2005 MITSUBISHI 380 service

HEATER, AIR CONDITIONING AND VENTILATION55-1
GROUP 55
HEATER, AIR
CONDITIONING AND
VENTILATION
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .55-3
AUTO A/C DIAGNOSIS . . . . . . . . . . .55-5
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 55-5
AUTOMATIC AIR CONDITIONING
TROUBLESHOOTING STRATEGY . . . . . . 55-5
DIAGNOSTIC FUNCTION . . . . . . . . . . . . . 55-5
DIAGNOSTIC TROUBLE CODE CHART . 55-9
DIAGNOSTIC TROUBLE CODE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 55-10
SYMPTOM CHART . . . . . . . . . . . . . . . . . . 55-68
SYMPTOM PROCEDURES . . . . . . . . . . . . 55-69
DATA LIST REFERENCE TABLE . . . . . . . 55-133
ACTUATOR TEST REFERENCE . . . . . . . . 55-136
CHECK AT A/C-ECU TERMINAL . . . . . . . . 55-137
SPECIAL TOOLS . . . . . . . . . . . . . . . .55-139
ON-VEHICLE SERVICE . . . . . . . . . . .55-141
REFRIGERANT LEVEL TEST . . . . . . . . . . 55-141
A/C COMPRESSOR CLUTCH TEST . . . . . 55-141
SIMPLE INSPECTION OF THE A/C
PRESSURE SENSOR . . . . . . . . . . . . . . . . 55-141
COMPRESSOR DRIVE BELT
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 55-142
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . 55-142
PERFORMANCE TEST . . . . . . . . . . . . . . . 55-143
REFRIGERANT LEAK INSPECTION
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-144A/C NOISE TEST . . . . . . . . . . . . . . . . . . . . 55-146
POWER RELAY CHECK . . . . . . . . . . . . . . . 55-148
IDLE-UP OPERATION CHECK . . . . . . . . . . 55-149
HEATER CONTROL ASSEMBLY AND
A/C SWITCH . . . . . . . . . . . . . . . . . . . .55-150
REMOVAL AND INSTALLATION . . . . . . . . 55-150
HEATER UNIT, HEATER CORE,
BLOWER ASSEMBLY AND
EVAPORATOR UNIT . . . . . . . . . . . . .55-151
REMOVAL AND INSTALLATION . . . . . . . . 55-151
REMOVAL AND INSTALLATION . . . . . . . . 55-153
DISASSEMBLY AND ASSEMBLY . . . . . . . 55-154
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-155
BLOWER ASSEMBLY DISASSEMBLY
AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 55-156
MOTORS AND TRANSISTOR . . . . . .55-157
REMOVAL AND INSTALLATION . . . . . . . . 55-157
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-158
SENSORS . . . . . . . . . . . . . . . . . . . . . .55-160
REMOVAL AND INSTALLATION . . . . . . . . 55-160
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-161
Continued on next page

HEATER, AIR CONDITIONING AND VENTILATION55-2
AMBIENT TEMPERATURE
SENSOR. . . . . . . . . . . . . . . . . . . . . . .55-162
REMOVAL AND INSTALLATION . . . . . . . . 55-162
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-163
COMPRESSOR ASSEMBLY AND
DRIVE BELT . . . . . . . . . . . . . . . . . . .55-164
REMOVAL AND INSTALLATION . . . . . . . . 55-164
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-166
AIR GAP CHECK . . . . . . . . . . . . . . . . . . . . 55-166
CONDENSER AND CONDENSER
FAN . . . . . . . . . . . . . . . . . . . . . . . . . .55-167
REMOVAL AND INSTALLATION . . . . . . . . 55-167
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-168
DRYER REPLACEMENT . . . . . . . . . . . . . . 55-168
REFRIGERANT LINE . . . . . . . . . . . . .55-170
REMOVAL AND INSTALLATION . . . . . . . . 55-170
O-RING AND PIPE INSTALLATION . . . . . . 55-172
DUCTS . . . . . . . . . . . . . . . . . . . . . . . .55-175
REMOVAL AND INSTALLATION . . . . . . . . 55-175
VENTILATORS . . . . . . . . . . . . . . . . . .55-177
REMOVAL AND INSTALLATION . . . . . . . . 55-177
SPECIFICATIONS . . . . . . . . . . . . . . .55-178
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 55-178
GENERAL SPECIFICATIONS . . . . . . . . . . 55-178
SERVICE SPECIFICATIONS . . . . . . . . . . . 55-178
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 55-178

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-11
STEP 1. Using diagnostic tool , diagnose the CAN bus line.
Use diagnostic tool to diagnose the CAN bus lines.
(1) Connect diagnostic tool to the data link connector.
(2) Turn the ignition switch to "ON" position.
(3) Diagnose the CAN bus line.
Q: Is the check result satisfactory?
YES : Go to Step 2.
NO : Repair the CAN bus lines. (Refer to GROUP 54C,
Diagnosis-CAN Bus Diagnostic Chart P.54C-405).
Then go to Step 7.
STEP 2. Recheck for diagnostic trouble code.
Recheck if the DTC is set.
(1) Erase the DTC.
(2) Turn the ignition switch to "ON" position.
(3) Check if the DTC is set.
Q: Is the check result satisfactory?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points
How to
Cope with Intermittent Malfunctions P.00-14.
NO : Go to Step 3.

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-12
STEP 3. Using diagnostic tool , check data list item 59:
Inside temperature sensor.
To prevent damage to diagnostic tool , always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting diagnostic tool .
(1) Connect diagnostic tool to the data link connector.
(2) Start the engine.
(3) Set diagnostic tool to the data reading mode for item 59:
Inside temperature sensor.
Check that the interior temperature matches the dis-
played value on the diagnostic tool.
NOTE: When this DTC is set and the system is in fail-safe
status, the value of service data displays 25
C.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Does the interior temperature match the displayed value
on the diagnostic tool?
YES : Replace the A/C-ECU. Then go to Step 7.
NO : Go to Step 4.

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-17
DIAGNOSIS
Required Special Tool:
: Diagnostic Tool (MUT-III Sub Assembly)
MB991824: Vehicle Communication Interface (V.C.I.)
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
STEP 1. Using diagnostic tool , diagnose the CAN bus line.
Use diagnostic tool to diagnose the CAN bus lines.
(1) Connect diagnostic tool to the data link connector.
(2) Turn the ignition switch to "ON" position.
(3) Diagnose the CAN bus line.
Q: Is the check result satisfactory?
YES : Go to Step 2.
NO : Repair the CAN bus lines. Repair the CAN bus lines
(Refer to GROUP 54C, Diagnosis-Can Bus
Diagnostic Chart P.54C-405). Then go to Step 8.
STEP 2. Recheck for diagnostic trouble code.
Recheck if the DTC is set.
(1) Erase the DTC.
(2) Turn the ignition switch to "ON" position.
(3) Check if the DTC is set.
Q: Is the check result satisfactory?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points
How to
Cope with Intermittent Malfunctions P.00-14.
NO : Go to Step 3.

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-18
STEP 3. Using diagnostic tool , check data list item 58:
Outside air temperature sensor.
To prevent damage to diagnostic tool , always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting diagnostic tool .
(1) Connect diagnostic tool to the data link connector.
(2) Start the engine.
(3) Set diagnostic tool to the data reading mode for item 58:
Outside air temperature sensor.
Check that the ambient temperature matches the dis-
played value on the diagnostic tool.
NOTE: When this DTC is set and the system is fail-safe sta-
tus, the value of service data displays 20
C.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the sensor within the specified range?
YES : Replace the A/C-ECU. Then go to Step 8.
NO : Go to Step 4.
STEP 4. Check ambient air temperature sensor connector
A-25 for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
Q: Is ambient air temperature sensor connector A-25 in
good condition?
YES : Go to Step 5.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Then go
to Step 8.

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-23
DIAGNOSIS
Required Special Tool:
: Diagnostic Tool (MUT-III Sub Assembly)
MB991824: Vehicle Communication Interface (V.C.I.)
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A (Vehicles with CAN
communication system)
STEP 1. Using diagnostic tool , diagnose the CAN bus line.
Use diagnostic tool to diagnose the CAN bus lines.
(1) Connect diagnostic tool to the data link connector.
(2) Turn the ignition switch to "ON" position.
(3) Diagnose the CAN bus line.
Q: Is the check result satisfactory?
YES : Go to Step 2.
NO : Repair the CAN bus lines. Repair the CAN bus lines
(Refer to GROUP 54C, Diagnosis-Can Bus
Diagnostic Chart P.54C-405). Then go to Step 7.
STEP 2. Recheck for diagnostic trouble code.
Recheck if the DTC is set.
(1) Erase the DTC.
(2) Turn the ignition switch to "ON" position.
(3) Check if the DTC is set.
Q: Is the check result satisfactory?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use
Troubleshooting/Inspection Service Points
How to
Cope with Intermittent Malfunctions P.00-14.
NO : Go to Step 3.

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-24
STEP 3. Using diagnostic tool , check data list item 20: Air
thermo sensor.
To prevent damage to diagnostic tool , always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting diagnostic tool .
(1) Connect diagnostic tool to the data link connector.
(2) Ignition switch: ON
(3) Set diagnostic tool to the data reading mode for item 20: Air
thermo sensor.
Check that the passenger room temperature matches
the displayed value on the diagnostic tool while the
engine is cold.
NOTE: When this DTC is set and the system is fail-safe sta-
tus, the value of service data displays
6C.
(4) Turn the ignition switch to the "LOCK" (OFF) position.
Q: Is the sensor within the specified range?
YES : Replace the A/C-ECU. Then go to Step 7.
NO : Go to Step 4.