Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMITSUBISHI2005LANCER EVOLUTION L4-2.0L DOHC TURBOREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRREMOVAL AND INSTALLATION
2005 Mitsubishi Lancer Evolution L4-2.0L DOHC Turbo
Removal and Installation
2005 Mitsubishi Lancer Evolution L4-2.0L DOHC TurboSECTION Removal and Installation
COMPRESSOR ASSEMBLY AND TENSION PULLEY
REMOVAL AND INSTALLATION
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 material, plug the dismantled hoses and compressor nipples.
<> DRIVE BELT REMOVAL
The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.
1. Securely insert the spindle handle or ratchet handle with a 12.7mm (1/2-inch) insertion angle into the jig hole of the auto-tensioner, and turn the auto-tensioner counterclockwise until it hits the stopper.
CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (to the right) on the back of the belt using chalk, etc.
2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.
<> A/C COMPRESSOR REMOVAL
Take care not to spill any compressor oil when removing the compressor.
INSTALLATION SERVICE POINT
>>A<< A/C COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor.
1. Measure the amount [X cu.cm (X floz)] of oil within the removed compressor.
2. Drain (from the new compressor) the amount [Y cu.cm (Y floz)] of oil calculated according to the following formula, and then install the new compressor.
New compressor oil amount=130 cu.cm (4.7 floz)
130 cu.cm - X cu.cm = Y cu.cm (4.7 floz - X floz = Y floz)
NOTE: Y cu.cm (Y floz) indicates the amount of oil in the refrigerant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same time as the compressor, subtract the rated oil amount of the each part from Y cu. cm (Y floz), and discharge from the new compressor.
Quantity:
- Evaporator: 60 cu.cm (2.0 floz)
- Condenser: 15 cu.cm (0.5 floz)
- Suction hose: 10 cu.cm (0.3 floz)
- Receiver: 10 cu.cm (0.3 floz)
Compressor Assembly And Tension Pully - Removal And Installation:
REMOVAL AND INSTALLATION
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 material, plug the dismantled hoses and compressor nipples.
<> DRIVE BELT REMOVAL
The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.
1. Securely insert the spindle handle or ratchet handle with a 12.7mm (1/2-inch) insertion angle into the jig hole of the auto-tensioner, and turn the auto-tensioner counterclockwise until it hits the stopper.
CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (to the right) on the back of the belt using chalk, etc.
2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.
<
Take care not to spill any compressor oil when removing the compressor.
INSTALLATION SERVICE POINT
>>A<< A/C COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor.
1. Measure the amount [X cu.cm (X floz)] of oil within the removed compressor.
2. Drain (from the new compressor) the amount [Y cu.cm (Y floz)] of oil calculated according to the following formula, and then install the new compressor.
New compressor oil amount=130 cu.cm (4.7 floz)
130 cu.cm - X cu.cm = Y cu.cm (4.7 floz - X floz = Y floz)
NOTE: Y cu.cm (Y floz) indicates the amount of oil in the refrigerant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same time as the compressor, subtract the rated oil amount of the each part from Y cu. cm (Y floz), and discharge from the new compressor.
Quantity:
- Evaporator: 60 cu.cm (2.0 floz)
- Condenser: 15 cu.cm (0.5 floz)
- Suction hose: 10 cu.cm (0.3 floz)
- Receiver: 10 cu.cm (0.3 floz)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.