belt MITSUBISHI LANCER 2005 Owner's Manual

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Page 553 of 788

MITSUBISHI LANCER 2005 Owners Manual 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

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 558 of 788

MITSUBISHI LANCER 2005 Owners Manual 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 (R

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 575 of 788

MITSUBISHI LANCER 2005 Owners Manual COMPRESSOR ASSEMBLY AND TENSION PULLEY
HEATER, AIR CONDITIONER AND VENTILATION55-91
COMPRESSOR ASSEMBLY AND TENSION PULLEY
REMOVAL AND INSTALLATIONM1552004100472
Pre-removal Operation
•Refrigerant D

Page 576 of 788
COMPRESSOR ASSEMBLY AND TENSION PULLEY
HEATER, AIR CONDITIONER AND VENTILATION55-92
REMOVAL SERVICE POINTS
<> FLEXIBLE SUCTION HOSE AND
FLEXIBLE DISCHARGE HOSE
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 hoses and compressor nipples.
<> DRIVE BELT REMOVAL <1300,
1600>
CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk.
1. Loosen the power steering oil pump fixing bolts A,
B and C.
2. Turn the adjusting bolt D in the anti-clockwise
direction (to the left) to remove the drive belt.
<> DRIVE BELT REMOVAL <2000>
The following operations will be needed due to the
serpentine drive system with the alternator drive belt
auto tensioner.
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig
hole of the alternator drive belt auto tensioner,
and turn the alternator drive belt auto tensioner
anti-clockwise until it hits the stopper.
CAUTION
To reuse the alternator drive belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the alternator drive belt using chalk.
2. Align hole A with hole B, insert an L-shaped
hexagon wrench, etc. to fix and then remove the
alternator drive belt.
<> COMPRESSOR REMOVAL
Take care not to spill any compressor oil when
removing the compressor.
AC203472
AC
DB A
C
AC107640ADHole A
Hole B
Alternator drive belt
auto tensioner
AC107641AC
L-shaped
hexagon
wrench
Alternator drive belt
auto tensioner

Page 593 of 788
SENSOR
COMPONENT LOCATIONS70-7
AC208762
A
AD
Timing belt front
upper coverTiming belt front
lower coverEngine crank
angle sensor
<4G1>
Engine crank angle
sensor connector
AC302008
A<4G6>
ABHeat protector
Crankshaft
sprocket
Engine crank angle
sensor connectorEngine crank
angle sensor
AC301752
B
AB
Ignition coil 2
<4G1>
Engine control detonation
sensor connector
Engine control
detonation sensor
AC302009
B
AB
Hydraulic unit
<4G6>
Alternator
Engine control detonation
sensor connectorEngine control
detonation sensor
AC208541
C
AE
<4G1>
Throttle body
Throttle body
throttle sensor
Inlet manifold absolute pressure sensor
(incorporating intake air temperature sensor)
AC302479
AB
C
Throttle body
<4G6>
Throttle body
throttle sensor

Page 595 of 788
SENSOR
COMPONENT LOCATIONS70-9
AC206775
AD
I
Input shaft
speed sensor
Output shaft
speed sensor
Air cleaner
bracket
AC301755
J
AB
Air thermo
sensorBlower assembly
AC300517
AD
K
Side impact
sensor (Front) Centre
pillar
AC300534
AC
L
Side impact
sensor (Rear)
Rear
seat belt
AC209080
M
AG
Wheel speed sensor
(Front) connector
Coil spring
Wheel speed
sensor (Front)
AC301753AB
SRS-ECU
N
Engine control
oxygen sensor
(Rear) connector
Engine control
oxygen sensor
(Rear)
AC209459
O
Wheel speed sensor
(Rear) connector
Parking brake cable
Coil spring
AE
Wheel speed
sensor (Rear)

Page 597 of 788
EARTH CABLE
COMPONENT LOCATIONS70-11
EARTH CABLE
M1701001000308
SOLENOID VALVE
M1701000800516
AC303148
AC206557
AC302485
AB
Timing belt front
upper cover
Throttle body
<4G1>
<4G6>
Name Symbol Name Symbol
A/T control solenoid valve assembly D Emission solenoid valve (Purge control
system) <4G6>B
Emission solenoid valve (EGR system) B Hydraulic unit (incorporating solenoid
valve)A
Emission solenoid valve (Purge control
system) <4G1>C

Page 628 of 788
FLOOR AND ROOF
CONFIGURATION DIAGRAMS80-22
FLOOR AND ROOF
FLOOR AND ROOF M1801000900844
AC301155
D-06
D-07
D-05 D-04 D-03 D-02 D-01
D-35
D-34
D-33
D-32
D-31
D-30
D-29
D-25
D-28D-27 D-24
D-23 Y
Y
YFloor wiring
harness (LH) Floor wiring
harness (RH)
Instrument panel
wiring harnessConnector
symbol
D
D-26
Roof wiring
harness
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
Antenna
feeder cable
D-08
D-13
D-14
D-15
D-16
D-17
D-18
D-19 D-20
D-21 D-22Y
YFuel wiring
harness
7
17
Y
Y

AC
Y
Y D-04 D-36 D-06 D-37
Roof wiring
harness
Antenna
feeder cable
D-01 (2) Side impact sensor (Front: RH)
D-02 (3) Door switch (Front: RH)
D-03 (8) Floor wiring harness (RH) and rear door
wiring harness (RH) combination
D-04 (2) Front room lamp
D-05 (2-B) Wheel speed sensor (Rear: RH)
D-06 (2-GR) Rear room lamp
D-07 (3) Door switch (Rear: RH)
D-08 (2-Y) Side impact sensor (Rear: RH)
D-13 (3-B) Fuel tank gauge unit
D-14 (2-Y) Side impact sensor (Rear: LH)
D-15 (3) Door switch (Rear: LH)
D-16 (5-GR) Fuel tank pump
D-17 (2-B) Wheel speed sensor (Rear: LH)
D-18 (8) Floor wiring harness (LH) and fuel wiring
harness combination
D-19 (8) Floor wiring harness (LH) and rear door
wiring harness (LH) combination
D-20 (3) Door switch (Front: LH)D-21 (2) Side impact sensor (Front: LH)
D-22 (2-B) Seat belt pre-tensioner (LH)
D-23 (2-R) Side air bag module (squib) (LH)
D-24 (3) Heated seat assembly (LH)
D-25 (9) Heated seat switch
D-26 (4) Instrument panel wiring harness and
console wiring harness combination
D-27 (6) Shift switch assembly
D-28 (1) Cigarette lighter
D-29 (1-B) Cigarette lighter
D-30 (2-B) Cigarette lighter illumination lamp
D-31 (2-B) Ashtray illumination lamp
D-32 (3) Heated seat assembly (RH)
D-33 (2-R) Side air bag module (squib) (RH)
D-34 (1-B) Parking brake switch
D-35 (2-B) Seat belt pre-tensioner (RH)
D-36 (2-B) Curtain air bag module (squib) (RH)
D-37 (2-B) Curtain air bag module (squib) (LH)

Page 629 of 788
FLOOR AND ROOF
CONFIGURATION DIAGRAMS80-23
FLOOR AND ROOF M1801000900855
AC301158
D-06
D-07
D-05 D-04 D-03 D-02 D-01
D-35
D-34
D-33
D-31
D-30
D-29
D-28D-27
D-23 Y
Y
YFloor wiring
harness (LH) Floor wiring
harness (RH)
Instrument panel
wiring harnessConnector
symbol
D
D-26
Roof wiring
harness
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
D-08
D-13
D-14
D-15
D-16
D-17
D-18
D-19 D-20
D-21 D-22Y
YFuel wiring
harness
7
17
Y
Y
Antenna
feeder cable
AB
Y
Y D-04 D-36 D-06 D-37Roof wiring
harness
Antenna
feeder cable
D-01 (2) Side impact sensor (Front: RH)
D-02 (3) Door switch (Front: RH)
D-03 (8) Floor wiring harness (RH) and rear door
wiring harness (RH) combination
D-04 (2) Front room lamp
D-05 (2-B) Wheel speed sensor (Rear: RH)
D-06 (2-GR) Rear room lamp
D-07 (3) Door switch (Rear: RH)
D-08 (2-Y) Side impact sensor (Rear: RH)
D-13 (3-B) Fuel tank gauge unit
D-14 (2-Y) Side impact sensor (Rear: LH)
D-15 (3) Door switch (Rear: LH)
D-16 (5-GR) Fuel tank pump
D-17 (2-B) Wheel speed sensor (Rear: LH)
D-18 (8) Floor wiring harness (LH) and fuel wiring
harness combination
D-19 (8) Floor wiring harness (LH) and rear door
wiring harness (LH) combinationD-20 (3) Door switch (Front: LH)
D-21 (2) Side impact sensor (Front: LH)
D-22 (2-B) Seat belt pre-tensioner (LH)
D-23 (2-R) Side air bag module (squib) (LH)
D-26 (4) Instrument panel wiring harness and
console wiring harness combination
D-27 (6) Shift switch assembly
D-28 (1) Cigarette lighter
D-29 (1-B) Cigarette lighter
D-30 (2-B) Cigarette lighter illumination lamp
D-31 (2-B) Ashtray illumination lamp
D-33 (2-R) Side air bag module (squib) (RH)
D-34 (1-B) Parking brake switch
D-35 (2-B) Seat belt pre-tensioner (RH)
D-36 (2-B) Curtain air bag module (squib) (RH)
D-37 (2-B) Curtain air bag module (squib) (LH)

Page 630 of 788
FLOOR AND ROOF
CONFIGURATION DIAGRAMS80-24
FLOOR AND ROOF M1801000900866
AC301161
D-07
D-08 D-05
D-04 D-03 D-02
D-01
D-35
D-34
D-33
D-31
D-30
D-29
D-28
D-24D-19 Y
Y
YConnector
symbol
D
D-20
Roof wiring
harness
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
D-09
D-22D-21D-23D-25D-26
D-32
D-27
Y
YInstrument panel
wiring harness
Floor wiring
harness (RH)
Y
Antenna
feeder
cable
D-10
D-12
D-14
D-15
D-16
D-17 D-18
Fuel wiring
harness
7
17Y
D-11
D-13
Floor wiring
harness (LH)

AB
YY D-04 D-36 D-06 D-37
Roof wiring
harness
Antenna
feeder cable
D-01 (2) Side impact sensor (Front: RH)
D-02 (3) Door switch (Front: RH)
D-03 (8) Floor wiring harness (RH) and rear door
wiring harness (RH) combination
D-04 (2) Front room lamp
D-05 (2-B) Wheel speed sensor (Rear: RH)
D-06 (2-GR) Rear room lamp
D-07 (3) Door switch (Rear: RH)
D-08 (2-Y) Side impact sensor (Rear: RH)
D-09 (3) Rear personal lamp (RH)
D-10 (3) Luggage room lamp
D-11 (2-B) Diode (for luggage room lamp circuit)
D-12 (3) Rear personal lamp (LH)
D-13 (3-B) Fuel tank gauge unit
D-14 (2-Y) Side impact sensor (Rear: LH)
D-15 (3) Door switch (Rear: LH)
D-16 (5-GR) Fuel tank pump
D-17 (2-B) Wheel speed sensor (Rear: LH)
D-18 (8) Floor wiring harness (LH) and fuel wiring
harness combination
D-19 (8) Floor wiring harness (LH) and rear door
wiring harness (LH) combinationD-20 (3) Door switch (Front: LH)
D-21 (2) Side impact sensor (Front: LH)
D-22 (2-B) Seat belt pre-tensioner (LH)
D-23 (2-R) Side air bag module (squib) (LH)
D-24 (3) Heated seat assembly (LH)
D-25 (9) Heated seat switch
D-26 (4) Instrument panel wiring harness and
console wiring harness combination
D-27 (6) Shift switch assembly
D-28 (1) Cigarette lighter
D-29 (1-B) Cigarette lighter
D-30 (2-B) Cigarette lighter illumination lamp
D-31 (2-B) Ashtray illumination lamp
D-32 (3) Heated seat assembly (RH)
D-33 (2-R) Side air bag module (squib) (RH)
D-34 (1-B) Parking brake switch
D-35 (2-B) Seat belt pre-tensioner (RH)
D-36 (2-B) Curtain air bag module (squib) (RH)
D-37 (2-B) Curtain air bag module (squib) (LH)

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