engine MITSUBISHI MONTERO 2000 Service Repair Manual

CHASSIS ELECTRICAL -Radio/Tape Player54A-71
A-3 Broadcasts can be heard but UKW/MW/LW has a lot of noise.
(1)(2)
Noise occurs when theengine is stopped.
YES
Do the following measures eliminate the noise?
DTune to a station with a strong signal.
DExtend the antenna completely.
DAdjust the sound quality to suppresshightones.YES
OK
NO
Is the radio body earth mounted securely?NOSecurely tighten the nuts for the
body earth.
YES
Is the antenna plug properly connected to the radio?NOCorrectly attach the antenna plug.
YES
Is the antenna itself ingood condition or is it properly
mounted?NOClean the antenna plug and earth
wire mounting area. Mount the anten-
na securely.
YES
If there is more noise than other radios, consult a ser-
vice centre.
Is the noise eliminated?
NOYES
OK
Noise occurs when theengine in running.
Inspect the vehicle’s noise suppressor. (Refer to A-4.)


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CHASSIS ELECTRICAL -RV Meter54A-17
Termi-Input/out-
t
Signal sym-
bl
Terminal
lt
Harness problemTrouble symptoms when there is a
hblnal No.
p
put
gy
bolvoltage
(V)Open
circuitshort-cir-
cuit
yp
harness problem
11 - 1 4––––––
15Input/out-
putK (engine
K-LINE
signal)Hi: Sys-
tem volt-
age
Lo:0 - 1ExistsExistsDWiring communication error
DCommunication between the
engine-A/T-ECU hicles> is not possible.
DAbnormal driving information
numerical display
16––––––
17Input/out-
putM-BUSY
(AUDIO)Hi:System
voltage
Lo:0 - 1ExistsExistsDAudio information does not
appear on the screen.
18–SHIELD-
EARTH
(AUDIO)––––
19Input/out-
putM-BUSY
(A/C)Hi:System
voltage
Lo:0 - 1ExistsExistsDAir conditioner information does
not appear on the screen.
DAmbient temperature is not
displayed.
20–SHIELD-
EARTH––––
22 - 21––––––
23InputAmbient
temperature
sensor–ExistsExistsDAmbient temperature is not
displayed.
24InputILL + (Light-
ing switch)Hi:System
voltage
Lo:0 - 1ExistsExistsDoes not illuminate.
25InputACC (ACC
power sup-
l)
System
voltageExists–Screen does not appear. No
operations are possible.
pp
ply)
g
–ExistsBlown multi-purpose fuse
26Input+BSystem
voltageExists–Screen does not appear. No
operations are possible.
g
–ExistsBlown multi-purpose fuse
27InputVSS (Vehicle
speed pulse
signal)Hi:System
voltage
Lo:0 - 1ExistsExistsDAbnormal “Distance km after
replacement” display in mainte-
nance screen
DSwitches which are not
supposed to operate during
driving do operate.
(Example:clock adjustment
screen, maintenance settings,
etc.)
DAmbient temperature display is
abnormally high.
28–Earth–Exists–Screen does not appear.


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SWS -Troubleshooting54B-45
Inspection Procedure P-6
Rear fog lamp switch signal is not sent to the ETACS-ECU.Probable cause
The rear foglampswitch input signal is used to operate the rear fog lamp. If
the signal fails, rear foglampwill not work normally.DMalfunction of fog lampswitch
DMalfunction of ETACS-ECU
DMalfunction of harness wire or connector
NG
Replace
OK
NG
NG
Repair
NG
Check the harness wire between foglampswitch and body earth.
OK
NG
Repair
NG
NG
Repair
OK
Replace the ETACS-ECU.
Check the harness wire between foglampswitch and ETACS-ECU.
OK
Check trouble symptoms.
Check the following connectors:
D-141, D-226
OK
Check trouble symptoms.
Check the following connectors:
D-141, D-30Measure at fog lampswitch connector D-141.
DDisconnect connector and measure at harness side.
DContinuity between terminal 6 and body earth.
OK:Continuity
Check the rear foglampswitch. (Refer to GROUP 54A – Fog
Lamp.)
Inspection Procedure P-7
Back-up lamp switch signal is not sent to the ETACS-ECU.
Probable cause
The back-uplampswitch input signal is used to operate the rear wiper. If the
signal is an error, the rear wiper will not operate consecutively twice when the
rear wiper is on and the shift lever is moved to R position.DMalfunction of back-uplampswitch
DMalfunction of ETACS-ECU
DMalfunction of harness wire or connector
NG
Replace
OK
NG
NG
Repair
NG
Check the harness wire between back-uplampswitch and ignition
switch (IG1).
OK
NG
Repair
NG
NG
Repair
OK
Replace the ETACS-ECU.
OK
Check trouble symptoms.
Check the following connectors:
C-18, E-115, D-32, D-213, D-208
Check the harness wire between back-uplampswitch and ETACS-
ECU.
OK
Check trouble symptoms.
Check the following connectors:
C-18, E-113, D-128 , E-13, D-33 drive vehicles>, D-226
Measure at back-uplampswitch connector C-18.
DDisconnect connector and measure at harness side.
DTurn the ignition switch to ON position.
DVoltage between terminal 2 and body earth.
OK:System voltage
Check the back-uplampswitch.


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SWS -Troubleshooting54B-46
Inspection Procedure P-8
Inhibitor switch (reverse) signal is not sent to the
ETACS-ECU. Probable cause
The inhibitor switch (reverse) input signal is used to operate the rear wiper. If
the signal is an error, the rear wiper will not operate consecutively twice when
the rear wiper is on and the selector lever is moved to R position.DMalfunction of inhibitor switch
DMalfunction of ETACS-ECU
DMalfunction of harness wire or connector
NG
Replace
OK
NG
NG
Repair
NG
Check the harness wire between inhibitor switch and ignition switch
(IG1).
OK
NG
Repair
NG
NG
Repair
OK
Replace the ETACS-ECU.
Check the harness wire between inhibitor switch and ETACS-ECU.
OK
Check trouble symptoms.
Check the following connectors:
C-05, E-113, D-128 , E-13, D-33 drive vehicles>, D-226
OK
Check trouble symptoms.
Check the following connectors:
C-05, E-115, D-32, D-213, D-208Measure at inhibitor switch connector C-05.
DDisconnect connector and measure at harness side.
DTurn the ignition switch to ON position.
DVoltage between terminal 7 and body earth.
OK:System voltage
Check the inhibitor switch. (Refer to GROUP 23 – On-vehicle Ser-
vice.)
Inspection Procedure P-9
Rear wiper motor auto-stop signal is not sent to the
ETACS-ECU.Probable cause
Rear wiper motor auto-stop signal is used to operate the rear wiper. If the signal
is an error, the rear wiper will not stop at the predetermined park position.DMalfunction of rear wiper motor
DMalfunction of ETACS-ECU
DMalfunction of harness wire or connector
NG
Replace
OK
NG
NG
Repair
NG
Check the harness wire between rear wiper motor and ignition
switch (ACC).
OK
NG
Repair
NG
NG
Repair
OK
Replace the ETACS-ECU.
Check the harness wire between rear wiper motor and ETACS-ECU.
OK
Check trouble symptoms.
Check the following connectors:
L.H. drive vehicles: I-07, G-06, D-124, D-218, D-224
R.H. drive vehicles: I-07, G-06, D-219, D-224
OK
Check trouble symptoms.
Check the following connectors:
L.H. drive vehicles: I-07, G-06, D-124, D-218, D-208
R.H. drive vehicles: I-07, G-06, D-219, D-208Measure at rear wiper motor connector I-07.
DDisconnect connector and measure at harness side.
DTurn the ignition switch to ACC position.
DVoltage between terminal 4 and ground.
OK:System voltage
Check the rear wiper motor. (Refer to GROUP 51 – Rear Wiper
and Washer.)


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55A-2
HEATER, AIR
CONDITIONER AND
VENTILATION

CONTENTS
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
TROUBLESHOOTING FRONT A/C> 4...............................
TROUBLESHOOTING REAR COOLER> 7...........................
ON-VEHICLE SERVICE 9.....................
Refrigerant Level Test through Performance Test 9.
Magnetic Clutch Test 10.........................
Receiver Drier Test 10..........................
Compressor Drive Belt Adjustment 10.............
Dual Pressure Switch Check 10..................
Charging 11...................................
Performance Test 15............................
Front Blower Relay and Rear Blower Relay
Continuity Check 18............................
Continuity Check of A/C Compressor Relay and
Condernser Fan Relay 18.......................
PTC Heater Relay Continuity Check 19...........
Idle-up Operation Check 19.............
Vacuum Actuator Check
20...................
Idle-up Solenoid Valve Check 21.................
Clean Air Filter Replacement Procedure 22........
FRONT A/C 23..............................
Air Conditioner Control Panel Assembly and
A/C Switch 23.................................
Heater Unit and Blower Assembly 26.............
Blower Motor and Resistor 29....................
Inside/Outside Air Changeover Damper Motor 30...
Automatic Compressor-ECU and
Air Thermo Sensor Assembly 31.................
REAR HEATER AND REAR COOLER 32.....
Rear A/C Switch, Front Rear Fan Switch 32.......
Rear A/C Control Unit 34........................
Rear Heater Unit 34............................
Rear Heater Unit and Rear Blower Assembly 37....
HEAT SWITCH 40...........................
COMPRESSOR 41...........................
CONDENSER ASSEMBLY AND
CONDENSER FAN 45........................
REFRIGERANT LINE 47.....................
ENGINE COOLANT TEMPERATURE SWITCH
51 ..........................................
IDLE-UP SYSTEM 53........................
DUCTS 54..................................
VENTILATION 56............................


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HEATER, AIR CONDITIONER AND VENTILATION - Troubleshooting55A-4
TROUBLESHOOTING
Trouble symp-
tomProbable causeRemedyRefer-
ence
page
The air condi-Malfunction of fuseReplace the fuse.–
tioner does notMalfunction of harness or connectorRepair the harness or connector.–work.
Refrigerant leak or overfilling of refrigerantReplenish the refrigerant, repair the leak
or take out some of the refrigerant.–
A/C compressor relay is defective.Replace the A/C compressor relay.55A-18
The A/C compressor magnetic clutch is
defective.Replace the A/C compressor.55A-10
The dual pressure switch is defective.Replace the dual-pressure switch.55A-10
The A/C switch is defective.Replace the heater control assembly.55A-24
The blower switch is defective.Replace the heater control assembly.55A-24
The air thermo sensor is defective.Replace the automatic compressor-ECU
and the air thermo sensor assembly.55A-31
The automatic compressor-ECU is defec-
tive.Replace the automatic compressor-ECU
and the air thermo sensor assembly.55A-6
The engine-ECU is defective.Replace the engine-ECU.–
When the A/C
is operating,Refrigerant leakReplenish the refrigerant and repair the
leak.–
temperature
inside the pas-The dual pressure switch is defective.Replace the dual-pressure switch.55A-10inside the pas-
senger
The condenser fan relay is defective.Replace the condenser fan relay.55A-18compartment
doesn’t de-
A/C compressor relay is defective.Replace the A/C compressor relay.55A-18
crease (cool
air is not
emitted).The A/C compressor magnetic clutch is
defective.Replace the A/C compressor.55A-10
When the A/C
is operating,
temperature
inside the pas-
senger
compartment
doesn’t in-
crease (warm
air is not
emitted).Malfunction of the air thermo sensorReplace the automatic compressor-ECU
and the air thermo sensor assembly.55A-31
The blowerMalfunction of fuseReplace the fuse.–
motor does notMalfunction of harness or connectorRepair the harness or connector.–run.
The blower relay is defective.Replace the blower relay.55A-18
The blower motor is defective.Replace the blower motor.55A-29
The blower switch is defective.Replace the heater control assembly.55A-24
Malfunction of the resistorReplace the resistor.55A-29
The automatic compressor-ECU is defec-
tive.Replace the automatic compressor-ECU
and the air thermo sensor assembly.55A-6


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HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service55A-17
REFRIGERANT LEAK REPAIR
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system. (See procedure.)
2. Charge the system with approximately one
pound of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
6. Replace receiver drier.
Caution
Replacement filter-drier units must be
sealed while in storage. The drier used in
these units will saturate water quickly upon
exposure to the atmosphere. When
installing a drier, have all tools and supplies
ready for quick reassembly to avoid keeping
the system open any longer than necessary.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are
produced in the system when it is operating.
Extreme care must be exercised to make sure that
all connections are pressure tight. Dirt and moisture
can enter the system when it is opened for repair
or replacement of lines or components. The
following precautions must be observed. The
system must be completely discharged before
opening any fitting of connection in the refrigeration
system. Open fittings with caution even after the
system has been discharged. If any pressure is
noticed as a fitting is loosened, allow trapped
pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use
the correct line for the installation you are servicing.
A good rule for the flexible hose lines is keep the
radius of all bends at least 10 times the diameter
of the hose.
Sharper bends will reduce the flow of refrigerant.
The flexible hose lines should be routed so that
they are at least 80 mm from the exhaust manifold.
It is good practice to inspect all flexible hose lines
at least once a year to make sure they are in good
condition and properly routed.
Unified plumbing connections with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or
any other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets,
or a loose clutch assembly. Verify accessory drive
belt tension (power steering or alternator).
Improper accessory drive belt tension can cause
a misleading noise when the compressor is
engaged and little or no noise when the compressor
is disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure),
restrict air flow through condenser. Install
manifold gauge set to make sure discharge
pressure doesn’t exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt.
Check to assure clutch coil is tight (no rotation
or wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge. (See “Charging
System”.)
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.


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HEATER, AIR CONDITIONER AND VENTILATION -Troubleshooting 55B-15
Inspection procedure 10
The condenser fan does not operate .
Probable cause
If the condenser fan does not operate, the condenser fan relay or motor may be
defective.DMalfunction of the condenser fan relay
DMalfunction of harness or connector
DMalfunction of the engine-A/T-ECU or
engine-ECU
NG
Check the harness wire between the condenser fan relay and
the ignition switch (IG2), and repair if necessary.
NG
Repair
NG
Check the harness wire between the condenser fan motor and
body earth, and repair if necessary.
NG
Repair
NG
Repair
OK
Replace the engine-A/T-ECU or engine-ECU
.
NG
Check the harness wire between the condenser fan relay and
fusible link (1), and repair if necessary.
NG
Repair
NG
Check the harness wires between the condenser fan relay
and the condenser fan motor, between the condenser fan
relay and the engine-A/T-ECU or the
engine-ECU.NG
Repair
OK
Check the trouble symptoms.
OK
Check the following connectors:A-10X, A-27,A-04 drive vehicles>, D-143, D-116,
D-119, D-110<4M41>
OK
Check the trouble symptoms.
OK
Measure at condenser fan motor connector A-27.
DDisconnect the connector and measure at the harness
side.
DContinuity between terminal 2 and body earth
OK:ContinuityNGCheck the following connector:A-27
OK
Check the trouble symptoms.
Check the following connector:A-10X
(2) NG
OK
Check the trouble symptoms.
OK
Measure at condenser fan relay connector A-10X.
DDisconnect the connector, and measure at the J/B side.
DIgnition switch: ON
(1) Voltage between terminal 3 and body earth
OK:System voltage
(2) Voltage between terminal 5 and body earth
OK:System voltage(1) NGCheck the following connectors:A-10X, A-15, D-27, D-210,
D-208
OK
Check the condenser fan motor
(Refer to GROUP 55A - Condenser Fan).NG
Replace
Check the condenser fan relay
(Refer to GROUP 55A - On-vehicle Service).NG
Replace


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HEATER, AIR CONDITIONER AND VENTILATION -Troubleshooting 55B-16
Inspection procedure 11
The condenser fan does not operate <4D56>.
Probable cause
If the condenser fan does not operate, the condenser fan relay or motor may be
defective.DMalfunction of the condenser fan relay
DMalfunction of harness or connector
DMalfunction of the engine-A/T-ECU or
engine-ECU
NG
Check the harness wire between the condenser fan relay and
the ignition switch (IG2), and repair if necessary.
NG
Repair
NG
Check the harness wire between the condenser fan motor and
body earth, and repair if necessary.
NG
Repair
NG
Repair
OK
NG
Check the harness wire between the condenser fan relay and
fusible link (1), and repair if necessary.
NG
Repair
NG
Check the harness wires between the condenser fan relay
and the condenser fan motor and between the condenser fan
relay and theengine coolant temperaturesensor, and repair if
necessary.
OK
Check the trouble symptoms.
OK
Check the following connectors:A-10X, A-27, A-04 drive vehicles>, D-143, B-47
OK
Check the trouble symptoms.
OK
Measure at condenser fan motor connector A-27.
DDisconnect the connector and measure at the harness
side.
DContinuity between terminal 2 and body earth
OK:ContinuityNGCheck the following connector:A-27
OK
Check the trouble symptoms.
Check the following connector:A-10X
(2) NG
OK
Check the trouble symptoms.
OK
Measure at condenser fan relay connector A-10X.
DDisconnect the connector, and measure at the J/B side.
DIgnition switch: ON
(1) Voltage between terminal 3 and body earth
OK:System voltage
(2) Voltage between terminal 5 and body earth
OK:System voltage(1) NGCheck the following connectors:A-10X, A-15, D-27, D-210,
D-208
OK
Check the condenser fan motor
(Refer to GROUP 55A - Condenser Fan).NG
Replace
Check the condenser fan relay
(Refer to GROUP 55A - On-vehicle Service).NG
Replace
NG
ReplaceReplace the engine coolant temperaturesensor.


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HEATER, AIR CONDITIONER AND VENTILATION -Troubleshooting 55B-19
Termi-
nal No.Normal condition Check conditions Check item
15Rear defoggerRear defogger: OFFSystem voltage
Rear defogger: ON1.5 V or less
16Multi center display unit communication
lineIgnition switch: ONHi: 4 - 5 V
Lo: 0 - 1 V
17Multi center display unit communication
lineIgnition switch: ONHi: 4 - 5 V
Lo: 0 - 1 V
18Multi center display unit communication
line shieldAt all times0V
19Diagnosis outputIgnition switch: ONA voltmeter needle
fluctuates between 0
and 12 V.
20Input from A/C compressor relayWhen the A/C is off.0V
When the A/C is in operation
(When compressor is operating)System voltage
21Power supply to potentiometerAt all times5V
22Input from outside air temperature
sensorSensor temperature: 25
_C (1.7 kW)1.9 V
23Input from heater water temperature
sensorSensor temperature: 25
_C(5kW)2.8 V
24Input from potentiometer for air mix
damperWhen the damper flap is moving to the
MAX HOT position.0.7 - 1.3 V
25Power supply to illuminationLighting switch: ONSystem voltage
26Power supply to ignition switch (IG2)Ignition switch: ONSystem voltage
27Power supply to ignition switch (ACC)Ignition switch: ACCSystem voltage
28Backup power supplyAt all timesSystem voltage
29Earth to sensor and potentiometerAt all times0V
30Input from air thermo sensorSensor temperature: 25
_C (1.5 kW)2.2 V
31Photo sensor (+)During 800 kcal/m2-h1V
32Input from potentiometer for the air
outlet changeover damperWhen the damper flap is moving to the
DEF position.0.7 - 1.3 V
33Diagnosis inputIgnition switch: ON0V
34Compressor lock signal (ignition signal)Engine speed: 3 000 r/min0.3 - 3.0
35Illumination earthAt all timesContinuity
36EarthAt all timesContinuity
CHECK AT ENGINE-A/T-ECU OR ENGINE-ECU TERMINALS
Refer to GROUP 13A – Troubleshooting or GROUP 13B – Troubleshooting .


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