relay MITSUBISHI 380 2005 Repair Manual

CENTRALISED JUNCTION
CIRCUIT DIAGRAMS90-12
CENTRALISED JUNCTIONM1901000301013
FUSIBLE LINK AND FUSE
ENGINE COMPARTMENT
NO. POWER SUPPLY
CIRCUITNAME RATED
CAPACITY (A)HOUSING
COLOURLOAD CIRCUIT
1 Battery/Alternator
(Fusible link No.27)Fusible
link80 Black Fuse Nos.5, 6, 9 and 10 (in junction
block) circuit
2 50 Blue Radiator fan motor
3 30 Pink ABS-ECU and ABS/TCL-ECU (motor
power supply)
4 40 Green Ignition switch circuit
5 40 Green Fuse Nos.3 and 4 (in junction block
circuit), front power window regulator
motor, power seat assembly, power
window main switch and rear power
window regulator motor
6 Fuse 15 Blue Fog lamp and fog lamp relay
720Yellow
8 15 Red Horn (High), horn (Low) and horn
relay
9 20 Yellow Camshaft position sensor, crankshaft
position sensor, engine oil control
valve, evaporative emission purge
solenoid, evaporative emission
ventilation solenoid, heated oxygen
sensor,ETACS-ECU, injector, mass
airflow sensor, MPI relay, Engine
ECU, A/T ECU, throttle actuator
control motor relay and fan control
relay
10 10 Red A/C compressor assembly and
A/C-ECU
11 15 Blue ABS-ECU, ABS/TCL-ECU,
high-mounted stoplamp, Engine ECU
and rear combination lamp
12
13 7.5 Brown
Alternator
14 10 Red ETACS-ECU, Hazard lamps
15 20 Yellow A/T control solenoid valve and Engine
ECU
16 Front-ECU
(Headlamp relay:
High)15 Blue Headlamp (RH) and headlamp (High:
RH)
17 15 Blue Headlamp (LH) and headlamp (High:
LH)
18 Front-ECU (Field
effect transistor for
headlamp: Low)10 Red Headlamp (RH) and headlamp (Low:
RH)

CENTRALISED JUNCTION
CIRCUIT DIAGRAMS90-13
19 Front-ECU (Field
effect transistor for
headlamp: Low)Fuse 10 Red Headlamp (LH) and headlamp (Low:
LH)
20 Front-ECU (Taillamp
relay)7.5 Brown A/C-ECU, A/T selector lever position
illumination lamp, combination meter,
fog lamp switch, headlamp (RH),
glove box lamp, hazard warning lamp
switch, multi-center display unit,
radio, CD player, rear combination
lamp (RH), rheostat and TCL switch
21 7.5 Brown Headlamp (LH), license plate lamp
and rear combination lamp (LH)
22 Battery/Alternator
(Fusible link No.27)15 Blue A/C-ECU, column switch,
combination meter, ETACS-ECU,
front-ECU, key reminder switch, multi-
center display unit, radio, CD player,
and vanity mirror lamp
23 Ignition switch (ACC) 10 Red A/C-ECU, accessory socket relay,
ETACS-ECU, multi-center display
unit, radio, CD player.
24 Battery/Alternator
(Fusible link No.27)15 Blue Fuel pump module
25 Ignition switch (ACC) 30 Green Front-ECU and windshield wiper
motor
26 Battery/Alternator
(Fusible link No.27)Fusible
link20 Light blue Anti-lock braking system(solenoid
valve)
27
Alternator120
Battery, front-ECU, fusible link Nos.1,
2, 3, 4, 5 and 26 and fuse Nos.6, 7, 8,
9, 10, 11, 13, 14, 15, 22 and 24 (in
relay box) NO. POWER SUPPLY
CIRCUITNAME RATED
CAPACITY (A)HOUSING
COLOURLOAD CIRCUIT

CENTRALISED JUNCTION
CIRCUIT DIAGRAMS90-15
NO. POWER SUPPLY
CIRCUITNAME RATED
CAPACITY (A)HOUSING
COLOURLOAD CIRCUIT
1 Fusible link No.1 Fuse 30 Green Rear window demister
2 30 Green Blower motor and resistor
3
4
5 15 Blue Accessory socket
6 15 Blue Data link connector and ETACS-ECU
7 Ignition switch (ACC) 15 Blue ETACS-ECU
8
9 Ignition switch (IG2) 7.5 Brown Sunroof assembly
10 Ignition switch (ACC) 7.5 Brown Remote controlled mirror
11
12
13 Ignition switch (IG1) 7.5 Brown Fuel pump relay and Engine ECU
14 Ignition switch (ACC) 20 Yellow Windscreen wiper
15 Fusible link No.1
(Fuse No.5 in junction
block)7.5 Brown Remote controlled mirror
16 Ignition switch (IG2) 7.5 Brown A/C compressor clutch relay,
A/C-ECU, blower relay, condenser
fan motor, fan control relay,
front-ECU, outside/inside air selection
damper control motor and rear
window defogger relay
17 Ignition switch (IG1)
18 7.5 Brown A/T control relay, input shaft speed
sensor, output shaft speed sensor,
Engine ECU, rear combination lamp
and SRS-ECU
19 7.5 Brown ABS-ECU, ABS/TCL-ECU, column
switch, combination meter,
ETACS-ECU, multi-center display unit
and SRS-ECU
20 10 Red Ignition coil
21
22
23 Fusible link No.5 20 Yellow Sunroof assembly
24

CENTRALISED JUNCTION
CIRCUIT DIAGRAMS90-17
CENTRALISED RELAY
NOTE: The triangle mark on the relay housing should face that on the relay box.CONNECTOR NO. NAME CONNECTOR NO. NAME
A-05X Fog lamp relay A-16X
A-06X Horn relay B-11X
A-07XB-12X
A-08XB-13X
A-09XB-14X
A-10X Fan control relay B-15X
A-11X Front-ECU B-16X A/T control relay
A-12X Front-ECU B-17X
MPI relay
A-15X
B-18X A/C compressor clutch relay

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

GENERAL DESCRIPTION
HEATER, AIR CONDITIONING AND VENTILATION55-4
OPERATION
.
CONDENSER FAN AND RADIATOR FAN
CONTROL
The ECU judges the required revolution speed of
radiator fan motor and condenser fan motor using
the input signals transmitted from A/C switch, output
shaft speed sensor and engine coolant temperature
sensor. The ECU activates the fan control relays to
drive the radiator fan motor and condenser fan
motor.
.
COMPRESSOR CONTROL
When operating the air conditioning switch
The air thermo sensor, which senses the temper-
ature of the air flowing out of the evaporator,
deactivates the compressor at 3
C (37.4F) or
below.
The dual pressure switch turns OFF when the
refrigerant pressure becomes excessively high or
low, thus protecting the compressor circuit (See
Table below).
When the air thermo sensor is activated, and the
ignition switch, blower switch, and air condition-
ing switch are ON, the A/C compressor clutch
relay is energized.
When operating the mode selection dial
The air conditioning will work when the mode
selection dial is set to the "Defroster" or
"Defroster/foot" position, or the temperature con-
trol dial is set to the "MAX A/C" position. In other
dial positions, when the air conditioning switch is
turned on, the air conditioning will work.
A/C Compressor Clutch Relay ON Conditions
Ignition switch (IG2) ONNOTE: A/C compressor clutch relay is
de-energized when any one switch, sensor
or control unit shown on the left turns off.
NOTE: The components marked by
*
communicate with the ECU. If the air thermo
sensor detects a temperature of 3
C
(37.4
F), the A/C-ECU will turn off the A/C
compressor clutch relay. Blower switch ON
Air conditioning switch, mode selection dial
defroster, defroster/foot position or temperature
control MAX A/CON
Air thermo sensor*
Pressure detected
by A/C pressure
sensor2940 kPa or less (If the
refrigerant pressure exceeds
2940 kPa, A/C compressor
clutch relay is not ON
condition until the refrigerant
pressure has been measured
up to 2350 kPa or less.)ON
190 kPa or more (If the
refrigerant pressure falls short
of 190 kPa, A/C compressor
clutch relay is not ON
condition until the refrigerant
pressure has been measured
up to 220 kPa or more.)
A/C compressor clutch relay driving transistor (within
ecu)ON

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-5
AUTO A/C DIAGNOSIS
INTRODUCTIONM1554006200062
After air is taken in through the damper, it is fed to
the evaporator by the blower fan and motor and
cooled. The air cooled by the air mix damper is
mixed appropriately with the warmed air to achieve a
comfortable temperature. If the A/C does not operate
or the cooled air is not discharged, the system com-
ponents or relay may be faulty.
AUTOMATIC AIR CONDITIONING TROUBLESHOOTING STRATEGYM1554004700157
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
heater, air conditioning and ventilation fault.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
DIAGNOSTIC FUNCTIONM1552019800046
HOW TO CONNECT THE DIAGNOSTIC TOOL
(MUT-III)
Required Special Tools:
: 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)
To prevent damage to diagnostic tool , always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting diagnostic tool .
1. Ensure that the ignition switch is at the "LOCK" (OFF)
position.
2. Start up the personal computer.
3. Connect special tool MB991827 to special tool MB991824
and the personal computer.
4. Connect special tool MB991910 to special tool MB991824
5. Connect special tool MB991910 to the data link connector.
6. Turn the power switch of special tool MB991824 to the "ON"
position.
NOTE: When the special tool MB991824 is energized, the
special tool MB991824 indicator light will be illuminated in a
green color.
7. Start the MUT-III system on the personal computer.
NOTE: Disconnecting the diagnostic tool special tool
MB991824 is the reverse of the connecting sequence, making
sure that the ignition switch is at the "LOCK" (OFF) position.

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-75
INSPECTION PROCEDURE 4: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted).
.
TECHNICAL DESCRIPTION (COMMENT)
If cool air is not distributed when the A/C switch is on,
the A/C compressor relay system may be defective.
.
TROUBLESHOOTING HINTS
Improper amount of refrigerant
Malfunction of the air thermo sensor
Malfunction of the ambient air temperature sen-
sor
Malfunction of the A/C pressure sensor
Malfunction of the A/C compressor relay
Malfunction of the A/C refrigerant temperature
switch
Malfunction of the air conditioning compressor
clutch
Malfunction of the A/C-ECU
Malfunction of the ECU
Damaged harness wires or connectors
Refer to component locations GROUP-70
Refer to configuration diagrams GROUP-80
Refer to circuit diagrams GROUP-90
DIAGNOSIS
Required Special Tools:
MB991223: Harness Set
: Scan Tool (MUT-III Sub Assembly)

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-77
STEP 5. Check A/C compressor clutch relay connector
B-18X for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
Q: Is A/C compressor clutch relay connector B-18X in
good condition?
YES : Go to Step 6.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
that the air conditioning works normally.
STEP 6. Check the A/C compressor clutch relay continuity.
Follow the table below to check the A/C compressor clutch
relay for continuity.
Q: Is the A/C compressor clutch relay in good condition?
YES : Go to Step 7.
NO : Replace the A/C compressor clutch relay. Check that
the air conditioning works normally.
BATTERY
VOLTAGETESTER
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

AUTO A/C DIAGNOSIS
HEATER, AIR CONDITIONING AND VENTILATION55-79
STEP 8. Measure the voltage at A/C compressor assembly
connector B-28.
(1) Disconnect A/C compressor assembly connector B-28 and
measure the voltage at the relay box side.
(2) Disconnect powertrain control module connector B-20 and
ground harness side terminal No.6.
(3) Turn the ignition switch to the "ON" position.
(4) A/C compressor assembly connector B-28 terminal 1 and
ground.
The measured value should be approximately 12 volts
(battery positive voltage).
Q: Is the measured voltage approx. 12 volts?
YES : Go to Step 15.
NO : Go to Step 9.