cooling MITSUBISHI 380 2005 Workshop Manual

90-1
GROUP 90
CIRCUIT DIAGRAMS
CONTENTS
HOW TO READ CIRCUIT DIAGRAMS90-3
JUNCTION BLOCK . . . . . . . . . . . . . .90-9
JOINT CONNECTOR . . . . . . . . . . . . .90-11
CENTRALISED JUNCTION . . . . . . . .90-12
POWER DISTRIBUTION SYSTEM . .90-18
STARTING SYSTEM . . . . . . . . . . . . .90-21
IGNITION SYSTEM . . . . . . . . . . . . . .90-22
CHARGING SYSTEM . . . . . . . . . . . .90-23
MULTIPOINT FUEL INJECTION (MPI)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .90-24
COOLING SYSTEM . . . . . . . . . . . . . .90-29
INVECS-II 5A/T . . . . . . . . . . . . . . . . .90-30
HEADLAMPS . . . . . . . . . . . . . . . . . . .90-35
TAIL LAMP, POSITION LAMP, AND
LICENCE PLATE LAMP . . . . . . . . . .90-38
FOG LAMPS . . . . . . . . . . . . . . . . . . .90-41FRONT DOME LAMP, REAR DOME LAMP,
TRUNK LAMP AND IGNITION KEY HOLE
ILLUMINATION LAMP . . . . . . . . . . . .90-44
GLOVE BOX LAMP . . . . . . . . . . . . . .90-48
VANITY MIRROR LAMP. . . . . . . . . . .90-49
TURN-SIGNAL LAMP AND HAZARD
WARNING LAMP . . . . . . . . . . . . . . . .90-50
BACKUP LAMP . . . . . . . . . . . . . . . . .90-54
STOPLAMP. . . . . . . . . . . . . . . . . . . . .90-55
HORN . . . . . . . . . . . . . . . . . . . . . . . . .90-56
METER AND GAUGE . . . . . . . . . . . . .90-57
BRAKE WARNING LAMP, OIL
PRESSURE WARNING LAMP, FUEL
WARNING LAMP . . . . . . . . . . . . . . . .90-60
POWER WINDOWS . . . . . . . . . . . . . .90-62
CENTRAL DOOR LOCKING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .90-64
Continued on next page

COOLING SYSTEM
CIRCUIT DIAGRAMS90-29
COOLING SYSTEMM1901001000937

GENERAL DESCRIPTION
HEATER, AIR CONDITIONING AND VENTILATION55-3
GENERAL DESCRIPTIONM1552000100351
The heater and cooling units are combined in a sin-
gle unit, which, with the mode film damper and flow
rate control valve in the heater unit, reduces ventila-
tion resistance, increases fan power, and decreases
noise.
SAFETY PRECAUTIONS
Wear safety goggles and gloves when servic-
ing the refrigeration system to prevent
severe damage to eyes and hands.
Because R-134a refrigerant is a hydro fluorocarbon
(HFC) which contains hydrogen atoms in place of
chlorine atoms, it will not cause damage to the ozone
layer.
Ozone filters out harmful radiation from the sun. To
assist in protecting the ozone layer, Mitsubishi
Motors Corporation recommends an R-134a refriger-
ant recycling device.
Refrigerant R-134a is transparent and colorless in
both the liquid and vapor state. Since it has a boiling
point of
29.8C (21.64F) at atmospheric pressure,
it will be a vapor at all normal temperatures and pres-
sures. The vapor is heavier than air, non-flammable,
and non-explosive. The following precautions must
be observed when handling R-134a.
Do not heat R-134a above 40C (104.0F) or it
may catch fire and explode.
R-134a evaporates so rapidly at normal atmospheric
pressures and temperatures that it tends to freeze
anything it contacts. For this reason, extreme care
must be taken to prevent any liquid refrigerant from
contacting the skin and especially the eyes. Always
wear safety goggles when servicing the refrigeration
part of the A/C system. Keep a bottle of sterile min-
eral oil handy when working on the refrigeration sys-
tem.1. If any liquid refrigerant gets into your eyes, use a
few drops of mineral oil to wash them out. R-134a
is rapidly absorbed by the oil.
2. Next, splash your eyes with plenty of cold water.
3. Call your doctor immediately even if irritation has
ceased.
Keep R-134a containers upright when charging
the system.
In most instances, moderate heat is required to bring
the pressure of the refrigerant in its container above
the pressure of the system when charging or adding
refrigerant.
A bucket or large pan of hot water not over 40
C
(104.0
F) is all the heat required for this purpose. Do
not heat the refrigerant container with a blow torch or
any other means that would raise temperature and
pressure above this temperature. Do not weld or
steam-clean on or near the system components or
refrigerant lines.
A leak detector for R-134a should be used to
check for refrigerant gas leaks.
Do not allow liquid refrigerant to touch bright
metal or it will be stained.
When metering R-134a into the refrigeration system,
keep the supply tank or cans in an upright position. If
the refrigerant container is on its side or upside
down, liquid refrigerant will enter the system and
damage the compressor.
Refrigerant will tarnish bright metal and chrome sur-
faces, and in combination with moisture can severely
corrode all metal surfaces. ITEM SPECIFICATION
Heater control assembly Dial type
Compressor 10S17
Compressor Model Swashplate type
Refrigerant and quantity (g) R-134a (HFC-134a), 435
475

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 VENTILATION55-149
A/C COMPRESSOR CLUTCH RELAY CONTINUITY
CHECK
IDLE-UP OPERATION CHECK
M1552001600401
Before inspection and adjustment, set vehicle in the following
condition:
Engine coolant temperature: 80 90 C (176.0 194.0 F)
Lights, electric cooling fan and accessories: OFF
Transmission: Neutral ("N" or "P" position)
Steering wheel: Straightforward
1. Check whether or not the idle speed is the standard value.
Standard value: 680
50 r/min
2. Turn on the air conditioning switch and the blower speed
selection dial. Engine idling speed should be within the
standard value:
Standard value: 680
50 r/min
NOTE: The Electronic control unit determines whether the
A/C load is low or high according to the output signal from
the A/C-ECU.
NOTE: It is not necessary to make an adjustment, because
the idling speed is automatically controlled by the ENGINE
ECU. BATTERY
V O LTA G ETESTER
CONNECTIONSPECIFIED
CONDITION
Not applied 1
4 Open circuit
Connect
terminal 2 to the
positive battery
terminal
Connect
terminal 3 to the
negative battery
terminal1
4 Less than 2 ohms

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 COOLING14-3
SYMPTOM CHARTM1141005600393
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Coolant Leak
DIAGNOSIS
STEP 1. Check for coolant leaks.
When pressure testing the cooling system, slowly
release cooling system pressure to avoid being
burned by hot coolant.
Be sure to completely clean away any moisture from
the places checked.
When the tester is removed, be careful not to spill any
coolant.
When installing and removing the tester and when test-
ing, be careful not to deform the filler neck of the radia-
tor.
Check that the coolant level is up to the filler neck. Install a radi-
ator tester and apply 160 kPa (23 psi) pressure, and then check
for leakage from the radiator hose or connections.
Q: Is leakage present from the radiator hose or
connections?
YES : Repair or replace the appropriate part, then go to
St e p 2 .
NO : There is no action to be taken.
STEP 2. Retest the system.
Q: Is there still coolant leakage?
YES : Return to Step 1.
NO : The procedure is complete. SYMPTOM INSPECTION
PROCEDUREREFERENCE
PA G E
Coolant leak 1
14-3
Engine overheating 2
14-4
Radiator fan and condenser fan do not operate 3
14-4
Radiator fan and condenser fan do not change speed or stop 4
14-20
Radiator fan does not operate 5
14-25
Condenser fan does not operate 6
14-25

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.

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-5
INSPECTION PROCEDURE 3: Radiator Fan and Condenser Fan do not Operate
.
CIRCUIT OPERATION
The fan controller is powered from fusible link
No.2.
The engine-ECU uses input signals from the A/C
switch, the water temperature sensor unit and the
vehicle speed sensor <M/T> or the output shaft
speed sensor <A/T> to control the speed of the
radiator fan motor and the condenser fan motor.
The engine-ECU controls the fan controller to
activate the radiator fan motor and the condenser
fan motor.
.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the fan con-
troller power supply or earth circuit.
If the communication line wiring harness between
the fan controller and the engine-ECU is
short-circuited to earth, the radiator fan motor
and the condenser fan motor will not rotate.
The cause could also be a malfunction of input
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor <M/T>
or the output shaft speed sensor <A/T> to the
engine-ECU.
The cause could also be a malfunction of the fan
controller or the engine-ECU.

.
TROUBLESHOOTING HINTS
Malfunction of fusible link No.2
Malfunction of fan control relay
Malfunction of cooling fan motor and fan control-
ler
Malfunction of engine-ECU.
Damaged wiring harness or connector
Refer to component locations GROUP-1
Refer to configuration diagrams GROUP-1
Refer to circuit diagrams GROUP-1