2005 MITSUBISHI 380 Workshop Manual

SPECIAL TOOLS
HEATER, AIR CONDITIONING AND VENTILATION55-140
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991914
F: MB991825
G: MB991826
MUT-III Sub
Assembly
A: Vehicle
communicatio
n interface
(V.C.I.)
B: MUT-III USB
cable
C: MUT-III main
harness A
(Vehicles with
CAN
communicatio
n system)
D: MUT-III main
harness B
(Vehicles
without CAN
communicatio
n system)
E: MUT-III main
harness C (for
Daimler
Chrysler
models only)
F: MUT-III
measurement
adapter
G: MUT-III
Trigger
HarnessMB991824-KIT
NOTE: . G:
MB991826 MUT-III
Trigger Harness is not
necessary when
pushing V.C.I.
ENTER key.Checking diagnostic trouble codes
For vehicles with CAN
communication, use MUT-III
main harness A to send
simulated vehicle speed. If you
connect MUT-III main harness B
instead, the CAN
communication does not
function correctly. TOOL TOOL NUMBER
AND NAMESUPERSESSION APPLICATION

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-141
ON-VEHICLE SERVICE
REFRIGERANT LEVEL TESTM1552008400408
Use the refrigerant recovery station to remove all of the refrig-
erant, and then calculate the amount of the refrigerant and
charge it.
A/C COMPRESSOR CLUTCH TESTM1552019900032
1. Disconnect the air conditioning compressor clutch connector
to the air conditioning compressor clutch.
2. Connect positive battery voltage directly to the connector for
the air conditioning compressor clutch.
3. If the air conditioning compressor clutch is normal, there will
be a "click." If the pulley and armature do not make contact
("no click"), there is a malfunction.
SIMPLE INSPECTION OF THE A/C PRESSURE
SENSOR
M1552014700118
1. Assemble a gauge manifold on the high pressure service
valve.
2. Disconnect the A/C pressure sensor connector and connect
special tool test harness MB991658 as shown in the illustra-
tion.
3. Turn ON the engine and then turn ON the air conditioner
switch.

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-142
4. At this time, check to see that the voltage of A/C pressure
sensor terminal No. 2 reflects the specifications of the fig-
ure.
NOTE: The allowance shall be defined as
5%.
COMPRESSOR DRIVE BELT ADJUSTMENTM1552001000357
Refer to GROUP 00, Maintenance Service Drive Belts
P.00-39.
CHARGING M1552001200403
Use the refrigerant recovery station to charge the refrigerant.
METHOD BY USING REFRIGERANT RECOVERY
AND RECYCLING UNIT
Using the refrigerant recovery and recycling unit, refill the
refrigerant.
NOTE: Refer to the Refrigerant Recovery and Recycling Unit’s
Instruction Manual for operation of the unit.
DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas
from the system.
NOTE: Refer to the Refrigerant Recovery and Recycling Unit’s
Instruction Manual for operation of the unit.
REFILLING OF OIL IN THE A/C SYSTEM
Too little oil will provide inadequate compressor lubrication and
cause a compressor failure. Too much oil will increase dis-
charge air temperature.
When a compressor is installed at the factory, it contains 140
ml of refrigerant 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 sys-
tem.
When the following system components are changed, it is nec-
essary to add oil to the system to replace the oil being removed
with the component.
Compressor oil: ND Oil 8
Quantity:
Evaporator: 40 ml
Condenser: 40 ml

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-143
PERFORMANCE TEST M1552001400526
The vehicles to be tested should be parked out of direct sun-
light.
1. Close the high and low-pressure valve of the gauge
manifold.
2. 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.
3. 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).
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. 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.
NOTE: The high-pressure service valve is on the A/C pipe
and the low-pressure service valve is on the suction hose.
5. Start the engine.
6. 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: Maximum air volume
7. Adjust engine speed to 1,500 r/min with A/C clutch engaged.
8. Engine should be warmed up with doors and windows
closed.
9. Insert a thermometer in the center air outlet and operate the
engine for 20 minutes.
NOTE: If the A/C clutch cycles, take the reading before the
clutch disengages.
10.Note the discharge air temperature.
PERFORMANCE TEMPERATURE CHART
GARAGE AMBIENT AIR TEMPERATURE C
(
F)20 (68) 25 (77) 30 (86) 35 (95)
Discharge air temperature
C (F) 1 (34) 6 (43)
Compressor high pressure kPa (psi) 1275 (185)
1863 (270)
Compressor low pressure kPa (psi) 49 (7.1)
294 (42.7)

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-144
REFRIGERANT LEAK INSPECTION PROCEDUREM1552001500299
LEAK INSPECTION
1. Check for leakage using Special Tool at the following loca-
tions.
Good ventilation is necessary during the leak inspection. If
the surrounding air is contaminated with refrigerant gas,
the inspection readings will not be accurate.
LEAK CHECK LOCATION
1. SUCTION HOSE TO TX VALVE
2. LIQUID TUBE TO TX VALVE
3. SUCTION HOSE JOINT
4. LOW PRESSURE SERVICE
VA LV E
5. HIGH PRESSURE SERVICE
VA LV E
6. CONDENSER-DISCHARGE
HOSE JOINT
7. PRESSURE SENSOR8. CONDENSER-LIQUID TUBE
JOINT
9. COMPRESSOR-SUCTION HOSE
JOINT
10. COMPRESSOR-DISCHARGE
HOSE JOINT
11. UNDER COMPRESSOR CLUTCH
12. AROUND MODULATOR CAP
13. TX VALVE TO EVAPORATOR
JOINT LEAK CHECK LOCATION

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-145
LOST CHARGE
If the system has lost all of its refrigerant charge due to a leak:
1. Evacuate the system. (Refer to P.55-142).
2. Charge the system with approximately 0.453 kg (1 pound) of
refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
Replacement filter-dryer units must be sealed while in
storage. The dryer used in these units will saturate water
quickly upon exposure to the atmosphere. When installing
a dryer, have all tools and supplies ready for quick assem-
bly to avoid keeping the system open any longer than nec-
essary.
6. Replace receiver dryer. (Refer toP.55-168).
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 pres-
sure 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 operat-
ing. Extreme care must be exercised to make sure that all con-
nections 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 fit-
ting 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 pres-
sure 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.

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-146
Sharper bends will reduce the flow of refrigerant. The flexible
hose lines should be routed so that they are at least 80 mm
(3.1 inches) 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.
AIR CONDITIONING NOISE TEST
You must first know the conditions when the noise occurs.
These conditions are: weather, vehicle speed, in gear or neu-
tral, engine temperature or any other special conditions.
Noises that develop during A/C operation can often be mislead-
ing. 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 generator).
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 prob-
lems within the compressor.
Normal air conditioning operation will generate some level of
operational noise. To judge what is normal and abnormal,
requires an understanding of the air conditioning system. This
test is to detail the most common noise complaints and the
repair methods.
VEHICLE CONDITION
1. Ensure the system is not over or under charged.(Refer to
P.55-142).
2. Tighten all compressor mounting bolts, clutch mounting
bolts and compressor drive belt.
3. Inspect layout of the system is correct, ie no interference
between hoses and all retaining clamps are in place.

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-147
TEST PROCEDURES
1. Select a quiet area for testing.
2. Duplicate problem (customer complaint) as much as
possible.
3. Judge if the noise is abnormal (ie. it is important to
understand the characteristics of the vehicle and its normal
state to judge what is abnormal) - Compare with similar
vehicle if necessary.
4. Detail what and how noise occurs.
5. Find the noise source and verify its transmission by isolating
the subject part from the vehicle.
6. Repair the problem.
7. Explain and report your findings.
DETAILS OF A/C NOISE
POSSIBLE CAUSES, CHECKS AND REPAIRS
NOISE DESCRIPTION WHEN IT OCCURS SOURCE OF NOISE
Rumbling (Bearing noise) With A/C On or Off Magnetic clutch, idler pulley
Clang-Clack noise When compressor is engaged Magnetic clutch operation
Squawking (Belt sliding noise) When compressor is engaged V-belt
Whistling or Whooping noise Immediately after the A/C is
engaged.Expansion valve
Hissing or swishing noise When A/C is engaged, but
decreases as flow is stable Refrigerant flow
Rattling (Internal compressor) When compressor is operating Compressor internal part
Wooing (Resonant noise) With A/C On, occurs at certain
speed.Resonance of accessories
Cooing (Discharge pulsation
noise)With A/C On or Off Resonating noise with the vehicle
body
NOISE DESCRIPTION POSSIBLE CAUSE CHECK REPAIR
Rumbling (Bearing
noise)Bearing damage in rotor Manual rotation of bearing Replace compressor
Rotor slipping on boss Wear on compressor boss
surfaceReplace compressor
Bearing damage in pulley Check alignment between
pulleysReplace compressor
Clang-Clack noise Hub to stator misaligned Wear on inner clutch face Replace compressor
Gap between clutch
surface is too largeCheck Air gap is within
specificationReplace compressor
Squawking (Belt sliding
noise)Oil/water between the belt
and rotor surfaceOil and water
contaminationClean
Low belt tension Belt tension Reset or Replace belt and
set tension to correct
specification
Whistling or Whooping
noiseVibration of expansion
valveExpansion valve Replace TX valve