dış MITSUBISHI LANCER 2005 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2005, Model line: LANCER, Model: MITSUBISHI LANCER 2005Pages: 788, PDF Size: 45.98 MB
Page 539 of 788
TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-55
STEP 4. Resistance measurement resistance at
C-139 A/C-ECU connector.
(1) Disconnect the connector, and measure at the
wiring harness side.
(2) Measure the resistance between terminal 12 and
body earth.
OK: 2 ohms or less
Q: Is the check result normal?
YES :
Replace the manual air conditioner control
panel (A/C-ECU).
NO : Go to Step 5.
STEP 5. Check the wiring harness between C-139
A/C-ECU connector terminal No.12 and the earth.
NOTE:
Prior to the wiring harness inspection, check joint
connector C-104, and repair if necessary.
•Check the A/C-ECU earth line for open circuit.
Q: Is the check result normal?
YES :
Replace the manual air conditioner control
panel (A/C-ECU).
NO : Repair the wiring harness.
AC303802
Connector: C-139
AE
C-139 (B)
Harness side
AC301541ER
Connector C-139
(Harness side)
91
1574
12111023135146168
AC303802
Connector: C-139
AE
C-139 (B)
Harness side
AC303804
Connector: C-104
AJ
C-104 (GR)
Page 541 of 788
TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-57
DIAGNOSIS
STEP 1. Connector check: C-139 A/C-ECU
connector
Q: Is the check result normal?
YES :
Go to Step 2.
NO : Repair the connector.
STEP 2. Voltage measurement at C-139 A/C-ECU
connector.
(1) Disconnect the connector, and measure at the
wiring harness side.
(2) Turn the ignition switch to the "ON" position.
(3) Measure the voltage between terminal 7 and
body earth.
OK: System voltage
Q: Is the check result normal?
YES :
Go to Step 4.
NO : Go to Step 3.
STEP 3. Check the wiring harness between C-139
A/C-ECU connector terminal No.7 and the
ignition switch (IG2).
NOTE:
Prior to the wiring harness inspection, check junction
block connectors C-210, C-212 and joint connector
C-35, and repair if necessary.
•Check the A/C-ECU power supply line for open
circuit.
AC303818
Connector: C-139
AJ
Harness side
C-139 (B)
11 12657 8 9 103 421
AC303818
Connector: C-139
AJ
Harness side
C-139 (B)
11 12657 8 9 103 421
AC301541ES
Connector C-139
(Harness side)
11 12
65
7 8 9 10
3 421
AC303818
Connector: C-139
AJ
Harness side
C-139 (B)
11 12657 8 9 103 421
AC303814
Connector: C-35
AS
C-35(L)
AC303823
Junction block (front view)
Connectors: C-210, C-212
C-210 Harness side
C-212
C-210
AJ
C-212
Harness side
Page 542 of 788
TROUBLESHOOTING
HEATER, AIR CONDITIONER AND VENTILATION55-58
Q: Is the check result normal?
YES :
The trouble can be an intermittent
malfunction (Refer to GROUP 00, How to
Cope with Intermittent Malfunction P.00-5).
NO : Repair the wiring harness.
STEP 4. Resistance measurement at the C-139
A/C-ECU connector.
(1) Disconnect the connector, and measure at the
wiring harness side.
(2) Measure the resistance between terminal 3 and
body earth.
OK: 2 ohms or less
Q: Is the check result normal?
YES :
Replace the manual air conditioner control
panel (A/C-ECU).
NO : Go to Step 5.
STEP 5. Check the wiring harness between C-139
A/C-ECU connector terminal No.3 and the earth.
•Check the A/C-ECU earth line for open circuit.
Q: Is the check result normal?
YES :
Replace the manual air conditioner control
panel (A/C-ECU).
NO : Repair the wiring harness.AC303818
Connector: C-139
AJ
Harness side
C-139 (B)
11 12657 8 9 103 421
AC301541ET
Connector C-139
(Harness side)
11 12657 8 9 103 421
AC303818
Connector: C-139
AJ
Harness side
C-139 (B)
11 12657 8 9 103 421
Page 553 of 788
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-69
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL
TEST
M1552008400378
1. Start the engine.
2. Operate the air-conditioner, and then set the
temperature to maximum cooling.
3. Hold the engine speed at 1500 r/min.
4. Check the refrigerant level (bubble state) through
the sight glass.
CAUTION
Use the low-pressure service valve.
NOTE: Use the refrigerant recovery station to
charge the specified refrigerant because you can
not calculate the amount of the refrigerant
properly with the sight glass.
MAGNETIC CLUTCH TESTM1552008500405
1. Disconnect the magnetic clutch connector to the
magnetic clutch.
2. Connect positive battery voltage directly to the
connector for the magnetic clutch.3. If the magnetic clutch is normal, there will be a
"click." If the pulley and armature do not make
contact ("click"), there is a malfunction.
COMPRESSOR DRIVE BELT
ADJUSTMENT
M1552001000335
<1300, 1600>
Refer to GROUP 11A, On-vehicle Service − Drive
Belt Tension Check P.11A-7.
<2000>
Refer to GROUP 11C, On-vehicle Service − Drive
Belt Tension Check P.11C-7.
DUAL PRESSURE SWITCH CHECKM1552010400320
1. Remove the dual pressure switch connector and
connect the high/low pressure side terminals
located on the harness side as shown in the
illustration..
2. Install a gauge manifold to the high-pressure side
service valve of the refrigerant line. (Refer to
P.55-98, P.55-99.)
3. When the high/low pressure sides of the dual
pressure switch are at operation pressure (ON)
the resistance should less than two ohms
between the terminals. If open circuit, replace the
switch. Items State
Insufficient Many bubbles are seen.
If refrigerant is extremely
low, it appears white.
Sufficient or excess
refrigerantNo bubbles are seen.
AC005963
Bubbles Insufficient
refrigerantSufficient or excess
refrigerant
AC
AC005671
Magnetic clutch connector
AC
AC001368AD High/Low
Pressure Side
Low-pressure side
High-pressure side
ON
OFFON
OFF
2650 ± 200 2060 ± 200230 ± 20 210 ± 25
(kPa)
Page 556 of 788
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
Page 557 of 788
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-73
PERFORMANCE TEST M1552001400355
1. The vehicles to be tested should be in a place that
is not in direct sunlight.
2. Close the high and low-pressure valve of the
gauge manifold.
3. Connect the charging hose (blue) to the
low-pressure valve and connect the charging
hose (red) to the high-pressure valve of the gauge
manifold.
CAUTION
•To connect the quick joint, press section A
firmly against the service valve until a click is
heard.
•When connecting, run your hand along the
hose while pressing to ensure that there are
no bends in the hose.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).NOTE: The high-pressure service valve is on the
A/C pipe and the low-pressure service valve is on
the suction hose.
5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick
joint (for high-pressure) to the high-pressure
service valve.
6. Start the engine.
7. Set the A/C controls as follows:
•A/C switch: A/C − ON position
•Mode selection: FACE position
•Temperature control: MAXIMUM COOLING
position
•Air selection: RECIRCULATION position
•Blower switch: "4" (Fast) position
8. Keep engine speed to idling speed with A/C clutch
engaged.
9. Engine should be warmed up with doors and all
windows opened.
10.Insert a thermometer in the centre air outlet and
operate the engine for 20 minutes.
NOTE: If the clutch cycles, take the reading before
the clutch disengages.
11.Note the discharge air temperature.
Performance Temperature Chart
AC001388
Low-pressure
valveHigh-pressure
valve
Gauge manifold
Charging
hose (red)
A
Sleeve Charging
hose (blue)
Adaptor valve
(for low-
pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
AB
Adaptor valve
(for high-
pressure)
AC304576
Thermometer
AB
Garage ambient temperature °C20 25 30 35
Discharge air temperature °C8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
Compressor high pressure kPa 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
Compressor low pressure kPa 150 − 190 190 − 240 240 − 300 300 − 375
Page 558 of 788
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.
Page 563 of 788
HEATER CONTROL ASSEMBLY AND A/C SWITCH
HEATER, AIR CONDITIONER AND VENTILATION55-79
INSPECTIONM1552014300927
BLOWER SWITCH CONTINUITY CHECK
DISASSEMBLY AND REASSEMBLY
M1552014200180
12
6 3
45
AC100615AB
Switch
positionTester connection Specified
condition
0 (OFF) 1 − 2, 2 − 4, 2 − 5, 2 − 6 Open circuit
1 (LO) 1 − 2 Less than 2
ohms
2 (ML) 2 − 4 Less than 2
ohms
3 (MH) 2 − 5 Less than 2
ohms
4 (HI) 2 − 6 Less than 2
ohms
AC100614
1 23
4
5 67 8
AB
Disassembly steps
1. Switch panel
2. Rear window defogger switch
3. Air conditioner switch
4. Inside/outside air selection switch
<>5. Mode selection damper control
cable
<>6. Air mixing damper control cable7. Blower switch assembly
8. Manual air conditioner control panel
(A/C-ECU) Disassembly steps (Continued)
Page 564 of 788
HEATER CONTROL ASSEMBLY AND A/C SWITCH
HEATER, AIR CONDITIONER AND VENTILATION55-80
DISASSEMBLY SERVICE POINT
<> BLOW VENT CHANGEOVER
DAMPER CABLE AND AIR MIX DAMPER
CABLE REMOVALInsert a flat-tipped screwdriver into the clip through
the inside of the control base and prize out the clip
claw to disconnect the cables.
AC100619
AB
Clip
claw
(-) flat-tipped
screwdriver
Page 565 of 788
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
<>6. Flexible suction hose connection
<>7. Liquid pipe B connection
8. O ring
9. Heater unitRemoval steps (Continued)