MITSUBISHI SPYDER 1990 Service Repair Manual

HEATER, AIR
AND VENTILATION On-vehicle
Bulk
Adaptorvalve
Bulk[Refrigerant container)
16. Turn the handle of the valve back allthe way
(valve closed), remove it from the gauge manifold a nd
install the bulk container.
17.. Open the valve of the bulk container.
18. Tighten the handle of the adaptor valve (valve open)
to charge the system with refrigerant.
Caution
If the bulk container is inverted, liquid refrigera nt may
be drawn into the compressor damaging it by hydrau-
lic lock. Keep the bulk container upright to ensure
that refrigerant is charged in gas state.
19. If the refrigerant is not drawn in, turn the ha ndle
the
adaptor valve back all the. way (valve closed).
20. Check for gas leaks using a leak detector.
If a gas leak is detected, re-tighten the connectio ns, and
then repeat the charging procedure from evacuation in
step (12).
Caution
A leak detector designed for should be
21. Start the engine.
22. Operate the A/C and set to the lowest temperatu re (MAX.
COOL).
23. the engine speed at
24. Tighten the handle of the adaptor valve (valve open)
to charge the required volume of refrigerant.
Caution
If the bulk container is inverted, liquid refrigera nt may
into the compressor damaging it by hydrau-
lic lock. Keep the bulk container upright to ensure
that refrigerant is charged in gas state.
25. After charging with refrigerant, turn the handl e of the
adaptor valve back all the way (valve closed).
26. Tighten the charging valve handle (valve closed ).
Remove the quick joint (for low pressure) from the
pressure service valve.
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HEATER, AIR
AND VENTILATION On-vehicle Service
Bulk container
[Refrigerant container)
Refrigerant container)Bulk container
(Refrigerant container)
Low-pressure
service valve
I
CORRECTING LOW REFRIGERANT LEVEL IN CASE THE
BULK CONTAINER IS USED
1.
2.
3.
4.
5.
Install the adaptor value with the handle turned al l the
way in (valve close) to the bulk container.
Connect the charging hose (blue) valve.
Connect the charging hose (blue) to
quick joint (for
low-pressure).
Open the valve of the bulk container.
Turn the handle of the adaptor valve to bleed the a ir.
6.Install the quick joint (for low-pressure) to the low-pressure
service valve.
NOTE
The low-pressure service valve should be connected to
the suction hose.
7.
a.
9.
10.
Start the engine.
Operate the air conditioner and set at the lowest t empera-
ture (MAX. COOL).
Fix the engine speed at 1,500
Tighten the handle of the adaptor valve (valve open ),
and replenish refrigerant checking the quantity thr ough
the sight glass.
Caution
If the bulk container is inverted, liquid refrigera nt may
be draw into the compressor damaging it by hydrauli c
lock. Keep the bulk container upright to ensure that
refrigerant is charged in gas state.
11. After replenishing is completed, turn the handl e of the
adaptor valve all the way in (valve close), and rem ove
the quick joint.
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HEATER, AIR
AND VENTILATION On-vehicle Service
USING REFRIGERANT RECOVERY
RECYCLING UNIT
the refrigerant recovery and recycling refill the
refrigerant.
NOTE
Refer to that Refrigerant Recovery and Recycling Unit Instruc-
tion Manual for operation of the unit.
DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas
from the system.
NOTE
Refer to that Refrigerant Recovery and Recycling Un it Instruc-
tion Manual for operation of the unit.
REFILLING OFOIL IN THE A/C SYSTEM
Too little oil will provide inadequate compressor l ubrication
and cause a compressor failure. Too much oil will i ncrease
discharge air temperature.
When a compressor is installed at the factory, it c ontains
170
(5.7 Engine (Turbo) and
100 (3.4 Engine (Non-turbo)> of refrigerant
oil.
the A/C is in operation, the oil is carried
through the entire system by the refrigerant. Some of this
oil will be trapped and retained in various parts of the system.
When the following system components are changed, i t is
necessary to add oil to the system to replace the o il being
removed with the component.
Engine (Turbo) and Engine>
Compressor oil: SUN PAG 56
Quantity
Evaporator: 60 (2.03
Condenser: 15
Suction hose: 10
Receiver: 10
Engine (Non-turbo)>
Compressor oil: ND-OIL 8
Q u a n t i t y Evaporator: 40
(1.35
Condenser: 40 (1.35
Suction hose: 10
Receiver: 16
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HEATER, AIR
AND VENTILATION On-vehicle Service
PERFORMANCE TEST
1. The vehicles to be tested should be in a place that is
not in direct sunlight.
2.Close the high and low-pressure valve of the gauge man-
ifold.
3. Connect the charging hose (blue) to the low-pres sure
valve and connect the charging hose (red) to the high-pres-
sure valve of the gauge manifold.
4. Install the quick joint (for low-pressure) to th e charging
hose (blue), and connect the quick joint (for high- pressure)
to the charging hose (red).
5.Connect the quick joint (for low-pressure) to the low-pres-
sure service valve and connect the quick joint (for
pressure) to the high-pressure service valve.
NOTE
The high-pressure service valve is on discharge pip e
and the low-pressure service valve is on the suction hose.
Caution
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.
6. Start the engine.
7. Set the A/C controls as follows: A/C switch: A/C
ON position
Mode selection: Face position
Temperature control: Max. cooling position
Air selection: Recirculation position
Blower switch: HI (Fast) position
8. Adjust engine speed to 1,000
with A/C clutch en-
gaged.
9. Engine should be warmed up with doors and window s
closed.
10. a thermometer in the left center A/C outlet and
operate the engine for 20 minutes.
11. Note the discharge air temperature.
NOTE
If the clutch cycles, take the reading before the c lutch
disengages.
Performance Temperature Chart
Garage ambient temperature 20 (68)25 (77)35 (95) 40 (104)
Discharge air temperature 3.5-7.5
(37-41)
(37-43) (38-46) (39-46)
Compressorhigh pressure (psi) 1,350 1,570 130.6)(139.3-227.8)
Compressor low pressure (psi)140
(20.3)
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HEATER, AIR
AND VENTILATION On-vehicle
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 o f 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
will absorb water/water vapor 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 anylonger than necessary.
,
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant c harge; locate and repair all leaks. If it is necess ary to
increase the system pressure to find the leak (beca use of an especially low charge) add refrigerant.
If it is possible to repair the leak without discha rging the refrigerant system, use the procedure for
low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in t he refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced i n 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 dis charged before opening any fitting or connection
in the refrigeration system. Open fittings with cau tion even after the system has been discharged. If
any pressure is noticed as a fitting is loosened, a llow trapped pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use th e 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 th ey are at least 80 mm (3 in.) from the exhaust mani fold.
It is good practice to inspect all flexible hose lines at least once a year to make sure they are in g ood
condition and properly routed.
O-rings used on connections are not reusable.
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6HEATER, AIR
AND VENTILATION On-vehicle Service
COMPRESSOR NOISE CHECK
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 caus ed by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory drive belt tension (power steering or generator).
Improper accessory drive belt tension can cause a m isleading noise when the compressor is engaged
and little or no noise when the compressor is disen gaged.
Drive belts are speed-sensitive. That is, at differ ent engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often mis taken 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 compresso r noise. To duplicate high ambient
head pressure), restrict air flow through condenser . Install manifold gauge set sure discharge
pressure doesn’t exceed 2,070 (300 psi).
2. Tighten all compressor mounting bolts, clutch mo unting bolt, and compressor drive belt. Check to
assure clutch coil is tight (no rotation or wobble) .
3. Check refrigerant hoses for rubbing or interfere nce that can cause unusual noises.
4. Check refrigerant charge. (Refer to
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mountin g bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and repea t Step 1.
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HEATER, AIR
AND VENTILATION On-vehicle Service
IDLE-UP OPERATION CHECK
1,Before inspection and adjustment, set the f&w-
ing condition:
lEngine coolant temperature:
lLights, electric cooling fan and accessories: Set t o
OFF
lTransmission: Neutral (N or for vehicles with
l Steering wheel:
2. Check whether or not the idling speed is the sta ndard
value.
Blower relay
Standard value:
100
Engine (Turbo) and Engine>
100 Engine (Non-turbo)>
3. When the
is running after turning the A/C switch
to ON, and the blower switch to the MH or HI positi on,
check to be sure that the idle speed is at the stan dard
value.
Standard value: (in Neutral)
NOTE
Idle speed is controlled by the system and is not
adjustable. If, idle speed is not within specifications, check
the system.
Engine (Non-turbo)>: Refer to GROUP On-
vehicle Service.)
Engine (Turbo)>: Refer to GROUP On-vehicle
Service.)
Engine>: Refer to GROUP On-vehicle Ser-
vice.)
POWER RELAY CHECK
BLOWER MOTOR RELAY CHECK
Battery voltage Terminal No.III
1235
Power is not supplied
Power is supplied0 0
0 0

Engine (Turbo)>HEATER,
AIRAND VENTILATION On-vehicle Service
A/C COMPRESSOR CLUTCH RELAY, CONDENSER FAN
RELAY (LO) AND (HI) CONTINUITY CHECK
Batteryvoltage Terminal No.
13 45
Power is not supplied0
Engine (Non-turbo)>
Condenser
fan relay (LO)
Engine>
NC
clutch relay
ment relay box
Power is supplied0
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HEATER, AIR
AND VENTILATION Heater
HEATER CONTROL ASSEMBLY
REMOVAL AND INSTALLATION
When and the floor console as-
let it
orthecomponents.
NOTE metal clip positions.
Removal steps
1. Center panel
2. Floor console (Refer to GROUP
Floor Console.)
3. Radio, tape player and CD player (Refer to GROUP
Radio,
Tape Player, CD
Speaker and Antenna.)
4. Stopper
5. Heater control assembly
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AIR ,
AND VENTILATION Heater
R E M O V A L
HEATER CONTROL REMOVAL
(1)Press the lever pin to disconnect the air outlet changeover
damper cable.
(2) Snap the boss and clamp with nippers or a flat- tipped
screwdriver, etc to remove the heater control assem bly.
NOTE
The boss and clamp are needed for assembly line at
the factory, but not needed for service work.
INSTALLATION SERVICE POINTS
HEATER CONTROL ASSEMBLY INSTALLATION
(1) Always snap the boss and clamp before installin g a new
heater control assembly to the instrument panel.
NOTE
The boss and clamp are ‘needed for assembly line at
the factory, but not needed for service work.
(2) Set the temperature control knob on the heater control
assembly to MAX HOT.
(3) Set the air mix
lever. at, the upper part of the
heater unit to the MAX HOT position, install the cable
to the lever pin.
(4) Push the outer cable in the direction of the ar row so
that there is no looseness, and then ‘secure it wit h the
clip.
,
(5) Set the knob for the air outlet changeover on the heater
control assembly to the DEF position.
(6) Set the air outlet changeover damper lever of t he heater
unit to DEF position and install the cable to the lever
pin.
(7) Push the outer cable in the direction of the ar row so
that there is no looseness, and then secure it with the
clip.
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