MITSUBISHI SPYDER 1990 Service Repair Manual

CONTENTS
AIR CONDITIONING SWITCH . . . . . . . . . . . . . . 23
LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
BLOWER ASSEMBLY AND RESISTOR*
. . . .26
COMPRESSOR AND TENSION PULLEY
ENGINE (NON-TURBO)>.. . . . . . . . . . . .38
COMPRESSOR AND TENSION PULLEY
ENGINE (TURBO) AND ENGINE>
ON-VEHICLE SERVICE. . . . . . . . . . . . . . . . . . . . .8
Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Compressor Noise Check. . . . . . . . . . . . . . . . . . . .16
Compressor Drive Belt Adjustment . . . . . . . . . . . .9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Dual Pressure Switch Check. . . . . . . . . . . . . . . . . .9
Handling Tubing and Fittings. . . . . . . . . . . . . . . . .15
CONDENSER AND CONDENSER
46Idle-up Operation Check. . . . . . . . . . . . . . . . . . . . .17FAN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic Clutch Test. . . . . . . . . . . . . . . . . . . . . . . . .9
COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GENERAL INFORMATION3. . . . . . . . . . . . . . . . . .
Performance Test. . . . . . . . . . . . . . . . . . . . . . . . . . .14
Power Relay Check . . . . . . . . . . . . . . . . . . . . . . . . .17
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . .4Receiver Drier Test. . . . . . . . . . . . . . . . . . . . . . . . . .9
. . . . . . . . . . . . . . . . . . . . .15HEATER CONTROL ASSEMBLY*19Refrigerant Leak Repair. . . . . . . . . .
Sight Glass Refrigerant Level Test . . . . . . . . . . . .8
HEATER UNIT AND HEATER CORE*. . . . . . . 24CONTINUED ON NEXT PAGE
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRA
INT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1)
improperservice or maintenance of any component of the SRS, or any SRS-related component, can lead to
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3)MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Supplemental straint System (SRS) and GROUP 00 Maintenance Service before beginning any service or maintenance of any com-
ponent of the SRS or any SRS-related component.
N O T EThe SRS includes the following components: SRS ECU, SRS warning light, air bag module, clocksprin g and interconnecting wiring.Other components (that may have to be removed/installed in connection with SRS service or maintenance) are indi-
cated in the table of contents by an asterisk(*).

55-2
REFRIGERANT LINE. . . . . . . . . . . . . . . . . . . . . .44 OUTLET). .. . . . . . .
SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . .VENTILATORS* (FLOOR). . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . .5 (INSTRUMENT PANEL) . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6

HEATER, AIR
AND VENTILATION General Information
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mixThe A/C system is basically the same as the
system that features high performance and lowtional system, but a new refrigerant system
operating noise, and includes an independent facebeen adopted as a response to
air blowing function and a air bypass function.use of chlorofluorocarbons. ,
Specifications
Heater unit type Two-way-flow full-air-mix system
Heater
controlassembly Dial and lever type
Compressor model
Engine (Turbo) and Scroll type
Engine>
Engine (Non-turbo)>Inclined-plate type
Dual pressure switch (psi)High-pressure switch OFF: 3,140 ON: 2,550 (370)
Low-pressureswitchOFF: 200 ON: 220 (32)
Refrigerant and quantity
(oz.) Approx. 700 740
OPERATION
Condenser fan and radiator fan control
lFor the operation of each fan, refer to COOLING
SYSTEM TROUBLESHOOTING.
Compressor control
lWhen the air conditioning switch is pushed in (A/C switch: ON) or the air outlet changeover
control knob is moved to the DEF or
position (defroster switch: ON), the air
conditioning system operates and compressor
control starts.
l The fin sensor, which senses the
temperature. of the air flowing out of the
evaporator, is deactivated with. temperature
3.2%
or below.
Here, the engine coolant ‘temperature sensor
senses the temperature of coolant,
it is turned off at or higher
peratures.
lThe dual pressure switch turns OFF when
refrigerant pressure becomes high
or low, thus the compressor circuit.
(See Table below.)
A/C ON Conditions
Ignition switch
Blower switch
ON
ON Remarks
compressor relay is deenergized when
anv one switch, sensor or control unit shown
l marked device measures the temper-
ature of the intake air, and according to the
magnetic clutch
for the compressor, the auto
ECU outputs the “HI” signal
sensor
DualLow-pressure side ON (32 psi) or
pressure
higher]
switch side ON (370 psi) or
lower]
compressor relay driving
transistor (within auto com-
pressor-ECU)ON
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55-4HEATER, AIR
AND VENTILATION General Information
SAFETY PRECAUTIONS
Because R-l refrigerant is a, hydrofluorocarbon
(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, Chrysler
Corporation recommends an R-l refrigerant re-
cycling device.
Refrigerant R-l is transparent and colorless
in both the liquid and vapor state. Since it has
a boiling point of at atmospher-
ic pressure, it will be a vapor at all normal tempe ra-
tures and pressures. The vapor is heavier than
air, non-flammable, and nonexplosive. The follow-
ing precautions must be observed when handling
R-l
Caution
Wear safety goggles when servicing the refrig-
eration system.
R-l evaporates so rapidly at normal atmospher-
ic pressures and temperatures that it tends to free ze
anything it contacts. For this reason, extreme care
must be taken to prevent any liquid refrigerant fro m
contacting the skin and especially the eyes. Always
wear safety goggles when servicing the refrigeratio n
part of the A/C system. Keep a bottle of sterile
mineral oil handy when working on the refrigeration
system. Should any liquid refrigerant get into the
eyes, use a few drops of mineral oil to wash them
out. is rapidly absorbed by the oil. Next
splash the eyes with plenty of cool water. Call your
doctor immediately even though irritation has
ceased after treatment.
Caution
Do not heat above
In most instances, moderate heat is required to
bring the pressure of the refrigerant inits
above the pressure of the system when charging
or adding refrigerant.
A bucket or large pan of hot water
over
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 tempera-
ture and pressure above this temperature. Do not
weld or steam clean on or near the system compo-
nents or refrigerant lines.
Caution
Keep
containers upright when charging
the system.
When adding into the refrigeration system
keep the supply tank or cans in an upright
position.
If the refrigerant container is on its or upside
down, liquid refrigerant will enter the
damage the compressor.
Caution
1.A leak detector designed
be used to check refrigerant gas
2.Do not allow liquid refrigerant to
metal.
Refrigerant will tarnish bright metal and chrome
surfaces, and in combination with moisture can
severely corrode all metal surfaces.
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HEATER, AIR Service
AND VENTILATION Special Tools
SERVICE SPECIFICATIONS
IStandard value ‘I
speed E n g i n e ( T u r b o ) a n d
EngineII
Engine (Non-turbo)I
up speed
Resistor (for blower motor) LO
100 in Neutral
1.83
MHI 0.31
Revolution pick up sensor standard resistance
Engine (Non-turbo)>
185
[when ambient temperature is
Refrigerant temperature switch ON (continuity) tempe rature
Engine (Turbo) and
Engine>OFF (no continuity) temperature
Approx. or less
Approx. or more
(until the temperature drops to approx.
when OFF)
Air gap (Magnetic clutch) mm (in.)
Engine (Turbo) and
Engine
Engine (Non-turbo)I
LUBRICANTS
ItemsSpecified lubricants Quantity
Each connection of refrigerant line ND-OIL 8 Engine (Non-turbo)>, SUN PAG 56 As required
Engine (Turbo) and Engine>
Lip seal of the compressor ND-OIL 8
Engine (Non-turbo)>As required
Compressor refrigerant unit lubricant SUN PAG 56
lubricant
Engine (Turbo) and Engine>
ND-OIL 8
Engine (Non-turbo)>
SPECIAL TOOLS
ToolTool number and nameSupersession Application
367Armature mounting nut of com-
e S p e c i a l s p a n n e r removal and installation
Engine (Turbo) and
Engine>
386
Pin
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HEATER, AIR
AND VENTILATION Troubleshooting
TROUBLESHOOTING
PROCEDURES
Trouble
symptom
When the ignitior
switch is “ON”,
the
does not
operate.
conditioning
does not
when
he air outlet
knob is
noved to the
or
position. Problem cause
compressor clutch relay
is defective
Magnetic clutch is defective
Refrigerant leak or overfilling
of refrigerant
Dual pressure switch is defec-
tive
A/C switch is defective Blower switch is defective
Fin
sensor is defective
Refrigerant temperature switch
is defective
Engine (Tur-
bo) and
Engine>
Automatic compressor-ECM
is defective
Revolution pick up sensor is
defective
Engine (Non-turbo)>
A/C compressor relay is de-
fective
1
Dual pressure switch is defec-
tive
Defroster switch is defective
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Magnetic clutch is defective
Refrigerant leak or overfilling
of refrigerant Remedy
Reference ReferencepagepageEngine
Engine(Non-turbo) (Turbo) Engine
Replace A/C compressor clutch 55-1855-18
relay
Replace the armature plate, rotor55-34
or clutch coil
Replenish the refrigerant, repair
0
the leak or take out some of therefrigerant
Replace the dual pressure switch 55-45
Replace the A/C switch 55-2355-23
Replace the blower switch55-22 55-22
Replace the fin sensor
Replace the refrigerant tempera-
ture switch
Replace the automatic
Replace the revolution pick up
sensor
55-26
Replace A/C compressor clutch55-18
relay
Replace the armature plate, rotor55-34
or clutch coil
Replenish the refrigerant, repair
the leak or take out some of the
refrigerant
Replace the dual pressure switch55-45
the defroster switch55-22 55-22
the blower switch55-225 5 - 2 2
temperature Replace the refrigerant tempera-
is defective
ture switch
compressor-ECU isReplace the automatic 55-26
sor-ECU
pick up sensor is
Replace the revolution pick up
sensor Engine

HEATER, AIR
AND VENTILATION Troubleshooting
Trouble
symptomProblem cause
Remedy
ReferencepageEngine Engine’
(Non-turbo)(Turbo) and Engine
When the A/C isRefrigerant leak
Replenish the refrigerant and 0o p e r a t i n g , t e r n -pair the leakperature inside
the passengerDual pressure switch is Replace the dual pressure switch55-45
compartmenttive
(no cool air).Fin sensor is defective
Replace the fin sensor
Refrigerant temperature switch Replace the refriger ant tempera-
is defective Engine (Tur-
ture switch
bo) and
Engine>
Automatic compressor-ECM Replace the automatic
55-26is defectivesor-ECM
Blower-motor/fan Blower moter relay is
Replace the blower moter relay55-1755-17inoperativetive
Blower fan and motor is Replace the blower fan and motor55-26
Resistor (for blower motor) is
Replace the resistor55-26
defective
Blower switch is defective Replace the blower switch
55-2255-22
Blower fan and Short circuit of the harness Repair the harness
motor keeps
between the blower fan and
ningmotor and the blower switch
Blower switch is defective Replace the blower switch
55-2255-22
Blower relay is defective
Replace the blower moter relay 55-1755-17
the A/C is Condenser fan motor is Replace the condenser fan motor55-47 55-46
fan Condenser fan relay (LO) is
Replace the condenser fan relay 55-18
defective
Condenser fan relay (HI) is Replace the condenser fa n relay55-1855-18
defective
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECM TERMINAL
Engine (Turbo) and Engine>
Terminal No.Name of Signal Check requirementsTerminal voltage
1Automatic compressor-ECM power The ignition switch, blower switch Battery positive
supply (output side) and A/C switch are all ON
v o l t a g e
2Automatic compressor-ECM power
supply (input side)
The ignition switch,
and switch are all ON Batteryvoltage
3A u t o m a t i c c o m p r e s s o r - E C M g r o u n d o v
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55-8HEATER, AIR
AND VENTILATION Troubleshooting/On-vehicle Service
Engine (Non-turbo)>
12
Sensor ground
Automatic compressor-ECM power
supply (output side)
Fin sensor power supply
o v
The ignition switch, blower switch andBattery positive
switch areall ONvoltage
The ignition switch, blower switch and
A/C switch are all ON
TROUBLESHOOTING HINTS
<Condenser fan and radiator fan control>
l R e f e r t o C O O L I N G S Y S T E M
SHOOTING.
<Compressor control>
Refer to
Terminal No.Name of Signal
Check requirements Terminal voltage
compressor clutch relay
When the compressor ON conditions Battery positive
are satisfied voltage
2Automatic compressor-ECM groundov
4Automatic compressor-ECM power
The ignition switch, blower switch and Battery positive
supply (input side) switch are all ONvoltage
5Automatic compressor-ECM powerTheignition switch is ONBattery positive
voltage
Engine (Turbo) and Engine>I
O N - V E H I C L E S E R V I C E
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass is a refrigerant level indicator. T o check the
refrigerant level, clean
sight glass and start the vehicle,
engine. Push the button to operate the compressor, place
the blower switch to high and move the temperature control
dial to max cool. After operating for a few minutes in this
manner, check the sight glass.
1.If the sight glass is clear, the magnetic clutch is engaged,
discharge line is warm and the compressor
suction line is cool; the system has a full charge.
2.If the sight glass is clear, the magnetic clutch is engaged
and there is no significant temperature difference between
compressor suction and discharge lines; the system has
most of its refrigerant charge.
3. If the sight glass shows foam or bubbles, the sy stem
could be low on refrigerant or the receiver drier is restricted.
The system has to be tested, leak checked then rech arged
with refrigerant.
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HEATER, AIR
AND VENTILATION On-vehicle Service
Magnetic clutch
High/Low-
pressure side terminals
LOW-PRESSURE HIGH-PRESSURESIDESIDE
0 0 0 0 0 1 6 9
MAGNETIC CLUTCH TEST
1. Disconnect the connector (1 P) to the magnetic c
lutch.
2. Connect battery
to compressor body.
3.Connect battery voltage directly to the connector for
the magnetic clutch.
4. If the magnetic clutch is normal, there will be a “click”.
If the pulley and armature do not make contact (‘cl ick’),
there is a malfunction.
RECEIVER DRIER TEST
Operate the unit and check the piping touching
the receiver drier outlet and inlet.
If there is a difference in the temperatures, the r eceiver drier
is restricted.
Replace the receiver drier.
DUAL PRESSURE SWITCH
1.Remove the dual pressure switch connector and conne ct
the high/low-pressure side terminals located on the har-
ness side as shown in the illustration.
2.installagauge manifold to the high-pressure side service
valve of the refrigerant line. (Refer to Performanc e Test.)
3. When the high/low-pressure sides of the dual pre ssure
switch are at operating pressure (ON) and there is continu-
ity between the respective terminals, then the condition
is normal. If there is no continuity, replace the s witch.
Unit: (psi)
ItemsSwitch position
OFF
ONON OFF
Low-pressure side2 2 0 ( 3 2 )200 (29)
High-pressure side2,550 (370) 3,140 (456)
COMPRESSOR DRIVE BELT ADJUSTMENT
Refer to GROUP On-vehicle Service.
Refer to GROUP
On-vehicle Service.
Refer to GROUP 11
On-vehicle Service.
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HEATER, AIR
AND On-vehicle Service
If the negative pressure (vacuum) is lost, check for
loose connections. Then, repeat the evacuation proc e-
dure from step 12. If negative pressure (vacuum) is
still lost, add 1 lb of refrigerant and check system
using an
compatible leak detector.
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CHARGING
1. With the handles turned in all the way (valve cl osed),
install the adaptor valve to the low-pressure
of the
gauge manifold.
2. Connect the charging hose (blue) to the adaptor valve.
3.Connect the quick joint (for low-pressure) to the charging
hose (blue).
4.Connect the quick joint (for low-pressure) to the
sure service valve.
NOTE
The low-pressure service valve should be connected to
the suction hose.
Caution
1. Use tools that are designed for
2. To install the quick joint, press section A firm ly
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.
5. Close the high and low-pressure valves of the ga uge
manifold.
6.Install the vacuum pump adaptor to the vacuum pump.
7. Connect the vacuum pump plug to the vacuum pump
adaptor.
8.Connect the charging hose (yellow) to the connec-
tion port of the vacuum pump adaptor.
9. Tighten the adaptor valve handle (valve open). 10. Open the low-pressure valve of the gauge manifo ld.
11. Turn the power switch of the vacuum pump to the ON
position.
NOTE
Even if the vacuum pump power switch is, turned ON,
the vacuum pump will not operate because of the pow er
supply connection in step (7).
12. Turn the vacuum pump adaptor switch
the
side to start the vacuum pump.
Caution Do not operate the
during evacuation.
13. Evacuate to a vacuum reading of 100 (29.5
or higher (takes approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and all ow
to stand it for 5 minutes.
Caution Do not operate the compressor in the vacuum condi-
tion; damage may occur.
15. Carry out a leak test. (Good if the negative pr essure
does not drop.)
Caution