MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
CONTENTS
HEATER AND MANUAL AIR
CONDITIONER 3. . . . . . . . . . . . . . . . . . . . . .
GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 3. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 3. . . . . . . . . . . . . .
LUBRICANTS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 4. . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6. . . . . . . . . . . . . . . . . .
Refrigerant Charging 6. . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Charging Amount Check 9. . . . . . . .
Replenishing System 10. . . . . . . . . . . . . . . . . . . . .
Discharging System 11. . . . . . . . . . . . . . . . . . . . . .
Performance Test 11. . . . . . . . . . . . . . . . . . . . . . . .
Dual Pressure Switch Simple Check 13. . . . . . .
Power Relay Check 13. . . . . . . . . . . . . . . . . . . . . .
Idle-up Operation Check 14. . . . . . . . . . . . . . . . . .
HEATER CONTROL ASSEMBLY AND A/C
SWITCH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER UNIT AND BLOWER UNIT
<VEHICLES WITHOUT
AIR CONDITIONER> 18. . . . . . . . . . . . . . . . . . .
HEATER UNIT, COOLING AND BLOWER
UNIT <VEHICLES WITH AIR
CONDITIONER> 19. . . . . . . . . . . . . . . . . . . . . . .
BLOWER MOTOR ASSEMBLY, RESISTOR
AND EVAPORATOR 20. . . . . . . . . . . . . . . . . . .
COMPRESSOR AND TENSION
PULLEY 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER AND CONDENSER FAN 28. .
REFRIGERANT LINE 30. . . . . . . . . . . . . . . . . .
DUCTS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTINUED ON NEXT PAGE

55-2
FULL-AUTOMATIC AIR
CONDITIONER 33. . . . . . . . . . . . . . . . . . . . .
GENERAL 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 33. . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 33. . . . . . . . . . . .
LUBRICANTS 33. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 33. . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 34. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 56. . . . . . . . . . . . . . . .
Refrigerant Charging, Level Check, Addition
and Removal, Performance Test, Dual
Pressure Switch Simple Check 56. . . . . . . . . . . .
Power Relay Check 57. . . . . . . . . . . . . . . . . . . . . .
Idle-up Operation Check 57. . . . . . . . . . . . . . . . . .
DAMPER CONTROL MOTOR ASSEMBLY
AND POWER TRANSISTOR 58. . . . . . . . . . . .
PHOTO SENSOR 61. . . . . . . . . . . . . . . . . . . . . .
OUTSIDE AIR TEMPERATURE
SENSOR 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER WATER TEMPERATURE
SENSOR 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OTHER MAINTENANCE SERVICE
POINTS 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General / Service Specifications /
Lubricants / Special Tools HEATER AND MANUAL
AIR CONDITIONER –55-3
HEATER AND MANUAL AIR CONDITIONER
GENERAL
OUTLINE OF CHANGE

The following service procedures have been established.
SERVICE SPECIFICATIONS
ItemsStandard value
Idle speed r/min700 ± 50
Idle up speed r/min850 ± 50
Resistor (for blower motor) ΩHI – LO (between terminals 3 and 2)2.81 ± 10%
HI – ML (between terminals 3 and 4)1.28 ± 10%
HI – MH (between terminals 3 and 1)0.33 ± 10%
Air gap (Compressor) mm0.4 – 0.6
LUBRICANTS
ItemsSpecified lubricantsQuantity
Compressor oil m
SUN PAG 56120 – 140
Pipe jointSUN PAG 56As required
Refrigerant gR134a (HFC-134a)555 – 595
SPECIAL TOOLS
ToolNumberNameUse
MB991367Special spannerRemoval and installation of armature mounting
nut of compressor
MB991386Pin

HEATER AND MANUAL AIR CONDITIONER – Troubleshooting55-4
TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES
1. Check air ducts, control rods, etc. for improper connection.
2. Check that the electrical connectors of the relevant components are connected securely and the
fuse is not blown.
3. Perform the troubleshooting as follows; first understand the items to be inspected and the the procedures
comprehensively using Trouble Symptom/Failed Component Cross-Reference Table and then inspect
the appropriate items sequentially.
4. Be sure to perform each component check after disconnecting the relevant connector.
Trouble Symptom/Failed Component Cross-Reference Table
Items to be checked1.
When the igni-
tion switch is
“ON”, the A/C
does not oper-
ate.2.
When the A/C
is operating,
temperature
inside the pas-
senger
compartment
does not
decrease (cool
air is not
emitted).3.
Blower fan
motor does not
turn.4.
Blower fan
motor does not
stop turning.5.
When A/C is
operating,
radiator fan
and condenser
fan do not run.
Fuse111
Harness, connector2212
Amount of refrigerant31
A/C compressor relay4
A/C compressor magnet
clutch5
Dual pressure switch623
A/C switch7
Blower switch832
Blower relay4
Resistor53
Blower motor6
Air thermo-sensor93
Condenser fan relay44
Condenser fan motor55
Radiator fan relay (HI, LO)66
Radiator fan motor77
Refrigerant temperature
switch108
Auto compressor control
unit119
Engine-ECU12108

HEATER AND MANUAL AIR CONDITIONER – Troubleshooting55-5
No.Trouble symp-
tomProblem causeRemedyRefer-
ence
page
1When the igni-
tion switch is
“ON”, the A/C
does not oper
Refrigerant leak or overfilling of refriger-
antReplenish the refrigerant, repair the
leak or take out some of the
refrigerant55-6
does not oper-
ate.A/C compressor relay is defectiveReplace the A/C compressor relay55-14ate.
A/C compressor magnetic clutch is
defectiveReplace the A/C compressor magnet
clutch55-26
Dual pressure switch is defectiveReplace the dual pressure switch55-13
A/C switch is defectiveReplace the A/C switch55-17
Blower switch is defectiveReplace the blower switch55-17
Air thermo-sensor is defectiveReplace the air thermo-sensor55-22
Refrigerant temperature switch is defec-
tiveReplace the refrigerant temperature
switch55-25
Automatic compressor-ECU is defectiveReplace the automatic compressor-
ECU–
2When the A/C is
operating, tem-
perat re inside
Refrigerant leakReplenish the refrigerant and repair
the leak55-6
perature inside
the
passengerDual pressure switch is defectiveReplace the dual pressure switch55-13the passenger
compartment
doesn’tde-Air thermo-sensor is defectiveReplace the air thermo-sensor–doesnt de-
crease (cool air
is not emitted)
Condenser fan relay is defectiveReplace the condenser fan relay55-14
is not emitted).Condenser fan motor is defectiveReplace the condenser fan motor55-29
Radiator fan relay (HI, LO) is defectiveReplace the radiator fan relay (HI, LO)55-14
Radiator fan motor is defectiveReplace the radiator fan motor–
Refrigerant temperature switch is defec-
tiveReplace the refrigerant temperature
switch55-25
Automatic compressor-ECU is defectiveReplace the automatic compressor-
ECU–
3Blower fan mo-
tor doesn’t turn
Blower switch is defectiveReplace the blower switch55-17
tor doesn’t turn.Blower relay is defectiveReplace the blower relay55-13
Resistor is defectiveReplace the resistor55-21
Blower fan motor is defectiveReplace the blower fan motor55-21
4Blower fan mo-
tor doesn’t stop
t rning
Defective harness between the blower
fan motor and the blower switchRepair the harness–
turning.Blower switch is defectiveReplace the blower switch55-17
Resistor is defectiveReplace the resistor55-21
5When the A/C is
operating con
Condenser fan relay is defectiveReplace the condenser fan relay55-14
operating con-
denser fan orCondenser fan motor is defectiveReplace the condenser fan motor55-29denser an or
radiator fan
does not runRadiator fan relay (HI, LO) is defectiveReplace the radiator fan relay (HI, LO)55-14does not run.
Radiator fan motor is defectiveReplace the radiator fan motor–
Dual pressure switch is defectiveReplace the dual pressure switch55-13
Engine-ECU is defectiveReplace the engine-ECU–

HEATER AND MANUAL AIR CONDITIONER –
Troubleshooting /
On-vehicle Service55-6
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL
Terminal
No.Check itemChecking requirementsNormal condition
1Output from ECU to A/C compressor
relay
A/C compressor relay: OFFSystem voltage
relay
A/C compressor relay: ON0 V
2Input from A/C switch to ECUA/C switch: OFF0 V
A/C switch: ONSystem voltage
3EarthAlways0 V
ON-VEHICLE SERVICE
REFRIGERANT CHARGING
Caution
The refrigerant generates toxic gases when it is expored
to a heat source such as fire. Keep flames away from
the refrigerant. Perform refrigerant charging at a
well-ventilated place.
1. Recommended charging tools
The following commercially available tools are recommended
for discharging and charging refrigerant.

Gas charging set [No. EA95 (R134a)]

Gas charging set case [No. EA101CS-2]

Gauge manifold [No. EA101N-1]

Charging valve [No. EA108N]

Adapter valve [No. EA104AD-3]
NOTE
The adapter valve opens when the handle is turned
clockwise and closes when it is turned counter-clockwise.

Quick joint (for low pressure) [No. EA413L]

Quick joint (for high pressure) [No. EA413H]

Charging hose (red) [No. EA104N-1]

Charging hose (blue) [No. EA104N-2]

Charging hose (yellow) [No. EA104N-3]

Vacuum pump [No. EA112A]

Vacuum pump adaptor [No. EA112X]
Gauge manifold
Adapter valve
(for low pressure)
Charging hoseVacuum
pump adaptor
Quick joint
(for low pressure)Charging valve
Quick joint
(for high pressure)
Vacuum pump

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-7
2. Charging
1. Open the low-pressure valve of the gauge manifold. Keep
the high-pressure valve closed.
2. With the handles turned back all the way (valve closed),
install the adaptor valve to the low-pressure side of the
gauge manifold.
3. Connect the charging hose (blue) to the adaptor valve
1.
4. Connect the quick joint 2 to the charging hose (blue).
5. Connect the quick joint 2 to the low pressure service
valve.
NOTE
The low-pressure service valve is provided on the suction
pipe.
Caution
(1) To install the quick joint, press section “A” firmly
against the service valve until a click is heard.
(2) When connecting, run your hand along the hose
while pressing to ensure that there are no bends
in the hose.
6. Connect the charging hose (yellow) to the valve 3 of
the gauge manifold.
7. Install the vacuum pump adaptor to the vacuum pump.
Caution
To supply the power, connect the power supply plug
of the vacuum pump to the vacuum pump adapter
and then the power supply plug of the vacuum pump
adapter to a 100 V power outlet.
8. Connect the charging hose (yellow) to the R134a
connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve 1 handle (valve closed).
10. Turn the power switch of the vacuum pump to the ON
position.
NOTE
Even if the vacuum pump power switch is turned ON,
the vacuum pump will not operate because of the power
supply connection in step (7).
11. Turn the vacuum pump adaptor switch to the R134a side
to start the vacuum pump.
Low-
pressure
valveHigh-
pressure
valve
Gauge
manifold
Adapter
valve (for low
pressure)
Charging hose (yellow)
Charging hose
(blue)
To 100 V
power
outletSwitchR134a
connec-
tion port
Vacuum
pump
adaptor
Vacuum
pump
Power
supply
plug Quick joint
(for low
pressure)
Low-
pressure
service
valve
Sleeve
Low-
pressure
gaugeHigh-
pressure
gauge
Valve
High-
pressure
service
valve
Air
condi-
tioning
system
A
Power
supply
plug
Switch

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-8
12. Evacuate to a vacuum reading of 100 kPa or higher (takes
approx. 10 minutes).
Start evacuation
Approx. for 10 minutes up to
100 kPa
Stop evacuation
Refrigerant charging
(until saturated pressure is reached)
Wait for 5 minutes
Air-tight checkIf faulty
Refrigerant charging
Gas leak check*If faultyRetighten connections
*: If the leaking point cannot be located even after
performing a gas leak check, ask an expert for
checking the system.
13. Return the handle of the adapter valve 1 to the original
position (valve closed), turn off the vacuum pump adapter
switch and leave as it is for 5 minutes.
14. Carry out a leak test. (Good if the negative pressure
does not drop.)
15. With the handle turned back all the way (valve open),
install the charging valve to the service can.
16. Remove the adaptor valve 1 from the gauge manifold
and install the service can.
17. Tighten the handle of the charging valve (valve closed)
and puncture the service can.
18. Turn the handle of the charging valve back (valve open)
and tighten the handle of the adaptor valve 1 (valve open)
to charge the system with refrigerant.
19. If the refrigerant is not drawn in, turn the handle of the
adaptor valve 1 back all the way (valve closed).
20. Check for gas leaks using a leak detector.
Caution
The leak detector for R134a should be used.
21. Start the engine.
22. Operate the A/C and set to the lowest temperature (MAX.
COOL).
23. Fix the engine speed at 1,500 r/min.
24. Tighten the handle of the adaptor valve 1 (valve open)
to charge the required volume of 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.
25. After charging with refrigerant, turn the handle of the
adaptor valve 1 back all the way (valve closed).
26. Tighten the charging valve handle (valve closed).
Charging
valveAdapter valve
(for low pressure)
Charging hose
(blue)
R134a
Service
can
Quick joint
(for low pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-9
27. Remove the quick joint 2 from the low-pressure service
valve.
28. Remove the service can.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve 1 closed
for the next charging.
REFRIGERANT CHARGING AMOUNT CHECK
1. Start the engine.
2. Operate A/C and set the temperature control to MAX
COOL.
3. Fix the engine speed at 1,500 r/min.
4. Check the refrigerant level (bubble generation) through
the sight glass of the receiver.
ItemCondition
Proper levelBubbles are generated some times. No
bubbles appear when the engine speed is
slightly increased.
Level too lowA large amount of air bubbles are generated. If
it looks milky white, the level is excessively
lowered.
Level too highNo air bubbles appear.
5. If the level is too low, add the refrigerant, and if the level
is too high, drain the refrigerant as necessary.
Caution
Be sure to work at the low-pressure side service valve.
Proper level Level too low Level too high
Bubble Bubble

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-10
REPLENISHING SYSTEM
1. Connect the charging hose (blue) to the adapter valve
1 with the handle fully turned back (valve closed).
2. Connect the charging hose (blue) to the quick joint 2
and to the low pressure service valve.
Caution
Never connect to the high-pressure side since
otherwise the refrigerant could flow back.
3. Open and close the valve by operating the handle of
the adapter valve 1 to bleed air from inside the charging
hose.
4. With the handle turned back all the way (valve open),
install the charging valve to the service van.
5. Tighten the handle of the charging valve (valve closed)
and puncture the service can.
6. Install the charging valve to the adapter valve 1 and turn
back the handle all the way (valve open).
7. Start the engine.
8. Operate the A/C and set to the lowest temperature (MAX.
COOL).
9. Fix the engine speed at 1,500 r/min.
10. Tighten the handle of the adapter valve 1 (valve open).
Replenish the system with refrigerant while checking the
level through the sight glass.
After charging with refrigerant, turn the handles of the
charging valve and the adapter valve 1 all the way back
(valve closed), then remove the quick joint 2.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve closed
for the next charging.Charging
valveAdapter valve
(for low pressure)
Charging hose
(blue)
R134a
Service
can
Quick joint
(for low pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system