MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

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

– Heater Control Assembly and A/C Switch HEATER AND MANUAL
AIR CONDITIONER55-17
5. Follow the steps below to install the inside/outside air
changeover damper lever cable.
(1) Set the inside/outside air changeover damper link
on the blower unit to the INSIDE position.
(2) Set the inside/outside air changeover damper knob
of the heater control assembly to the INSIDE 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 blower
unit.
(4) After installation, ensure that inside/outside air
changeover damper operates smoothly by operating
the heater control assembly knob.
INSPECTION
A/C SWITCH CONTINUITY CHECK
Switch
iti
Terminal No.
position1ILL2IND457
OFF
ON
BLOWER SWITCH CONTINUITY CHECK
Switch positionTerminal No.
1235678
OFF

(LO)

(ML)

(MH)

(HI)
INSIDE position
Push
OFFON

– Heater Unit and Blower Unit HEATER AND MANUAL
AIR CONDITIONER55-18
HEATER UNIT AND BLOWER UNIT

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Engine Coolant Draining and Refilling

Air Cleaner Cover and Hose Removal and
Installation

Floor Console and Instrument Panel Removal and
Installation

Rear Seat Heater Duct Removal and Installation
(Refer to P.55-31.)
1
34
5
6
2 7 8
9 1011
Removal steps
1. Center reinforcement RH
2. Heater control assembly
3. Center reinforcement LH
4. Center ventilation duct
5. Foot distribution duct
6. Joint duct7. Blower unit
8. Heater hose
9. Heater unit
10. Heater core support
11. Heater core

– Heater Unit, Cooling and Blower Unit HEATER AND MANUAL
AIR CONDITIONER55-19
HEATER UNIT, COOLING AND BLOWER UNIT

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
(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

2. Blower motor assembly
Resistor removal steps
1. Under cover


Glove box, glove box frame
3. ResistorEvaporator removal steps


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.