service MITSUBISHI 380 2005 Manual Online

COMPRESSOR ASSEMBLY AND DRIVE BELT
HEATER, AIR CONDITIONING AND VENTILATION55-164
COMPRESSOR ASSEMBLY AND DRIVE BELT
REMOVAL AND INSTALLATIONM1552004100289
Pre-removal Operation
Refrigerant Discharging (Refer to P.55-142).
Front Bumper Under Cover (Refer to GROUP 51, FRONT
BUMPERP.51-2).
Front Under Cover RH (Refer to GROUP 51, UNDER
COVER P.51-13).Post-installation Operation
Drive Belt Tension Adjustment (Refer to GROUP 00,
Maintenance Service
Drive Belt P.00-39).
Refrigerant Charging (Refer to P.55-142).
Front Bumper Under Cover (Refer to GROUP 51, FRONT
BUMPERP.51-2).
Front Under Cover RH (Refer to GROUP 51, UNDER
COVER P.51-13).
REMOVAL STEPS
<<A>>>>A<<1. FLEXIBLE SUCTION HOSE
CONNECTION
<<A>>2. FLEXIBLE DISCHARGE HOSE
CONNECTION
3. O-RING4. DRIVE BELT
<<B>> >>B<<5. A/C COMPRESSOR
6. ALTERNATOR
7. A/C COMPRESSOR BRACKETREMOVAL STEPS (Continued)

COMPRESSOR ASSEMBLY AND DRIVE BELT
HEATER, AIR CONDITIONING AND VENTILATION55-165
REMOVAL SERVICE POINTS
.
<<A>> FLEXIBLE SUCTION HOSE AND FLEXIBLE
DISCHARGE HOSE DISCONNECTION
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 bodies, plug the
dismantled hoses and compressor nipples.
.
<<B>> COMPRESSOR REMOVAL
Take care not to spill any compressor oil when removing the
compressor.
INSTALLATION SERVICE POINT
.
>>A<< FLEXIBLE SUCTION HOSE CONNECTION
To prevent mis-alignment of suction hose to bracket use the
folowing assembly procedure.
1. Insert hoseconnector into compressor and hand start bolt.
2. Assemble P-clip to hose and suction hose bracket. Tighten
bolt.
3. Tighten bolt between compressor and hose connector.
.
>>B<< 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 ml) of oil within the removed
compressor.
2. Drain (from the new compressor) the amount of oil
calculated according to the following formula, and then
install the new compressor.
New compressor oil amount = 140 ml
140 ml
X ml = Y ml
NOTE: Y ml indicates the amount of oil in the refrigerant line,
the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same times as
the compressor, subtract the rated oil amount of each part from
Y ml and discharge from the new compressor.
Compressor oil: ND Oil 8
Quantity:
Evaporator: 40 ml
Condenser: 40 ml
Receiver: 40 ml

CONDENSER AND CONDENSER FAN
HEATER, AIR CONDITIONING AND VENTILATION55-168
REMOVAL SERVICE POINTS
.
<<A>> FLEXIBLE SUCTION HOSE AND LIQUID
PIPE A DISCONNECTION
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 bodies, plug the
dismantled hose and condenser assembly nipples.
INSTALLATION SERVICE POINT
.
>>A<< DRYER REMOVAL PROCEDURE
1. Remove the condenser assembly from the vehicle to access
the modulator.
2. Remove the modulator cap using a14 mm hexagon wrench.
3. Remove the desiccant bag from the modulator.
Do not remove the desiccant bag from the plastic bag until
just before inserting it into the modulator.
.
<<B>> DRYER REPLACEMENT PROCEDURE
1. Fit the desiccant bag with the welded portion facing the
bottom of the modulator towards the screw-thread end.
2. Add 40 ml of ND Oil 8 into system to balance the oil
removed from the system.
3. Tighten the cap to the required torque.
2.9
1.0 Nm
Because the plastic cap has a large, 14 mm hex socket, it
is susceptible to generating excessive torque. Therefore,
be careful not to damage the crown portion of the cap.
.
<<B>> >>A<<6. CAP WITH FILTER
<<B>> >>A<<7. DESICCANT BAG
FRONT UNDER COVER
RADIATOR GRILLES
FRONT END STRUCTURE BAR
CONDENSER FAN REMOVAL
STEPS
8. CONDENSER FAN ASSEMBLY
9. RADIATOR AND FAN ASSEMBLYCONDENSER REMOVAL STEPS

REFRIGERANT LINE
HEATER, AIR CONDITIONING AND VENTILATION55-171
REMOVAL SERVICE POINT
.
<<A>> HOSE/PIPE DISCONNECTION
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 other foreign bodies, plug the con-
denser, compressor, and expansion valve nipples.
.
<<B>> SUCTION PIPE AND SUCTION FLEXIBLE
HOSE DISCONNECTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To disconnect the suction hose from the suction flexible hose,
loosen the union nut on the suction pipe counterclockwise until
nut is completely disengaged from suction hose thread .
Plug the hose nipple to prevent entry of dust and dirt.
INSTALLATION SERVICE POINT
.
>>A<< SUCTION HOSE INSTALLATION
1. When replacing the suction hose, refill them with a specified
amount of compressor oil, and then install them.
2. Ensure o-ring is installed correctly and lubricated then fit
suction hose into suction pipe fitting. With suitable tools hold
the suction hose fitting while tightening union nut to
specified torque.

REFRIGERANT LINE
HEATER, AIR CONDITIONING AND VENTILATION55-172
O-RING AND PIPE SERVICE POINT
.
O-RING AND PIPE FITTING
1. The following o-rings and pipe fittings are used in this air
conditioning system.
2.Ensure the correct size o-ring is installed as required during
service of system.
3.Two types of pipe fittings are used in this air conditioning
system.
.

SPECIFICATIONS
HEATER, AIR CONDITIONING AND VENTILATION55-178
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1552012100273
GENERAL SPECIFICATIONSM1552000200262
SERVICE SPECIFICATIONSM1552000300333
LUBRICANTSM1552000400329
ITEM SPECIFICATION
Liquid pipe mounting nut (heater unit side) 4.9
0.9 Nm (43 8 in-lb)
Liquid pipe mounting bolt (condenser side) 4.9
0.9 Nm (44 8 in-lb)
Suction flexible hose mounting nut (compressor side) 25
4 Nm (18 3 ft-lb)
Suction pipe mounting nut (heater unit side) 12
2 Nm (107 17 in-lb)
Suction pipe to suction hose union nut 32
2 Nm
Discharge flexible hose mounting bolt (compressor side) 25
4 Nm (18 3 ft-lb)
Discharge flexible hose mounting nut (condenser side) 12
2 Nm (107 17 in-lb)
ITEM MANUAL AIR CONDITIONING
Heater control Dial type
Air conditioning switch Push-button type
Compressor Type 10S17 (Swashplate type)
Displacement (cm
3)188
Refrigerant Type R134a (HFC-134a)
Amount (grams) 435
475
ITEM STANDARD VALUE
Idle speed r/min 680
50
Idle-up speed r/min 680
50
Air mix damper potentiometer resistance k
1.7 5.0
Air outlet changeover damper potentiometer resistance k
0.8 4.8
Air gap (air conditioning compressor clutch) mm (in) 0.3
0.5 (0.012 0.020)
ITEM SPECIFIED LUBRICANT QUANTITY(ml)
Each connection of refrigerant line ND Oil 8 As required
Compressor refrigerant unit lubricant (ml) ND Oil 8 140

14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .14-2
SPECIAL TOOL . . . . . . . . . . . . . . . . .14-2
ENGINE COOLING DIAGNOSIS . . . .14-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 14-2
TROUBLESHOOTING STRATEGY . . . . . . 14-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 14-3
SYMPTOM PROCEDURES . . . . . . . . . . . . 14-3
ON-VEHICLE SERVICE . . . . . . . . . . .14-26
ENGINE COOLANT LEAK CHECK . . . . . . 14-26
RADIATOR CAP PRESSURE CHECK . . . . 14-27
ENGINE COOLANT REPLACEMENT . . . . 14-27
ENGINE COOLANT CONCENTRATION TEST14-29
FAN CONTROLLER CHECK . . . . . . . . . . . 14-29
FAN CONTROL RELAY CONTINUITY CHECK14-31
RADIATOR . . . . . . . . . . . . . . . . . . . . .14-32
REMOVAL AND INSTALLATION . . . . . . . . 14-32
THERMOSTAT . . . . . . . . . . . . . . . . . .14-35
REMOVAL AND INSTALLATION . . . . . . . . 14-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-38
WATER PUMP . . . . . . . . . . . . . . . . . .14-39
REMOVAL AND INSTALLATION . . . . . . . . 14-39
WATER HOSE AND WATER PIPE . .14-40
REMOVAL AND INSTALLATION . . . . . . . . 14-40
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-41
SPECIFICATIONS . . . . . . . . . . . . . . .14-42
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 14-42
SERVICE SPECIFICATION . . . . . . . . . . . . 14-43
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 14-43
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 14-43

GENERAL DESCRIPTION
ENGINE COOLING14-2
GENERAL DESCRIPTIONM1141000100401
The cooling system is designed to keep every
part of the engine at appropriate temperature in
whatever condition the engine may be operated.
The cooling method is of the water-cooled, pres-
sure forced circulation type in which the water
pump pressurizes coolant and circulates it
throughout the engine. If the coolant temperature exceeds the prescribed temperature, the thermo-
stat opens to circulate the coolant through the
radiator as well so that the heat absorbed by the
coolant may be radiated into the air. The water
pump is of the centrifugal type and is driven by
the drive belt from the crankshaft. The radiator is
the corrugated fin, down flow type.
SPECIAL TOOLM1141000600279
ENGINE COOLING DIAGNOSIS
INTRODUCTIONM1141005300347
The system cools the engine so that it does not over-
heat and maintains the engine at an optimum tem-
perature. The system components are the radiator,
water pump, thermostat, condenser and fan assem-
blies. Possible faults include low coolant, contamina-
tion, belt loosening and component damage.
TROUBLESHOOTING STRATEGYM1141005200340
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure to find
most of the engine cooling faults.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find and repair the malfunction by following the
SYMPTOM CHART.
4. Verify that the malfunction is eliminated. TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MB991871
LLC changerGeneral service tool Coolant refilling

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-4
INSPECTION PROCEDURE 2: Engine Overheating
DIAGNOSIS
STEP 1. Remove the radiator cap and check for coolant
contamination.
Q: Is the coolant contaminated with rust and oil?
YES : Replace it. Refer to P.14-27.
NO : There is no action to be taken. Go to Step 2.
STEP 2. Check the radiator cap valve opening pressure.
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
(1) Use a cap adapter to attach the cap to the tester.
(2) Increase the pressure until the gauge indicator stops
moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93
123 kPa (14 18 psi)
Q: Does the reading remain at or above the minimum limit?
YES : Go to Step 3.
NO : Replace the radiator cap. Then go to Step 5.
STEP 3. Check thermostat operation.
Refer to 38.
Q: Does the thermostat operate correctly?
YES : Go to Step 4.
NO : Replace the thermostat, then go to Step 5.
STEP 4. Check the drive belt for slippage or damage.
Refer to GROUP 00, Maintenance Service
Drive Belts
(Check Condition). <3.8L Engine>39 .
Q: Is the drive belt loose or damaged?
YES : Adjust or replace the drive belt, then go to Step 5.
NO : There is no action to be taken.
STEP 5. Retest the system.
Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
YES : Return to Step 2.
NO : The procedure is complete.

ON-VEHICLE SERVICE
ENGINE COOLING14-26
DIAGNOSIS
STEP 1. Check the condenser fan motor.
Condenser fan motor check. (Refer to GROUP 55, Condenser
and Condenser Fan Motor.
Q: Is the condenser fan motor in good condition?
YES : Go to Step 2.
NO : Replace the condenser fan motor, then go to Step 3.
STEP 2. Check the fan controller.
Refer to 29.
Q: Is the fan controller in good condition?
YES : Go to Step 3.
NO : Replace the fan motor and fan controller (Refer to
14-25). Then go to Step 3.
STEP 3. Check the symptoms.
Q: Do the condenser fan operate?
YES : This symptom is complete.
NO : Return to Step 1.
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECKM1141001000333
When pressure testing the cooling system, slowly
release cooling system pressure to avoid getting
burned by hot coolant.
Be sure to completely clean away any moisture from
the places checked.
When the tester is taken out, be careful not to spill any
coolant.
Be careful when installing and removing the tester and
when testing not to deform the filler neck of the radia-
tor.
1. Check that the coolant level is up to the filler neck. Install a
radiator tester and apply 160 kPa (23 psi) pressure, and
then check for leakage from the radiator hose or
connections.
2. If there is leakage, repair or replace the appropriate part.