service MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

– Heater Unit, Cooling and Blower Unit HEATER AND MANUAL
AIR CONDITIONER55-19
HEATER UNIT, COOLING AND BLOWER UNIT
<VEHICLES WITH AIR CONDITIONER>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Engine Coolant Draining and Refilling

Discharging and Charging of Refrigerant
(Refer to P.55-6.)

Air Cleaner Cover and Hose Removal and
Installation

Floor Console and Instrument Panel Removal and
Installation

Rear Seat Heater Duct Removal and Installation
<Vehicles for cold regions> (Refer to P.55-31.)
1
34
5 6
2 7
8 9
10 1112
Piping connection
O-ring
A/C Compressor oil: SUN PAG 56
Removal steps
1. Center reinforcement RH
2. Heater control assembly
3. Center reinforcement LH
4. Center ventilation duct
5. Foot distribution duct
6. Drain hose
A7. Connection between cooling unit
and refrigerant line8. Cooling and blower unit
9. Heater hose
10. Heater unit
11. Heater core support
12. Heater core
REMOVAL SERVICE POINT
AREMOVAL OF REFRIGERANT LINE FROM
COOLING UNIT
Plug the open end of the removed hose and the opening
in the cooling unit to prevent entry of dust and foreign
substances.
Caution
Compressor oil and the receiver are highly
moisture-absorptive.
Do not use plugs allowing ventilation.

– Blower Motor Assembly, Resistor and Evaporator HEATER AND MANUAL
AIR CONDITIONER55-20
BLOWER MOTOR ASSEMBLY, RESISTOR AND EVAPORATOR
REMOVAL AND INSTALLATION
4
6 2
1 5
3
7
Piping connection
O-ring
A/C Compressor oil: SUN PAG 56
Blower motor assembly removal
steps
1. Under cover
<Vehicles for cold regions>
2. Blower motor assembly
Resistor removal steps
1. Under cover
<Vehicles for cold regions>

Glove box, glove box frame
3. ResistorEvaporator removal steps
<Vehicles with A/C>

Discharging and Charging of
refrigerant (Refer to P.55-6.)

Glove box, glove box frame
4. Drain hose
A5. Connection between evaporator
and refrigerant line
B6. Case cover
B7. Evaporator
REMOVAL SERVICE POINT
AREMOVAL OF REFRIGERANT LINE FROM
EVAPORATOR
Plug the open end of the removed hose and the opening
in the evaporator to prevent entry of dust and foreign
substances.
Caution
Compressor oil and the receiver are highly
moisture-absorptive.
Do not use plugs allowing ventilation.

– Compressor and Tension Pulley HEATER AND MANUAL
AIR CONDITIONER55-24
REMOVAL SERVICE POINTS
ADRIVE BELT REMOVAL
1. Align the hole in the auto-tensioner bracket with that in
the arm and insert a screwdriver into the holes.
2. Remove the drive belt.
BSUCTION HOSE, DISCHARGE HOSE
DISCONNECTION
Plug the disconnected hose and the compressor nipple not
to let foreign matter get into them.
Caution
Seal the hoses completely, otherwise the compressor
oil and receiver will absorb water vapour easily.
CCOMPRESSOR REMOVAL
When doing this work, be careful not to spill the compressor
oil.
Auto-tensioner
Hole in
arm
Hole in
bracket
Screwdriver (+)

– Compressor and Tension Pulley HEATER AND MANUAL
AIR CONDITIONER55-25
INSTALLATION SERVICE POINT
ACOMPRESSOR 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 m
) 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
120 to 140 m
– X m
= Y m

NOTE
(1)“120 to 140 ml” is the amount of oil filled in a new
compressor.
(2) Y m
indicates the amount of oil in the refrigerant
line, the condenser, the cooling unit etc.
INSPECTION
REFRIGERANT-TEMPERATURE SWITCH SIMPLE
CHECK
When the A/C is off, check that there is continuity between
the refrigerant-temperature switch terminals. If no, replace
the compressor assembly.
COMPRESSOR MAGNETIC CLUTCH OPERATION
INSPECTION
Connect the battery (+) terminal to the compressor side
terminal, and earth the battery (–) terminal to the body of
the compressor. The condition is normal if the sound of the
magnetic clutch (click) can be heard.AView A
Refrigerant temperature
switch terminal

– Compressor and Tension Pulley HEATER AND MANUAL
AIR CONDITIONER55-26
MAGNETIC CLUTCH
DISASSEMBLY AND REASSEMBLY
46
2 1
53
Disassembly steps
E
Air gap adjustment
AD1. Self-locking nut
C2. Armature
3. ShimsB4. Snap ring
5. Rotor
A6. Field core
DISASSEMBLY SERVICE POINT
ASELF-LOCKING NUT REMOVAL
REASSEMBLY SERVICE POINTS
AFIELD CORE INSTALLATION
When installing the field core to the compressor body, install
so that the pin hole of the compressor body and the field
core projection are aligned.
MB991386
MB991367
Field core
projection
Compressor
body pin hole

– Condenser and Condenser Fan HEATER AND MANUAL
AIR CONDITIONER55-29
REMOVAL SERVICE POINTS
AFAN MOTOR AND SHROUD ASSEMBLY
REMOVAL
Remove the clamp bolt of the power steering oil cooler pipe.
Remove the fan motor and shroud assembly while pulling
the power steering oil cooler pipe toward you.
BDISCHARGE HOSE / LIQUID PIPE A
DISCONNECTION
Plug the open end of the disconnected hose and the opening
in the cooling unit not to let foreign matter get into them.
Caution
Seal the hoses completely, otherwise the compressor
oil and receiver will absorb water vapour easily.
CCONDENSER REMOVAL
Move the radiator to the engine side and then lift up the
condenser to remove it.
INSPECTION
CONDENSER FAN MOTOR CHECK
Battery connection terminalCondenser fan operation
12
Rotate
Condenser

FULL-AUTOMATIC AIR CONDITIONER –
General / Service Specifications /
Lubricants / Special Tools55-33
FULL-AUTOMATIC AIR CONDITIONER
GENERAL
OUTLINE OF CHANGE

The following service procedures have been established.
SERVICE SPECIFICATIONS
ItemsStandard value
Idle speed r/min750
50
Idle-up speed r/min850
50
Air gap (Compressor) mm0.4 – 0.6
Air mix damper potentiometer
resistance kΩ
MAX. HOT position4.82
resistance kΩMAX. COOL position0.18
Outlet air changeover damper
potentiometer resistance kΩ
DEF position0.18
potentiometer resistance kΩFACE position4.82
LUBRICANTS
ItemsSpecified lubricantsQuantity
Compressor oil mSUN PAG 56120 – 140
Each connection of refrigerant lineSUN PAG 56As required
Refrigerant gR134a (HFC-134a)555 – 595
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-II
sub-assemblyInspection of full-automatic air conditioner
MB991529Diagnosis code
check harnessInspection of full-automatic air conditioner
using a voltmeter

FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting55-34
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK
Connect the MUT-II or a voltmeter to the diagnosis connector (16-pin), then check diagnosis codes.
(Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.)
ERASING DIAGNOSIS CODES
Refer to GROUP 00 – How to Use Troubleshooting/Inspection Service Points.
INSPECTION CHART FOR DIAGNOSIS CODES
Code No.Diagnosis itemReference
page
11Inside air temperature sensor system (open circuit)55-34
12Inside air temperature sensor system (short circuit)55-34
13Outside air temperature sensor system (open circuit)55-35
14Outside air temperature sensor system (short circuit)55-35
15Heater water temperature sensor system (open circuit)55-36
16Heater water temperature sensor system (short circuit)55-36
21Air thermo sensor system (open circuit)55-37
22Air thermo sensor system (short circuit)55-37
31Potentiometer system of air mix damper assembly55-38
32Potentiometer system of air outlet changeover damper assembly55-39
41Drive system of air mix damper motor assembly55-40
42Drive system of air outlet changeover damper motor assembly55-40
INSPECTION PROCEDURES FOR DIAGNOSIS CODES
Code No.11 Inside air temperature sensor system (open
circuit)Probable cause
This diagnosis code is output if the power supply line or input line of the inside
air temperature sensor inside A/C-ECU is open-circuited and no signal is input
from the inside air temperature sensor to A/C-ECU.
Malfunction of the A/C-ECU
Replace the A/C-ECU.
Code No.12 Inside air temperature sensor system (short
circuit)Probable cause
This diagnosis code is output if the power supply line or input line of the inside
air temperature sensor inside A/C-ECU is short-circuited and inside air
temperature sensor power supply voltage signals are input to A/C-ECU.
Malfunction of the A/C-ECU
Replace the A/C-ECU.

FULL-AUTOMATIC AIR CONDITIONER –
Troubleshooting /
On-vehicle Service55-56
Terminal
No.Normal condition Check condition Check item
25Air mix damper motor (MAX. HOT)When damper is moved to MAX.
COOL positionAlmost no voltage
(0.5 V)
When damper is moved to MAX. HOT
position10 V
26Inside/outside air changeover damper
motor (Outside)When switch is set to inside air
position10 V
When switch is set to outside air
positionAlmost no voltage
(0.5 V)
28IG2 power supplyWhen ignition switch is ONSystem voltage
29EarthAt all timesContinuity
30ILL power supplyWhen lighting switch is at ONSystem voltage
34A/C outputWhen A/C is OFF0 V
When A/C is ONSystem voltage
35EarthAt all timesContinuity
ON-VEHICLE SERVICE
REFRIGERANT CHARGING, LEVEL CHECK,
ADDITION AND REMOVAL, PERFORMANCE
TEST, DUAL PRESSURE SWITCH SIMPLE
CHECK
Follow the same procedures as for the heater and manual
air conditioner. (Refer to P.55-6.)

FULL-AUTOMATIC AIR CONDITIONER – On-vehicle Service55-57
POWER RELAY CHECK
Follow the same procedures as for the heater and manual
air conditioner except for the following. (Refer to P.55-13.)
BLOWER HIGH SPEED RELAY
Battery voltageTerminal No.
1234
Power is not supplied
Power is supplied
IDLE-UP OPERATION CHECK
The idle-up inspection procedures are the same as for the
heater and manual air conditioner. (Refer to P.55-14.)
<Idle speed>
Standard value: 750 ± 50 r/min
<Idle-up speed>
Standard value: 850 ± 50 r/min
NOTE
If the idling speed is not within the standard value range,
adjust it.
Blower high speed relay