service MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

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

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-11
DISCHARGING SYSTEM
1. Run the engine at an engine speed of 1,200–1,500 r/min
for approximately 5 minutes with the A/C operating to
return to the oil.
NOTE
Returning the oil will be more effective if it is done while
driving.
2. Stop the engine.
3. Connect the charging hose (blue) to the adaptor valve
1 with its handle turned back all the way (valve closed).
4. Connect the quick joint 2 to the charging hose (blue),
and install the quick joint to the low-pressure service valve.
NOTE
The low-pressure service valve is provided on the suction
pipe.
Caution
(1) To connect 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.
5. Place the adaptor valve 1 inside the container and
discharge the refrigerant by opening the handle gradually
so that oil does not gush out.
NOTE
Any oil remaining in the container should be returned
to the A/C system.
PERFORMANCE TEST
1. The vehicle to be tested should be placed in a place
that is not exposed to direct sunlight.
2. The ambient condition should be 16 – 30 °C in temperature
and 60 – 100 % in relative humidity.
3. Open all the doors so that the air condition inside the
passenger compartment may be identical to that of the
outside.
4. With the high-pressure side of the gauge manifold closed,
connect the charging hose (red) to the gauge manifold
high-pressure side. Attach the quick joint for high-pressure
to the charging hose (red) and install it to the high-pressure
service valve on the vehicle side.
NOTE
The high-pressure service valve is found on liquid pipe
B.
Sleeve
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system Adapter
valve (for low
pressure)Charging hose
(blue)
Quick joint (for
low pressure)Air conditioning
compressor oilA
Low-pressure
valve
Gauge manifold
Charging hose (red)
Quick joint
(for high pressure)
Low-
pressure
service
valve
Sleeve
Low-pressure
gaugeHigh-pressure
gauge
High-
pressure
service
valve
Air conditioning system
A
High-
pressure
valve

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-12
Caution
(1) To connect 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.
5. Start the engine.
6. Set the blower switch to HI (Fast) position
7. Set the A/C switch to ON position
8. Set the temperature control to Max. cooling position
9. Set the mode selection to Face position
10. Set the air selection to Recirculation position
11. Fix engine speed to 1,500 r/min.
12. Check that the high-pressure side pressure is 1,667 –
1,765 kPa.
NOTE
If the pressure is not within this range, adjust it as follows;
cool down the condenser using a cooling fan if the
pressure is higher, and cover the condenser to protect
it from ventilation air if it is lower.
13. Set a dry-bulb/wet-bulb thermometer at the air inlet, and
set a dry-bulb thermometer at the air outlet.
Caution
(1) Set the dry-bulb thermometer at a position where
the temperature sensing section can be directly
blown with cooled air.
(2) Place the dry-bulb/wet-bulb thermometer at a
position where it is not exposed to cooled air
blown out.
14. After the temperature of the air blown out from the air
outlet has been stabilized (10 – 15 minutes after starting),
read the dry-bulb thermometer set at the air outlet and
the wet-valve thermometer set at the air inlet.
15. The air conditioning system is considered in good
condition if the intersecting point of the measurements
obtained in Step (14) is below the performance evaluation
reference line on the graph.
Caution
Do not remove the quick joint immediately after the
performance test has been completed. Stop the engine
and wait until the high-pressure side pressure of the
gauge manifold has been lowered sufficiently.
Dry-bulb ther-
mometer
Dry-bulb/wet-bulb
thermometer
Reading of wet-bulb thermometer
set at air inlet (°C)
Performance
evaluation
reference line
In order
Not in order
0Reading of dry-bulb
thermometer set at air outlet
(°C)
15 20 25 30 5 10 15 20 25

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-13
DUAL PRESSURE SWITCH SIMPLE CHECK
Measure the high-pressure side pressure. If there is a
continuity between the dual pressure switch terminals with
the dual pressure switch in ON condition as shown in the
graph at left, the switch is in good condition. If not, it is faulty.
Replace the switch.
POWER RELAY CHECK
BLOWER RELAY
Battery voltageTerminal No.
1325
Power is not supplied
Power is supplied
Dual pressure switch
ON
Pressure
196 ± 20 221 2,354 ± 196 2,942 ± 196
OFF
kPa
Blower relay

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-14
A/C COMPRESSOR RELAY, CONDENSER FAN RELAY
Battery voltageTerminal No.
1345
Power is not supplied
Power is supplied
IDLE-UP OPERATION CHECK
1. Before inspection and adjustment, set vehicle in the
pre-inspection condition:
2. Check whether or not the idle speed is the standard value.
Standard value: 700 ± 50 r/min
NOTE
There is no necessity to make an adjustment, because
the idle speed is automatically adjusted by the ISC system.
If, however, there occurs a deviation from the standard
value for some reason, check the fuel control system.
3. When the A/C is running after turning the A/C switch
to ON, check to be sure that the idle speed is at the
standard value.
Standard value: 850 ± 50 r/min
Fan control relay
Compressor
relay
Radiator
fan relay
Condenser
fan relay

– Heater Control Assembly and A/C Switch HEATER AND MANUAL
AIR CONDITIONER55-15
HEATER CONTROL ASSEMBLY AND A/C SWITCH
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Instrument Lower Panel and Heater Control Panel
Removal and Installation

Floor Console Assembly Removal and Installation

Foot Duct Removal and Installation
(Refer to P.55-31.)
3 4
1
2 5
Removal steps
AA1. Heater control assembly
2. Rear window defogger switch
3. A/C switch
4. Knob
5. Blower switch
REMOVAL SERVICE POINT
AHEATER CONTROL ASSEMBLY REMOVAL
1. Remove the heater control assembly mounting screws.
2. Bend the clamp and the bosses (2 each side), which
are inserted into the centre reinforcement.
3. Remove the heater control assembly.
Clamp
Boss
Boss

– Heater Control Assembly and A/C Switch HEATER AND MANUAL
AIR CONDITIONER55-16
INSTALLATION SERVICE POINT
AHEATER CONTROL ASSEMBLY INSTALLATION
1. Cut off the bosses and clamp shown before installing
a new heater control assembly.
2. Install the heater control assembly mounting screws.
3. Follow the steps below to install the air outlet changeover
damper lever cable.
(1) Set the air outlet changeover link of the heater unit
to the DEF position.
(2) Set the air outlet changeover control knob on the
heater control assembly to the DEF position.
(3) After inserting the inner cable into the link, pull the
outer cable to the heater control assembly side and
then fasten the outer cable to the clip of the heater
unit.
(4) After installation, operate the heater control knob to
check if the mode changeover can be accomplished
smoothly.
4. Follow the steps below to install the air mix damper lever
cable.
(1) Set the air mix damper link on the heater unit to
the MAX HOT position.
(2) Set the air mix damper knob of the heater control
assembly to the MAX HOT position.
(3) After inserting the inner cable into the link, pull the
outer cable to the heater control assembly side and
then fasten the outer cable to the clip of the heater
unit.
(4) After installation, operate the heater control knob to
check if the air mix damper can be actuated smoothly.
Clamp
Boss
Boss
DEF
position
MAX HOT position