Group 80 MITSUBISHI LANCER 2005 Workshop Manual

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-76
FAN CONTROL RELAY CONTINUITY
CHECK
IDLE-UP OPERATION CHECK
M1552001600371
1. Before inspection and adjustment, set vehicle in
the following condition:
•Engine coolant temperature: 80 − 90 °C•Lamps, electric cooling fan and accessories: Set
to OFF
•Transmission: Neutral ("N" or "P" for vehicles with
A/T)
•Steering wheel: Straightforward
2. Check whether or not the idle speed is the
standard value. <1300, 1600> Refer to GROUP
13A, On-vehicle Service − Basic Idle Speed
Adjustment P.13A-387.
<2000> Refer to GROUP 13B, On-vehicle Service
− Basic Idle Speed Adjustment P.13B-324.
Standard value: 750 ± 50 r/min
3. When the A/C is running after turning the A/C
switch to ON, and the blower switch to the 3(MH)
or 4(HI) position, check to be sure that the idle
speed is at the standard value.
Standard value: 850 ± 50 r/min
NOTE: It is not necessary to make an adjustment,
because the idling speed is automatically
adjusted by the ISC system. If, however, a
deviation from the standard value occurs for some
reason, check the ISC system.
CLEAN AIR FILTER REPLACEMENT
PROCEDURE
M1552020100030
1. Remove the glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
2. Remove the two screws as shown, and replace
the clean air filter.
3. Install the glove box. Battery voltage Tester
connectionSpecified
condition
Not applied 2 − 4 Open circuit
•Connect
terminal 1 to
the positive
battery
terminal
•Connect
terminal 3 to
the negative
battery
terminal2 − 4 Less than 2
ohms
AC305307
Fan control relay
13
4 2
3 4
1 2
AC
AC305114AB
Air filter
Instrument panel

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)

BLOWERMOTOR, RESISTOR AND OUTSIDE/ INSIDE AIR SELECTION DAMPER CONTROL MOTOR
HEATER, AIR CONDITIONER AND VENTILATION55-85
BLOWERMOTOR, RESISTOR AND OUTSIDE/
INSIDE AIR SELECTION DAMPER CONTROL MOTOR
REMOVAL AND INSTALLATION
M1551002800320
AC304885AB
2
31
Blower motor removal step
•Front passenger's side under cover
<<A>>1. Blower motor
Resistor removal step
•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).
2. ResistorOutside/inside air selection
damper control motor removal
step
•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).
3. Outside/inside air selection damper
control motor

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)

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
<<A>>1. Flexible suction hose connection
<<A>>2. Flexible discharge hose connection
3. O ring
<<B>>4. Drive belt <1300, 1600>
<<C>>5. Drive belt <2000>
<<D>> >>A<<6. A/C compressor
7. A/C compressor bracketRemoval steps (Continued)

CONDENSER AND CONDENSER FAN MOTOR
HEATER, AIR CONDITIONER AND VENTILATION55-96
CONDENSER AND CONDENSER FAN MOTOR
REMOVAL AND INSTALLATIONM1552006700384
Pre-removal and Post-installation Operation
•Refrigerant draining and Refilling (Refer to Charging
P.55-70 and Discharging P.55-72).
•Air cleaner cover and air flow sensor assembly Removal
and Installation (Refer to GROUP 15, Air cleaner P.15-3).
AC304889
5, 6
A/C compressor oil:
SUN PAG 56-Pipe coupling
O ring
2
5
10
106
7
9
8
1034
1
NN
NAB
4.9 ± 0.9 N·m
Fan shroud assembly removal
steps
1. Fan shroud assembly
2. Fan
3. Fan motor
4. Fan shroudCondenser removal steps<<A>>5. Liquid pipe A connection
<<A>>6. Flexible discharge hose connection
>>A<<7. Condenser assembly
8. Clamp
9. Receiver
10. O ring

REFRIGERANT LINE
HEATER, AIR CONDITIONER AND VENTILATION55-98
REFRIGERANT LINE
REMOVAL AND INSTALLATION <L.H.D.>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
<<A>>1. Dual pressure switch
<<A>>2. Liquid pipe A
<<A>>3. Flexible discharge hose
4. Expansion valve cover
<<A>> >>A<<5. Flexible suction hose
<<A>> >>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
<<A>> 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 <R.H.D.>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
<<A>>1. Dual pressure switch
<<A>>2. Liquid pipe A
<<A>>3. Flexible discharge hose
4. Expansion valve cover
<<A>> >>A<<5. Flexible suction hose
<<A>> >>A<<6. Liquid pipe B
7. Expansion valve cover
8. O ringRemoval steps (Continued)

DUCTS
HEATER, AIR CONDITIONER AND VENTILATION55-101
DUCTS
REMOVAL AND INSTALLATIONM1553001000101
AC304890
7
8
13
12 11 109364 5 4
3
2
1
AB A
A
Clip
Instrument panel
1 Cross-section A-A
Air Outlet Removal steps
1. Centre Air Outlet Panel
2. Centre Air Outlet
3. Side Air Outlet
Defroster nozzle and Distribution
duct Removal steps
•Instrument Panel (Refer to 52A,
Instrument Panel P.52A-2.)
4. Side defroster duct
5. Defroster nozzle
6. Distribution duct
Foot duct Removal steps
•Console cover and Glove box
(Refer to GROUP 52A, Instrument
panel P.52A-2.)
7. Foot duct (RH)8. Rear heater duct A (RH) upper side
•Under cover (Refer to GROUP
52A, Instrument panel P.52A-2.)
9. Foot duct (LH)
Rear heater duct Removal steps
•Front floor console (Refer to
GROUP 52A, Front floor console
assembly P.52A-6.)
•Front seat (Refer to GROUP 52A -
Front seat assembly P.52A-24.)
•Floor carpet and Floor pads
10. Rear heater duct A (LH)
11. Left -hand rear heater duct B
12. Right-hand rear heater duct B
13. Rear heater duct A (RH) lower sideFoot duct Removal steps