the defogger and outside/inside air selection
damper control motor work normally?
YES :
Go to Step 2.
NO : Refer to Inspection procedure 10
"Malfunction of the A/C-ECU power supply
system <R.H.D.>P.55-56 ."
STEP 2. Check the blower motor operation.
Q: Does the blower motor work normally?
YES :
Go to Step 3.
NO : Refer to Inspection procedure 5 "Blower fan
and motor do not turn P.55-29."
STEP 3. Check the A/C compressor.
Check the A/C compressor for compressor oil leaks.
Q: Is the check result satisfactory?
YES :
Go to Step 4.
NO : Replace the A/C compressor or the
expansion valve.
STEP 4. Connector check: B-114 A/C compressor
connector and C-123 engine-ECU connector
<M/T> or C-122 engine-A/T-ECU connector <A/T>
Q: Is the check result normal?
YES :
Go to Step 5.
NO : Repair the connector.
AC303786
Connector: B-114
<4G1-R.H.D.>
AB
Harness side
B-114 (B)
AC303794
Connector: B-114
<4G6-R.H.D.>
AB
Harness side
B-114 (B)
AC303817
Connectors: C-122 <A/T>, C-123 <M/T>
AF
<R.H.D.>
C-122C-122 (GR)
C-123 (Y)
C-123 Harness side

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.

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
HEATER, AIR CONDITIONER AND VENTILATION55-81
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY
AND EVAPORATOR UNIT
REMOVAL AND INSTALLATION
M1552011600457
Pre-removal and Post-installation Operation
•Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
•Engine coolant Draining and Refilling (Refer to GROUP
14, On vehicles service P.14-22).
•Instrument Panel Removal and Installation (Refer to
GROUP 52A, Instrument Panel P.52A-2).
•Air cleaner cover and air flow sensor assembly Removal
and Installation (Refer to GROUP 15, Air cleaner P.15-3).
•Rear console assembly Removal and Installation (Refer
to GROUP 52A, Rear console assembly P.52A-8).
•Front floor console assembly Removal and Installation
(Refer to GROUP 52A, Front floor console assembly
P.52A-6).
•Front seat assembly Removal and Installation (Refer to
GROUP 52A, Front seat assembly P.52A-24).
AC304861
1
2
3
4 5
6
7
8
N
9
AB
12 ± 2 N·m
6, 7O ring -Pipe coupling
A/C compressor oil:
SUN PAG 56
44 ± 10 N·m
44 ± 10 N·m
Removal steps
1. Front deck crossmember
2. Centre duct
3. Intake duct
•Foot duct (RH), Rear heater duct A
(RH) upper side (Refer to
P.55-101.)4. Blower assembly
5. Heater hose connection
<<A>>6. Flexible suction hose connection
<<A>>7. Liquid pipe B connection
8. O ring
9. Heater unitRemoval steps (Continued)

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
HEATER, AIR CONDITIONER AND VENTILATION55-82
REMOVAL SERVICE POINT
<<A>> FLEXIBLE SUCTION HOSE AND
LIQUID PIPE B 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 dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.
HEATER UNIT
DISASSEMBLY AND REASSEMBLY
<L.H.D.>
M1551005400224
AC304862
1
2
3
4
5
6
7
8
9
10
AB
4, 7O ring -Pipe coupling
A/C compressor oil:
SUN PAG 56
N
Disassembly steps
1. Foot duct (LH)
2. Heater core
3. Expansion valve
4. Joint
5. O ring6. Evaporator cover
7. Evaporator
8. Air thermo sensor clip
9. Air thermo sensor
10. Heater caseDisassembly steps (Continued)

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
HEATER, AIR CONDITIONER AND VENTILATION55-83
DISASSEMBLY AND ASSEMBLY <R.H.D.>M1551005400235
AC304863
1
2
3
4
5
N
6
7
8
9
AB
6O ring -Pipe coupling
A/C compressor oil:
SUN PAG 56
Disassembly steps
1. Foot duct (RH)
2. Heater core
3. Expansion valve
4. O ring
5. Evaporator cover6. Evaporator
7. Air thermo sensor clip
8. Air thermo sensor
9. Heater caseDisassembly steps (Continued)

EVAPORATOR ASSEMBLY
HEATER, AIR CONDITIONER AND VENTILATION55-88
EVAPORATOR ASSEMBLY
REMOVAL AND INSTALLATION <L.H.D.>M1552003600355
REMOVAL SERVICE POINT
<<A>> FLEXIBLE SUCTION HOSE AND
LIQUID PIPE B 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 dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.
Pre-removal and Post-installation Operation
•Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
•Air cleaner assembly <1300,1600> or Air cleaner and air
cleaner air flow sensor assembly <2000> Removal and
Installation (Refer to GROUP 15, Air cleaner P.15-3).
Y2346AU
1, 2, 4, 7
A/C compressor oil:
SUN PAG 56O ring
-Pipe coupling
2
101
3 4
7
6
5 98
8
12 ± 2 N·m
Removal steps
<<A>>1. Flexible suction hose connection
<<A>>2. Liquid pipe B connection
3. Expansion valve
4. Joint
•Glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
•Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> (Refer to
GROUP 13A, Engine-ECU and
Engine-A/T-ECU P.13A-401).
5. Joint duct
•Foot duct (LH), Rear heater duct
(LH), Rear heater duct (LH) (Refer
to P.55-101).
6. Evaporator cover
7. Evaporator
8. O ring 9. Air thermo sensor clip
10. Air thermo sensorRemoval steps (Continued)

EVAPORATOR ASSEMBLY
HEATER, AIR CONDITIONER AND VENTILATION55-89
REMOVAL AND INSTALLATION <R.H.D.>M1552003600366
Pre-removal and Post-installation Operation
•Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
•Air cleaner assembly <1300,1600> or Air cleaner and air
cleaner air flow sensor assembly <2000> Removal and
Installation (Refer to GROUP 15, Air cleaner P.15-3).
AC304886AB
12 ± 2 N·m
7
7
2
1
9
8
6
5
4 3 1, 2, 6
A/C compressor oil:
SUN PAG 56O ring
-Pipe coupling
Removal steps
<<A>>1. Flexible suction hose connection
<<A>>2. Liquid pipe B connection
3. Expansion valve
•Glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
•Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> (Refer to
GROUP 13A, Engine-ECU and
Engine-A/T-ECU P.13A-401).
4. Joint duct•Foot duct (LH), Rear heater duct
(LH) (Refer to P.55-101).
5. Evaporator cover
<<B>>6. Evaporator
7. O ring
8. Air thermo sensor clip
9. Air thermo sensorRemoval steps (Continued)

EVAPORATOR ASSEMBLY
HEATER, AIR CONDITIONER AND VENTILATION55-90
REMOVAL SERVICE POINT
<<A>> FLEXIBLE SUCTION HOSE AND
LIQUID PIPE B 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 dust or other foreign bodies,
plug the dismantled hose and the nipples of the
expansion valves.
<<B>> EVAPORATOR REMOVAL
CAUTION
Do not cut the upper side of the pad.
1. When removing the evaporator, cut and fold back
the dashboard pad as in the diagram. (The
thickness of the pad interferes with the removal of
the evaporator.)
2. Remove the evaporator.
INSPECTIONM1552014300938
AIR THERMO SENSOR INSPECTION
Measure the resistance between connector terminals
4 and 5 under at least two different temperatures.
The resistance values should generally match those
in the graph.
NOTE: The temperature at the check should not
exceed the range in the graph.
AC305312AB
Dashboard pad
Blower unit
AC103376
Resistance
Temperature (˚C) -10 01020
30
40 (kΩ)
05 10 152025
AB