Climate Control Student Guide

CLIMATECONTROL (CC1)

MitsubishiAcademy.com

STUDENT GUIDE

Course

Guide

CC1Student

Course Guide

Climate ControlStudent Course Guide

DIAMONDPRO CERTIFIEDTECHNICAL TRAINING

Course DescriptionMitsubishi vehicles are equipped with both automatic and manual climate control systems. In order to diagnose these systems accurately, technicians must master refrigeration basics, passenger compartment air flow control, heating and air conditioning components, as well as related control systems and devices.

A solid understanding of the principles and components presented here will improve Mitsubishi technician Fixed Right the First Time performance and thus, dealership CSI scores.

2Course Guide Mitsubishi Motors North America, Inc.

Climate Control Student Course Guide

Course

Guide SAFETY IS YOUR RESPONSIBILITY

This section is for use by professional Mitsubishi Motors dealership service technicians. The descriptions and procedures in this publication supplement existing service manuals, technical service bulletins, and other documents provided by Mitsubishi Motors North America, Inc. (MMNA). As a result, the use of these sources may be required to ensure a proper repair.

Within this section there are Notes, Cautions, and Warnings. These references provide guidance to help you do your job efficiently and safely. The definitions for these terms are listed below.

NOTEA Note exists to help you do your job more efficiently. A Note may also provide additional information to help clarify a particular point or procedure.

CAUTIONA Caution alerts you to the possibility of damage to either tools, equipment, or to the vehicle itself. A Caution recommends that a procedure must be done in a certain way to avoid potential problems resulting from improper technique or method.

WARNINGA Warning alerts you to the highest level of risk. Warnings inform you that a procedure must be done in a particular way to minimize the chances of an accident that could result in personal injury or even loss of life.

Note

Caution

!

When you see a Note, Caution, or Warning, be sure you understand the message before you attempt to perform any part of a service procedure. Also keep in mind it is impossible for MMNA to anticipate or evaluate every service situation a technician may encounter. For that reason, you have the final responsibility for personal safety–yours and those working around you. Be sure to always wear proper protective clothing and safety equipment, use the proper tools, and follow the repair procedures as outlined in various service publications provided by MMNA.

No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Mitsubishi Motors North America, Inc. MMNA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.

Copyright © 2014 Mitsubishi Motors North America, Inc.Corporate Technical Training Department

3Course GuideMitsubishi Motors North America, Inc.

Climate Control Student Course GuideC

ourseG

uideCOURSE DESCRIPTION The course details the fundamentals of heating, air conditioning, and ventilation systems and of the associated components.

A solid understanding of climate control principles and components presented here will improve technician Fixed-Right First-Time performance and dealership CSI scores.

COURSE GOALS • Apply the four phases of the refrigeration cycle to principles of heat transfer and energy conservation.

• Describe the various functions of the Ventilation System along with the related control devices.

• Describe the climate control components used with the Mitsubishi vehicles along with their functions and operations.

• Describe the Manual and Automatic control systems used to manage passenger compartment and Traction Battery temperatures.

• Define technician safety responsibilities associated with A/C service and R134a handling.

• Demonstrate the effective use of diagnostic and service equipment to identify causes of A/C system malfunctions.

PREREQUISITES Successful completion of the following courses is required for enrollment in Climate Control. Consult MitsubishiAcademy.com for details.

• Electrical Systems 1 (ES1 or ELFB or ES1W)• MEDIC 2 (MED2)• MEDIC 3 (ME3W)• Scan Tool Viewer (STV or STV 2 or STV3)• Basics of Climate Control (MACW)

Slide Course Guide-3a

Slide Course Guide-3b

Slide Course Guide-3c



Course

Guide

SCHEDULE • Prerequisite Review• Heat Transfer Principles (55.00A)• Ventilation Systems (55.01A)• Climate Control Components (55.02A)• Electronic Control Systems (55.03A)• Day 1 Exam

• Service Equipment (55.04A)• Diagnosis and Repair (55.05A)• Day 2 Exam

DAY 1

DAY 2

SYMBOLS

Symbols are used throughout the course to aid in navigating the sections.

The Student Guide includes the following elements.• Prerequisite Review Questions (Front pocket)• Name Tent (Front pocket)• Day 1 and Day 2 Quizzes (Front pocket)• Course Achievement Worksheet (Front pocket)• Course Guide• Section 55.00A - Heat Transfer Principles• Section 55.01A - Ventilation System• Section 55.02A - Climate Control Components• Section 55.03A - Electronic Control Systems• Section 55.04A - Service Equipment• Section 55.05A - Diagnosis and Repair

CSI Pay special attention to these details asthey help Diagnose Customer Concernscorrectly to Fix It Right The First Time.

Video Refer to the related video material foradditional information.

Reference Refer to the related reference publicationfor additional information.

Activity Perform the related activity and answer therelated questions.

FeedbackComplete the Knowledge Check to verifyyour understanding of the materials.



STUDENT GUIDE CONTENTS



ourseG

uide

Take advantage of your time during this course to get the most from it.

Make notes or drawings any place in the StudentGuide to help recall the details later.

One of the main goals of Mitsubishi Training is to provide as much individual instruction as possible. If you do not understand something in the classroom or shop, ask your instructor to clarify the point.

Hands-on activities offer the opportunity to work as part of a team. Rotate your roles in the team so that everyone has a chance to complete the exercise. Only by actively participating will you learn from the experience.

The training course is an opportunity to learn successfully in a controlled environment under the guidance of a trained instructor. Learn from your mistakes, practice good safety habits, and use equipment and vehicles properly. Have a good experience here and return to your dealership with confidence in your abilities as a trained professional.

Because Mitsubishi technical training is competency based, hands-on activities comprise 60% of the student’s evaluation. The instructor will observe and evaluate each technician’s performance, offering assistance when necessary.

Summaries and Knowledge Check questions wrap up each course section. Technician participation in these activities comprises an additional 10% of the evaluation.

Daily exams contribute to the final 30% of the evaluation.

SUGGESTIONS FOR SUCCESSFUL COMPLETION

Spend the Time Wisely

Take Notes

Ask Questions

Teamwork

Learn From Your Mistakes

STUDENT EVALUATION

Skill & Diagnosis Sections

Summaries and Knowledge Checks

Written Exams





Course

Guide

Slide NumbersNumbers at the lower right corner of each slide aid in student guide navigation.

• Section number indicates the topic. • Student Guide page number follows. • Completing the identification is a lower case letter indicating the position on the slide on the page: a = Top b = Middle c = Bottom

55.01A = Ventilation System 16 = Student Guide Page # a = Top of page

Slide 55.01A-16b

Segmented Permanent Magnet Rotor

Stator Windings

ElectricalConnector

Stator Poles

Stator Poles

STUDENT GUIDE NAVIGATION

Printed on the edge of each page are section number tabs (for example, 55.02A as shown at right).

Page numbers are located on the lower outside corner of each page (for example, 55.02A 42 as shown at right). Simply thumb through the pages to find a specific page number.





ourseG

uide

To ensure the information presented in the prerequisite courses (ES1, MEDIC, STV, and MACW) has been mastered, students will complete the enclosed review questions. It does not count toward the final score but is useful for reviewing elements of electrical system basics, the use of Mitsubishi’s scan tool, and technician ability to research information using MEDIC. With the previously completed courseware thoroughly in mind, all students begin the Climate Control course fully prepared.

PREREQUISITE REVIEW

COURSE ACHIEVEMENT WORKSHEET

Climate Control 1Technician Course Achievement Worksheet

Student Name: _________________________ Course Dates: _______________________________________

SKILL ACTIVITIES (60%) Possible Instructor’s Actual Points Verification Points

Ventilation System Activities 10 _______ _____Compressor Clutch Activities 10 _______ _____Heated Seat Circuit Worksheets 10 _______ _____Diagnosis Practice 30 _______ _____ Total 60 _______ _____

Instructor Comments:

QUIZZES (30%) Day 1 Quiz (15 points possible) _______

Day 2 Quiz (15 points possible) _______

(30 points possible) _______

FINAL GRADE SUMMARY(Minimum 80% = Passing Score)

Skill Activities (60 points) _______

Quizzes (30 Points) _______

Participation (10 points) _______

TOTAL _______

Mitsubishi Motors North America, Inc. 04/2014

Dealer Name: __________________________ Dealer Code: __________ Instructor: __________________


55.00A


Heat Transfer Principles

Section DescriptionDiagnosing automotive climate control systems requires a thorough understanding of energy conservation and heat transfer through the four phases of the refrigeration cycle to move heat from the passenger compartment to the outside air.

Theory Section

55.00A

1Section 55.00A Mitsubishi Motors North America, Inc.


55.00A

SAFETY IS YOUR RESPONSIBILITY






Note

Caution

!




Mitsubishi Motors North America, Inc. 2Section 55.00AMitsubishi Motors North America, Inc.

Heat Transfers Principles55.00A

Table of Contents Section Introduction Section Goal ………………………………………………………………...…… 3 Section Objectives ………………………………………………………………. 3 Needed Materials ……………………………………………………………….. 3 Time to Complete ……………………………………………………………….. 3 Automotive Climate Control ……………………………………………………………. 4

System Overview & Functions ………………………………………………… 4 Solid, Liquid, and Gas ………..……………………...…………………………………. 5 Kinetic Energy & Changing State: Adding or Removing Heat ……………………... 6 Heat Energy ……………….…………………………………………………………….. 7 Sensible Heat ……………………………………………………………………. 7 Measuring Heat …………………………………………………………………. 8 Heat Transfer ……………………………………………………………………. 8 Temperature …………………………………………………………………….. 9 Energy Conservation …………………………………………………………………… 11 Forms of Energy ………………………………………………………………… 11 Transferring Heat ……………………………………………………………….. 11 Heating System and Heater Core …………………………………………….. 12 Heat Transfer ……………………………………………………………………. 13 Radiation ………………………………………………………………………… 13 Conduction …………………………………………………………………….… 14 Convection …………………………………………………………………….… 15 Evaporation ………………………………………………………………………. 15 Humidity & Comfort Zone ……………………………………………………… 16 Temperature and Pressure …………………………………………………………… 18 Heat Saturation & Engine Cooling……………………………………………. 19 Refrigeration Cycle …………………………………………………………………….. 20 Compressor ……………………………………………………………………… 21 Condenser ………………………………………………………………………. 22 Receiver-Drier …………………………………………………………………... 23 Thermostatic Expansion Valve (TXV) ………………………………………… 24 Fixed Orifice Tube (FOT) ………………………………………………………. 25 Accumulator ……………………………………………………………………… 25 Refrigerant Flow in a Fixed Orifice System ………………………………….. 26 Evaporator ……………………………………………………………………….. 27 Refrigeration Cycle Review ……………………………………………………. 28 Demonstration …………………………………………………………………… 29 Section Summary ……………………………………………………………………….. 31 Knowledge Review Questions ………………………………………………………… 33



55.00A

SECTION GOAL

SECTION OBJECTIVES After completing this section, you will be able to perform the following tasks.

• Identify the basic principles of energy conservation and heat transfer.

• Identify when refrigerant is in a liquid or gaseous state.

• Identify the points in the refrigeration cycle when refrigerant is a liquid or gas

• Identify the points in the refrigeration cycle when refrigerant is at low and high pressure

• Identify what type of heat transfer occurs when refrigerant changes states under different temperatures and pressures.

• Identify and explain the operation of system components involved in the refrigeration cycle.

NEEDED MATERIALS

TIME TO COMPLETE

Section 55.00A only.

About 45 minutes

Slide 55.00A-3a

Slide 55.00A-3b

Apply the four phases of the refrigeration cycleto the principles of heat transfer and energyconservation.



AUTOMOTIVE CLIMATE CONTROL

Automotive air conditioning has been used for over seventy five years, providing passenger comfort and convenience adding to pleasurable driving experiences. Today, it is standard equipment in virtually every car and truck sold in North America.

The functions of an automotive climate control system are listed below.• Provide heated or cooled and filtered air to the passenger compartment.• Dehumidify air directed to the windshield.• Clear side windows for increased visibility.• Circulate fresh or recirculated air to the passenger compartment.

Slide 55.00A-4a

SYSTEM OVERVIEW

High Pressure Vapor

Low Pressure VaporHigh Pressure Liquid

Low Pressure Liquid

Heat absorbed frompassenger compartment

Pressure dropsto cool refrigerant

Heat released to atmosphere

Pressure increaseto superheatrefrigerant

Slide 55.00A-4b

To achieve all of these functions, systems rely on basic heat exchange principles to operate efficiently.

Road Surface

Exhaust

68°F

85°F

Engine

Transmission

Sunlight & Ambient

Sunlight & Ambient

Sunlight & Ambient



55.00A

SOLID, LIQUID, or GAS While discussing a refrigeration system, it is necessary to understand of how gases, liquids, and solids behave under various conditions. All matter, whether solid, liquid, or gas consist of billions of molecules. Molecules are formed when atoms come together to share electrons.

Molecular Motion:LIQUID

Slide 55.00A-5a

Slide 55.00A-5b

Molecular Motion:SOLID

In solid form, the electrons have insufficient energy and tend to remain close together. This causes the atoms within each molecule to stay close together and in turn molecules exert a mutual attraction to each other. This attraction is called cohesion.

In the liquid form, the electrons have more energy and the distance between them increases. Distance between atoms and molecules increase, causing them to become less cohesive.

Molecular Motion:

GAS

As a gas, molecules have very little attraction to oneanother (or very low cohesion).

Slide 55.00A-5c

Solid

Liquid

Gas

Rem

oving heat reduces kinetic energy

Add

ing

heat

incr

ease

s ki

netic

ene

rgy

Instructor Note:At temperatures near absolute zero (−459.67°F) nearly all molecular motion ceases.



KINETIC ENERGY Whether solid, liquid or gas the molecules in a substance are constantly in motion. The colder the substance, the less the molecules move. The motion of the molecules increases as the temperature increases.

The movement of molecules within matter is calledkinetic energy, or energy of motion. A temperature reading is a measurement of the amount of kinetic energy of the molecules.

CHANGING STATE:ADDING OR REMOVING HEAT

When enough heat energy is removed from (or added to) a substance, a change of state occurs.

Removing heat reduces kinetic energy and causes molecular movement to slow down: gases becomeliquids and liquids become solids.

Adding heat increases kinetic energy and causes the molecular movement to speed up: solids become liquids and liquids become gases.

Slide 55.00A-6a

There are two types of heat energy:• Sensible Heat• Latent Heat.



55.00A

HEAT ENERGY

Sensible Heat

Sensible Heat is any heat that can be felt (or sensed) and measured with a thermometer.

Slide 55.00A-7a

Temperature

Slide 55.00A-7b

Temperature is a measurement of the amount of heat energy absorbed and retained by matter. Somethings feel hot, while others feel cold, but regardlessof whether it feels hot or cold, everything has somedegree of heat. A change in temperature is an indication of a change in the amount of heat energy being absorbed or released. Temperature can be measured in either Celsius (º C) or Fahrenheit (º F).



Measuring Heat1 calorie raises 2.2 lbs. of H20 1.8ºF

1 BTU raises 1 lb. of H20 1ºF

1 kW = 3412.142 BTU/hr

Heat is measured in calories, British Thermal Units(BTU), and kilowatts.

• One calorie is the amount of heat required to raise 2.2 pounds of water 1.8º F.

• One BTU is the amount of heat required to raise 1 pound of water 1º F. (1 calorie = 1.22 BTU).

• One kW = 3412.142 BTU/hr

Note: The total heating and cooling capabilities of many Mitsubishi climate control systems are often listed in kilowatts.

Slide 55.00A-8a

Heat Transfer

Some form of energy is required to generate the heat which causes the change in temperature. Energy, in the form of heat, is transferred from one object to another to cause the change in temperatures. Thus, temperature is the measurement of the amount of heat energy stored, released and absorbed during the transfer.

Slide 55.00A-8b



55.00A

Latent Heat

Latent Heat is unseen, or hidden. Latent heat is the additional heat required to change matter from a solid to a liquid or from a liquid to a gas. It is the energy needed to break the cohesive bonds that hold the molecules in one particular state. (Think of latent heat as a heat storage battery. Just as a battery stores unseen electricity, latent heat stores heat energy in cohesive bonds.)

Slide 55.00A-9a

Water212ºF

Steam212ºF

For example we know water boils at sea level at 212º F. When water boils, it changes into a gas in the form of water vapor or steam. If we were to measure the temperature of the steam, it would be the same temperature as the boiling water (212º F).

Slide 55.00A-9b



Unseen or “latent heat” is the additional heat (energy) absorbed to excite the water molecules on the surface to move faster than molecules in the liquid and change state to steam.

Heat a pound of water at 32º F until it turns to steam. The water absorbs 180 BTUs to reach its boiling point of 212º F. When the water reaches 212º F, it can’t be made any hotter by applying more heat (sensible heat). By continuing to apply more heat, the water changes to a gas without a change in temperature.

An additional 970 BTUs must be applied to change one pound of 212º F water into 212º F steam.

The opposite is also true when water changes from gas to liquid. Energy in the form of “latent heat” is removed from the gas to convert it into a liquid.

So, Sensible Heat refers to Temperature while Latent Heat refers to Change-of-State Energy.



55.00A

ENERGY CONSERVATION A basic law of physics states that energy cannot becreated or destroyed. It can only change forms. Aswe have seen, all matter has kinetic energy (aboveabsolute zero).

Energy can take various forms.• Kinetic Energy• Thermal (Heat) Energy• Chemical Energy• Mechanical Energy• Electrical Energy• Radiation

Energy can be converted from one form to another.The mechanical energy used by a driver to apply the brakes on a car is used to do the work of forcing the brake pads against the brake rotor. This changes the kinetic energy of the rotating wheel to thermal (heat) energy at the brake rotor and pads. The heatenergy at the brake pads and rotor is transferred tothe atmosphere and remains as heat energy.

Transferring Heat

Slide 55.00A-11a

Forms of Energy

Air conditioning systems transfer heat energy fromthe passenger compartment (evaporator, A) to the outside atmosphere (condenser, B) by using a change of state inside the sealed refrigerant system from liquid to gas and then back into a liquid.

A

B



Heating System

The heating system uses the same principles of heat transfer as the air conditioning system, but in a somewhat different way.

The chemical energy stored in gasoline is released when electrical energy from the ignition system ignites the air-fuel mixture. The result is the thermal energy caused from combustion.

Slide 55.00A-12a

Coolant transfers heat in the engine. The heat of combustion is absorbed into the coolant and moved to the heater core. As the temperature of the coolant flowing through the heater core is greater than the air passing over the heater core fins, the heat from the coolant is passed to the incoming air.

Slide 55.00A-12b

Heater Core

Heat can be transferred from one object to anotherthrough four natural processes:• Radiation• Conduction• Convection• Evaporation

Heat Transfer

Slide 55.00A-13b

Slide 55.00A-13a

Hot Cool

Heat always moves from a warmer object to a cooler object until both are at the same temperature. This is the #1 principle involved in climate control systems. Nature always seeks a balance. Whenever a difference in temperature or pressure exists, natural laws will tend to move them back to equilibrium as much as possible.

Radiation is the movement of heat by particles, waves, or rays. Radiation does not require air to transfer heat.

Radiation

Instructor Note: Vehicle color effects heat absorbtion.



55.00A

Road Surface

Exhaust

68°F

85°F

Engine

Transmission

Sunlight & Ambient

Sunlight & Ambient

Sunlight & Ambient

Conduction is the indirect transfer of heat through a conductive material. The car’s radiator is an example of conductive heat transfer.

Conduction



Slide 55.00A-14a

Slide 55.00A-14b

The metal of the radiator conducts the heat from thecoolant to the air that passes over the radiator. It isa conductive transfer because the coolant, which ishot, never comes in contact with the outside air thatabsorbs the heat.

Insulation is used to reduce conduction. Insulation materials have millions of small air pockets. Air does not readily conduct heat without the presence of moisture. Insulation resists the heat outside from conducting (through the metal of the vehicle) into the passenger compartment.

Note



55.00A

Convection There are two components of convection:• Heat Exchange• Circulatory Motion

Slide 55.00A-15a

HEAT

Cooler air falls.

Warmer air rises

As air is heated, it rises. As it cools, it falls. This causes a circulatory motion that continues the heat transfer process.

Glass

Steam212°

970 BTU’s

Liquid

Liquid

Vapor

1 lbs.

Evaporation is the process where a liquid absorbs heat and is transformed into vapor. As moisture evaporates from a warm surface, it removes latent heat and lowers the temperature of the surface. It then releases the heat into the air and condenses back into a liquid.

Evaporation

Slide 55.00A-15b



Slide 55.00A-16a

Humidity & Comfort Zone

Humidity is the amount of moisture contained in the air. Relative humidity is the amount of moisture as a percent of air’s capacity to absorb moisture.

Humidity plays an important role in the ability of thehuman body to maintain a comfort zone. That comfort zone is 65ºF (70% humidity) to 91ºF (10% humidity). Temperatures and humidity levels outside this range produce discomfort.

When the relative humidity is high, air is less able to absorb moisture. As a result, heat radiated from the body does not evaporate as readily and appears as perspiration. Perspiration increases passenger discomfort in an automobile as the body temperature remains outside the comfort zone.

One of the primary functions of the air conditioning system is to dehumidify the air in the passenger compartment so excess heat from the passengers‘ bodies is readily transferred to the air inside the passenger compartment.

SetTemperature

91°F @10% Humidity

65°F @70% Humidity



55.00A

Evaporator Drain

Slide 55.00A-17a

The air conditioning system removes moisture from the air passing over the evaporator fins through condensation. The moisture in the air condenses on the evaporator fins where the cooler temperature of the evaporator causes the moisture in the air to change state from a vapor to a liquid. The water that results from this change of state is directed out of the vehicle through the evaporator case drain.

Removing the moisture in the incoming air makes the transfer of heat from the passengers to the air inside of the vehicle easier and maintains the passengers’ comfort zone in the range of human comfort.

Evaporator Drain Tube



TEMPERATURE and PRESSURE

Slide 55.00A-18a

Pressure plays an important role in heat transfer and represents the amount of force exerted by one object upon the surface of another.

Gravity acts on the gases in the atmosphere and results in an air pressure of 14.7 pounds per squareinch (psi) of atmospheric pressure at sea level.

Pressure and temperature are directly related. If an enclosed space is heated, the pressure in that space increases. Likewise, increasing the pressure of a substance (by reducing the volume of the enclosed space) will increase the temperature.

Pressure also has an affect on the temperature at which a liquid will boil and change to a gas. Atmospheric pressure at sea level requires a water temperature of 212º F to overcome that pressure and transform the liquid to a gas.

However, at 5,000 feet elevation, water boils at about 203ºF.

Vacuum Boiling Vacuum Boiling(in. Hg) Point (in. Hg) Point

29 76.62 7 198.8728 99.93 6 200.9627 114.22 5 202.2526 124.77 4 204.8525 133.22 3 206.724 140.31 2 208.523 146.45 1 210.2522 151.87 0 lb.21 156.75 (14.7 psi)20 161.19 1 lb. 215.619 165.24 2 lb. 218.518 169.00 4 lb. 224.417 172.51 6 lb. 229.816 175.80 8 lb. 234.815 178.91 10 lb. 239.414 181.82 15 lb. 249.813 184.61 25 lb. 266.812 187.21 50 lb. 297.711 189.75 75 lb. 320.110 192.19 100 lb. 337.99 194.50 125 lb. 352.98 196.73 200 lb. 387.9

Water Boiling Points at Various Pressures

212.0

Instructor Note: Use the chart on page 55.01-18 to explain further if necessary.



55.00A

Heat Saturation

Slide 55.00A-19a

Water boils when it contains all the heat it can for a given pressure. If water at a lower pressure boils at a lower temperature, it contains less heat than if it boils at a higher pressure.

Engine Cooling

Automotive engine cooling systems use pressure totransfer heat more effectively.

Each pound of pressure applied to a cooling system raises the boiling point about 2.5ºF. A system pressurized at 16 psi will not boil until about 250ºF at sea level. The system continues to absorb heat up to a higher temperature without turning into steam. Pressure increases the amount of heat transfer taking place.

Slide 55.00A-19b



REFRIGERATION CYCLE

Slide 55.00A-20a

High Pressure Vapor


Low Pressure Liquid

Heat absorbed frompassenger compartment

Pressure dropsto cool refrigerant

Heat released to atmosphere

Pressure increaseto superheatrefrigerant

Air conditioning systems use the principles of heat, temperature, and pressure to move heat from the passenger compartment to the outside air.

The refrigeration cycle changes the refrigerant from a gas to a liquid and then back into a gas, dropping pressure to absorb heat, and increasing pressure to release heat.

Any time there is a change in pressure, there is a change in temperature. During these pressure-temperature changes, there will also be a change of state from liquid to gas or gas to liquid.

Instructor Note: PlayCompressor Operation.avi



55.00A

Compressor

The compressor is the heart of the air conditioning system. It is the pump that converts mechanical energy into heat energy.

Slide 55.00A-21a

Compressor

35 psi160 psi

Slide 55.00A-21b

The compressor draws low-pressure gas from a Thermostatic Expansion Valve (or Fixed Orifice) through the evaporator and into the suction side of the compressor. The compressor pressurizes the refrigerant, which also raises the temperature, and discharges the superheated gas from the outlet side as a high-temperature, high-pressure gas.

Instructor Note: PlayCondenser Operation 2.avi



Condenser

Slide 55.00A-22a

Refrigerant gas exits the compressor and flows to the condenser located in front of the radiator.

Parallel Flow Condensor

Slide 55.00A-22b

Superheated gas from the compressor enters the condenser passing through a series of coils. Since the temperature of the coils is now higher than the outside air passing over the coils, heat is transferred to the atmosphere through conduction. To provide maximum heat transfer, a fan is used to force air over the condenser coils.

Instructor Note: PlayReceiver-Drier Operation.avi



55.00A

Receiver-Drier

Slide 55.00A-23a

As heat is transferred from the refrigerant to the atmosphere, the refrigerant looses heat energy andcondenses from a high-pressure gas to a high-pressure-liquid.

After leaving the condenser, the high-pressure, liquid refrigerant flows into the receiver-drier.

Receiver-Drier

Slide 55.00A-23b

The receiver-drier is located between the condenserand the evaporator, mounted next to, or integrated with, the condenser as one component.

Strainer

Strainer

Desiccant

Instructor Note: PlayFOT & TXV General Operation.avi

Instructor Note: PlayTXV Operation.avi


Heat Transfers Principles55.00AThermostatic Expansion Valve

(TXV)

Slide 55.00A-24a

The receiver-drier stores excess refrigerant and oil to ensure a continuous supply. Receiver-driers also contain a desiccant or drying agent to purify the refrigerant. The refrigerant flow design also helps trap debris at the bottom.

The high-pressure liquid from the compressor is metered through the Thermal Expansion Valve (TXV) to provide the necessary amount of refrigerant to cool the interior of the car. It is housed inside the evaporator housing, mounted to the evaporator. The TXV is the system component located between the receiver-drier and the evaporator.

The TXV is a variable restriction. Restrictions drop pressure and thus temperature. The high-pressure liquid is turned into a low-pressure, low-temperature liquid mist as it is forced through the metering device and on through the evaporator. The TXV varies the amount of restriction to control the corresponding pressure and temperature drop.

Slide 55.00A-24b



55.00A

Fixed Orifice Tube(FOT)

Fine MeshFilter Inlet

FromCondenser

Low Pressure Liquid

High Pressure Liquid

“O” Rings

Fine MeshFilter Outlet

To Evaporator

Fixed SmallDiameter BronzeTube (Restriction)

2006-2009 Mitsubishi Raider uses a Fixed Orifice Tube system. Like the TXV, the fixed orifice provides a restriction to refrigerant flow to the evaporator, causing the refrigerant to change from high-pressure liguid to a low-pressure liquid mist. The rate of flow depends on the pressure difference across the restriction. Because the restriction is a fixed size, system operation depends upon proper compressor cycle times to function correctly.

Fine gauze filters are located at the inlet and outlet sides of the orifice tube to prevent contaminates from passing onto the evaporator.

Slide 55.00A-25a

AccumulatorVapor Pick Up Tube

From Evaporator (Low-Pressure Liquid or Vapor)

To Compressor(Low-Pressure Vapor)

Desiccant

Liquid

Slide 55.00A-25b

Located between the evaporator and compressor, the accumulator stores refrigerant, filters particles, absorbs moisture, and separates gaseous refrigerant from liquid refrigerant.



High Pressure Vapor


Low Pressure Liquid

Fixed Orifice Tube

Accumulator

Slide 55.00A-26a

Refrigerant Flow in aFixed Orifice System

In a fixed orifice system, refrigerant leaves the evaporator as a mixture of vapor and/or liquid. This mixture enters the accumulator and falls to the bottom. The vapor rises to the top and continues onto compressor. Liquid refrigerant in the bottom of the accumulator gradually vaporizes and is pulled into the compressor.

From the compressor, high-pressure refrigerant flows to the condenser. High-pressure liquid refrigerant exits the condenser and flows to the orifice tube where it changes to a low-pressure mist entering the evaporator. The process then repeats.

The presence of an accumulator identifies the system as Fixed Orifice versus TXV which uses a receiver drier.

Also remember the accumulator is located on the outlet side of the evaporator whereas the receiver drier is located on the outlet side of the condenser.

Instructor Note: PlayEvaporator Operation 2.avi



55.00A

Slide 54.56A-19a

Slide 55.00A-27a

Evaporator

The evaporator absorbs heat from the passenger compartment and transfers it to the condenser (through the refrigerant) which releases the heat to the atmosphere.

Slide 55.00A-27b

Evaporator

Instructor Note: PlayRefrigeration Cycle.avi



Air from inside the vehicle is blown over the fins of the evaporator. Passenger compartment heat is transferred to the low-pressure, low-temperature refrigerant passing through the coils. As the refrigerant absorbs heat, it changes state to a low-pressure gas. The gaseous refrigerant is drawn from the evaporator outlet into the suction side of the compressor in a TXV system.

High Pressure Vapor


Low Pressure Liquid

Plate and Fin Evaporator

Parallel Flow Condensor

Compressor

Sensing Bulb-TypeThermostatic Expansion Valve

Receiver/Dryer

Refrigeration Cycle Review

Slide 55.00A-28a



55.00A

This activity reviews the refrigeration cycle and demonstrates normal line temperatures and pressures.

Before starting the engine, use MEDIC to locate the Heater, Air Conditioning & Ventilation (Group 55A) for the assigned vehicle.

1. On what page does the Performance Test procedure begin? _______________________

2. Complete the following Test Condition chart.

gsnitteSmetIEnvironmentalCondition

Measurement LocationerutarepmeT

ytidimuH

Vehicle Body Condition

dooHrooD

Air Conditioning Condition

Air Conditioning SwitchemuloV riA

Temperature ControlteltuO riA

Outside/Inside Air SelectiondeepS enignE

noissimsnarT

3. Connect the manifold gauge set to the LOW and HIGH side ports. Static pressure = ______

Start the engine and allow it to reach operating temperature. Set the climate control system according to the Test Condition chart.

4. Center Air Outlet Temperature: ________

5. Pressures: HIGH Side _____ LOW Side _____

6. Using the illustration on the next page, circle the line temperatures as either hot or cold.

Activity



Hot or Cold Hot or Cold

Hot or Cold



55.00A

Automotive air conditioning systems rely on the principles of energy conservation and heat transfer to maintain the desired comfort zone in the passenger compartment.

Matter is composed of molecules, which are in constant motion at any temperature above absolutezero. Molecular movement results in kinetic energy. As heat energy is added to a solid, kinetic energy increases and the molecules move faster.

When enough heat energy has been added the solid changes state into a liquid. When enough additional heat energy is added, the liquid changes into a gas. Removing heat from a gas will cause it to change state into a liquid, and removing more heat will change it into a solid.

Temperature refers to sensible heat and can be felt or measured. Latent heat is absorbed or released to cause a change of state in matter.

Energy cannot be created or destroyed; it can only change form. An air conditioning system uses this principle to transfer heat from the passenger compartment to the outside atmosphere. Similarly, heat from engine coolant is transferred to the passenger compartment.

Pressure and temperature are directly proportional. Adding pressure to a substance raises the heat saturation point, or the amount of heat that the substance can absorb before changing state.

Pressurizing a hot gas superheats the gas making it easier to remove its latent heat. Lowering pressure decreases temperature allowing a gas to absorb latent heat.

The heat transfer process is referred to as the refrigerant cycle.

A compressor draws warm low-pressure vaporized refrigerant from the evaporator and pressurizes it, creating a high-temperature, high-pressure gas. The gaseous refrigerant flows to the condenser.

HEAT TRANSFER PRINCIPLES SUMMARY



The condenser releases superheat from the refrigerant to the atmosphere changing its state to a high-temperature liquid. To aid the heat transfer, an electric fan is used which blows air over the condenser coils.

A TXV or fixed orifice tube is used to change high-pressure liquid refrigerant flowing from the condenser to a low-pressure, low-temperature liquid mist entering the evaporator.

As the fan motor blows air across the evaporator coils, passenger compartment heat is transferred to the low-temperature refrigerant. After absorbing the passenger compartment heat, the vaporized refrigerant is drawn from the evaporator into the suction side of the compressor.

Page 14

Page 13

Page 15

Page 14

Page 14



55.00A

Answer the following questions to review the material from this section. If you don’t know the answer, look it up. If you answer a question incorrectly, read the material covering the topic again until you fully understand the information.

1. Adding heat reduces kinetic energy. a. TRUE b. FALSE

2. The transfer of heat through matter is called a. radiation. b. convection. c. conduction. d. condensation.

3. The movement of heat energy from the surface of warmer materials to colder materials through air is called a. radiation. b. convection. c. conduction. d. condensation.

4. The transfer of heat by the movement of warmed gasses or liquids is called a. radiation b. convection c. conduction d. condensation.

5. Which of the following represents heat transfer through a radiator? a. radiation b. convection c. conduction d. condensation

6. Which of the following represents heat transfer through a condensor? a. radiation b. convection c. conduction d. condensation

KNOWLEDGE CHECK

Feedback

Pages 24 and 25

Page 26

Page 10

Page 21



7. What device increases the refrigerant’s temperature and pressure? a. condenser b. evaporator c. TXV or FOT d. compressor

8. What device decreases the refrigerant’s temperature and pressure? a. condenser b. evaporator c. TXV or FOT d. compressor

9. Refrigerant leaves the evaporator and flows to the receiver-drier in a FOT system. a. TRUE b. FALSE

10. Latent heat refers to temperature and can be measured with a thermomter. a. TRUE b. FALSE

55.01A


Ventilation System

Section DescriptionThe ventilation system routes filtered, heated, or cooled air into the passenger compartment through a series of ducts and outlets to the defroster, panel, and floor.

Theory Section

55.01A


Ventilation System

55.01A







Note

Caution

!




2Section 55.01AMitsubishi Motors North America, Inc.

Ventilation System55.01A

Table of Contents Section Introduction Section Goal ………………………………………………………………...…… 3 Section Objectives ………………………………………………………………. 3 Needed Materials ……………………………………………………………….. 3 Time to Complete ……………………………………………………………….. 3 Ventilation System Functions ………….……………………………………………… 4 Blower Motor …………………..……………………...…………………………………. 5 Blower Motor Speed ……………………………………………..……………………... 6 Cabin Air Filter …………….…………………………………………………………….. 9 Air Dampers Single Zone ……………………………………..……………………………….. 9 Dual Zone ……………………………………………………………………….. 11 Mode Film ………………………………………………….…………………….. 12 Air Damper Motors Bidirectional DC Motor …………………………………………………………. 15 Stepper Motor …………………………………………………………………… 16 Endeavor Rear Blower …………………………………………………………………. 19 Raider Truck ……………………………………………………….……………………. 20 Ventilation System Odor Treatment …………………………………………………… 21 Air Exit …………………………………………….……………………………………… 21 Ventilation System Shop Activities ……………………………………………………. 22 Ventilation System Summary ……………….…………………….…………………… 30 Knowledge Review Questions ………………………………………………………… 31


Ventilation System

55.01A

SECTION GOAL

SECTION OBJECTIVES After completing this section, you will be able to perform the following tasks.

• Identify ventilation system functions.

• Describe blower operation and controls.

• Describe Single and Dual Zone systems.

• Describe Mode Film Damper operation.

• Identify damper motor designs and describe the operations of each type.

NEEDED MATERIALS

TIME TO COMPLETE


About 30 minutes

Slide 55.01A-3a

Slide 55.01A-3b

Describe the various functions of the Ventilation System along with the related control devices.

Instructor Note: Drawing above is used for illustration purposes only and does not represent the damper arrangement used with Mitsubishi vehicles.



The ventilation system routes filtered, heated, and cooled air into the passenger compartment through a series of ducts and outlets.

Slide 55.01A-4b

VENTILATION SYSTEM

Slide 55.01A-4a

Functions of the ventilation system.• Bring outside air into the vehicle• Recirculate interior air• Circulate air through evaporator to remove heat• Circulate air through heater core to add heat• Direct air to floor, face, and defrost registers


Ventilation System

55.01A

Blower Motor

The blower motor forces air through the evaporator and/or the heater core and out the registers.

Slide 55.01A-5a

Through a small tube, air is directed to the blower motor from the heater case to cool the motor during operation.

Slide 55.01A-5b

Instructor Note: MHI’s Power Transistor uses an N-channel MOSFET device made by Fuji Electric. At the instructor’s discretion, explain its operation using the data sheet and YouTube video found in the Instructor Support Information folder.

Power Transistor (Outlander, Outlander Sport, and Lancer) uses a UMI123 thermal fuse rated at 266º F.



Power Transistor Cooling

Slide 55.01A-6a

Blower Motor Speed

Mitsubishi vehicles use either a power transistor or a stepped resistor to control blower speed.

Battery voltage is supplied to the blower from the blower motor relay housed in the ETACS-ECU (or the Raider’s Integrated Power Module). The power transistor or stepped resistor varies the current on the motor’s ground circuit to change blower speed.

Thermal limiters (fuses) are used with both power transistors and stepped resistors to protect the blower circuit when temperatures climb due to excessive current draw.

Thermal Limiter

Power Transistor Stepped Resistor

Heat Sink

Slide 55.01A-6b

To help keep it cool, a heat sink is used with a power transistor to conduct heat to the surrounding air. As in this Lancer example, the power transistor is mounted at the bottom of the heater case and exposed to cooling air flow from the fan.


Ventilation System

55.01A

Blower Motor Speed Control - Power Transistor (Lancer Sportback)

Slide 55.01A-7a



Blower Speed Control - Stepped Resistor (Eclipse)

Slide 55.01A-8a

FUSIBLELINK 1

BLOWERMOTOR

BLOWERSWITCH

RESISTOR


Ventilation System

55.01A

Cabin Air Filter

Air Dampers (Single Zone)

Slide 55.01A-9a

Also known as an air purifier, clean air filter, or pollen filter, the element accomplishes these functions.• Traps particles, pollen, mold, and spores• Reduces unpleasant odors• Improves A/C and heater performance

The filter element should be inspected and replaced at regular intervals as indicated in the Mitsubishi maintenance manual.

Air Mix Damper

Heater Core

EvaporatorMode Damper

Outside/Inside Air Damper

Intake Duct

Cabin Air Filter

Slide 55.01A-9b

Instructor Note:TSB-12-55-001REV states some affected vehicles may exhibit inability to change to face vents when selected. Under cold conditions (including A/C operation), the mode door may bind against the inside wall of the heater unit, causing improper mode door travel. (Units built before June 14, 2011)

2007−2011 Outlander2008−2011 Lancer2008−2011 Lancer Evolution2009−2011 Lancer Sportback2011 Outlander Sport



Dampers are used to control air flow based on input from the controller. Dampers on some older vehicles were controlled directly by cables or by vacuum controlled actuators. Currently, Mitsubishi vehicles use electric motors to position the dampers.

Slide 55.01A-10a

Heater Core

Evaporator Heater Outlet

RecirculationFresh

Cabin Air Filter


Mode Damper

To Panel Vents

To Defroster Vents

Air Mix Damper

After flowing through the evaporator, air can be directed to the heater core by the Air Mix Damper if a warm temperature is selected by the driver. The damper can be positioned to provide full heat (all air is directed to the heater core), full cool (all air is blocked from flowing to the heater core) or a position between the two allowing a blended temperature.

Depending upon its position, the Mode Damper directs airflow to the panel registers, defrost vents, or floor ducts.

The Outside/Inside Damper is opened to allow fresh air into the vehicle or closed to recirculate existing passenger compartment air.

Instructor Note: Currently the 2014 Outlander is equipped with Dual Zone.


Ventilation System

55.01A

Air Dampers (Dual Zone)

Some Mitsubishi vehicles are equipped with a Dual Zone system where the driver’s side and passenger’s side temperatures are controlled independently.

A separator plate is installed in the case between the evaporator and heater core. Individual air mix dampers control the temperature to the driver (LH) and passenger (RH) sides. Note in the illustration above, the mode dampers are split to allow movement over the separator plate.

Slide 55.01A-11a

Slide 55.01A-11b

Air Mix Damper (LH)

Heater core

EvaporatorMode Damper


Clean Air Filter

Air Mix Damper (RH)

Separator Plate



Mode Film Damper

A bidirectional electric motor rotates the Mode Film Damper to direct air to the defroster vents, panel vents, and floor outlets.


Mode Damper(Mode Film Damper)

MAX A/C Damper

Air Mix DamperHeater Core

Evaporator

Slide 55.01A-12a

Eclipse, Endeavor, and Galant vehicles use a Mode Film Damper to control airflow through the case.

Blower Motor

(Mode Film Damper)Mode Damper

MAX A/C Damper

Air MixDamper

Outside/InsideAir Damper

Recirculation Fresh

Heater Outlet

Defroster Vents

Panel Vents

Heater Core

Evaporator

Flow RateControl Valve

Slide 55.01A-12b

Instructor Note: TSB-12-55-02 states sloshing water noise from the center of the dash, or water dripping onto the carpet may be caused by the case drain being clogged, allowing water to collect in lower case.2004 - 2011 Endeavor2004 - 2012 Galant2006 - 2012 Eclipse2007 - 2012 Eclipse Spyder


Ventilation System

55.01A

Air throughHeater Core

To Air Outlets

Slide 55.01A-13a

After flowing through the heater core, air is directed into the Mode Film Damper and exits through the vents as shown above. However, if the driver selects PANEL, airflow from the heater core is directed through the small center opening and exits at the bottom of the damper. See PANEL VENTS ONLY in the illustration below.

PANELPANEL

FLOOR

DEFROSTDEFROST

FLOOR

FLOOR

PANEL VENTS ONLY

DEFROST VENTS ONLY

FLOOR OUTLETS ONLYPANEL AND FLOOR

DEFROST AND FLOOR

MAX A/C Damper

Air MixDamper

In all positions except PANEL VENTS ONLY, both the MAX A/C and Air Mix dampers close to force all air to flow through the heater core.

Slide 55.01A-13b



To improve air conditioner performance with a system using a Mode Film Damper, a Flow Rate Control Valve is used to regulate coolant flow into the heater core. Coolant is blocked from flowing to the heater core when the driver selects maximum A/C preventing the cooled air from being reheated.

Note: the Air Mix Damper motor also regulates the Flow Rate Control Valve.

Flow Rate Control ValveFrom Engine

Return to Engine

Air Mix Damperregulates coolant flow

Coolant Bypass

Slide 55.01A-14b

Slide 55.01A-14a

Note the center shaft position when the motor drives the Mode Film Damper to panel vents or defrost vents (maximum travel positions).

Panel Vents OnlyDefrost Vents Only


Ventilation System

55.01A

Slide 55.01A-15a

MODE SELECTIONDAMPER CONTROLMOTOR AND POTENTIOMETER

AIRTHERMOSENSOR

MOTORDRIVECIRCUIT

JOINTCONNECTOR (2)

JOINTCONNECTOR (2)

AIR MIXINGDAMPER CONTROLMOTOR ANDPOTENSIOMETER

INTERIORTEMPERA-TURESENSOR

JOINTCONNECTOR(2)

Electric motors position the Outside/Inside, Mode, and Air Mix dampers.

Some Mitsubishi vehicles use a potentiometer incorporated in the bidirectional motor assembly to determine damper position. (Wiring schematic of an Endeavor is shown below as an example.)

Air Damper Motors

Bidirectional DC Motor



Many current Mitsubishi vehicles use stepper motors to control the Outside/Inside, Air Mix, and Mode damper positions.

Stepper Motor

Slide 55.01A-16b

Mode Damper Motor

Outside/Inside Damper Motor

Air Mix Damper Motor

Slide 55.01A-16a

A stepper motor is a brushless DC electric motor that divides one full rotation into multiple equal steps. The motor’s position is commanded to move and hold at one of these steps without the need of a feedback sensor.

The permanent magnet rotor is constructed with alternating north and south poles arranged parallel to the rotor shaft.

Segmented Permanent Magnet Rotor

Stator Windings

ElectricalConnector

Stator Poles

Stator Poles


Ventilation System

55.01A

Four sets of stator poles are arranged around the two stator windings. One set of poles is mounted above each winding and one set below.

Using NPN transistors, the controller alternately energizes the two stator windings to magnetize the poles which attract or repel the rotor’s permanent magnets in sequential steps.

Diodes are used to eliminate current spikes when each stator is de-energized.

When reviewing Data List items, remember any % displayed on the scan tool represents a calculation of damper position only and not a direct feedback.

Slide 55.01A-17a

NN NN N

NS

NS

S S SS

Stator Pole

Stator Winding

Note



Slide 55.01A-18a

MODE SELECTION DAMPER CONTROL MOTOR

AIR MIXING DAMPER CONTROL MOTOR

OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

12V

A/C CONTROL UNIT

Slide 55.01A-18b

The pattern above illustrates the signal produced by the A/C-ECU to move the rotor in individual steps.


Ventilation System

55.01A

Rear Blower Motor

Rear Blower Unit

Rear BlowerResistor

Rear Blower Speed Control

Endeavor Rear Blower Unit

Slide 55.01A-19a

The Endeavor uses a rear blower unit installed in the center console for back seat passengers.

When the front blower is ON and the Air Mode Damper is set to PANEL or PANEL/FLOOR, the rear blower can be operated.

Only the rear fan speed can be set. Rear outlet temperature is set with the front controls.



Where other Mitsubishi systems use one Air Mode damper to control air flow to the defroster, panel, and floor, the Raider system uses two (9 and 11 shown in the drawing above). Other than this exception, all air flow functions are the same.

1. Air to defrost2. Heater core3. Temperature blend damper4. Fresh air entry5. Outside/Inside damper6. Recirculated air flow

7. Evaporator8. Air to floor9. Floor, panel, defroster damper10. Air to panel vents11. Panel, defrost damper

Heater Case - Raider Truck

Slide 55.01A-20a

1. Case2. Heater core3. Blend-air doors & actuator4. Evaporator5. Blower motor resistor

6. Recirc door and actuator7. Blower motor8. Evaporator temp sensor9. Mode-air doors & actuator

Slide 55.01A-20B

Heater Case Air Flow - Raider Truck

Instructor Note:• Pass around the bottle of Mitsubishi Cooling Coil Coating.• Discuss the causes for the odor and temporary nature of the odor treatment.• See AirSept, Inc. article in Instructor Resource Folder


Ventilation System

55.01A

Musty Odors from the Climate Control System

Some customers may complain of an unpleasant “musty” odor in the passenger compartment when the fan blower is switched on. This condition occurs more often in humid climates. Condensation on the evaporator mixes with airborne pollutants and substances. To temporarily eliminate these odors, the evaporator can be treated with Mitsubishi Cooling Coil Coating. Refer to TSB-02-55-005 for more details.

Slide 55.01A-21a

Air Exit

To complete the ventilation system, a path for air to exit the passenger compartment is provided at the rear of the vehicle. (Mirage is shown below.)

Slide 55.01A-21b

X

8

8

3-4

75-76

71

66

61



VENTILATION SYSTEM - Outlander

NOTE: The results observed during this activity may vary slightly depending on shop air temperature.

Start the engine and allow it to reach operating temperature. Press the AUTO button. Set both driver & passenger temperatures to 89º F.

1. Is the compressor engaged? YES or NO

2. Where is the air flow directed? Face Floor Floor/Face Defrost

3. Number of blower speed bars displayed? ____

Decrease the driver side temperature to 88º F.



Decrease the driver side temperature to 87º F.


Continue to decrease driver temperature.

7. At what temperature does the air flow direction change from floor to floor/face? ________ º F

Continue to decrease driver temperature.

8. At what temperature does the air flow direction change to face only? ____ º F

Continue to decrease driver side temperature.

9. At what temperature does the blower speed begin to increase? ____ º F

10. At what temperature does the blower speed increase to maximum (8 bars) ? ____ º F

Activity

8

X

DUAL

8

8

No Change


Ventilation System

55.01A

Reset the driver side temperature to 89º F.


12. Number of blower speed bars displayed. ____


Set the passenger side temperature to 88º F.

14. The system is now in _______ zone mode.



Decrease passenger side temperature to 87º F.


18. Decrease passenger side temperature to 61º F and describe the system operation. ____________

X

resumed

71º

68º

1

67º



VENTILATION SYSTEM - Mirage

NOTE: The results observed during this activity may vary slightly depending on shop air temperature.

Start the engine and allow it to reach operating temperature. Press the AUTO button. Set the temperature to 89º F.


2. What is the air source? (Outside or Inside)

Decrease blower speed to 3 bars then press the AUTO button and note the blower speed.

3. What happened to the blower speed? ________

Decrease the set temperature to 88º F.

4. Does the compressor engage? YES or NO

Reduce temperature to 75º F.

5. How many blower speed bars are displayed? ___

Continue to decrease set temperature.

6. At what temperature does the air flow direction change to floor/face? _____


7. At what temperature does the air flow direction change to face? _____


7. At what temperature does the Outside/Inside damper change to recirculation? _____


Activity

63º

Defrost

Floor/Defrost

Outside


Ventilation System

55.01A

7. At what temperature does blower speed begin to increase? _____

Press the Defrost button.

8. What is the air source? Outside or Inside

9. Did blower speed or set temperature change? YES or NO

Set the temperature to 85º F. Using the mode button, set the air discharge to floor/defrost. Touch Defrost button.

10. Where is air flow directed? _______________

11. When the Defrost button is pressed again, where is the air flow directed? ________________

12. Touch OFF. Where is air source? __________

Recirculation

0 - 100

Recirculation

0 - 100

No longer hear the blower fromoutside of the vehicle.



VENTILATION SYSTEM - Outlander Sport

In this activity, ventilation system components will be activated with MUT-III.

Start the engine and allow it to reach operating temperature. Set the controls to max heat, high blower speed, air discharge to face, and engage the compressor. From System Select, click Air Conditioner and click the Actuator Test button.

From the Actuator Test screen, click the Drop Down Arrow and select #5 Inside/Outside Damper from the list.

On the right side of the screen, click the Data List (Text) button. Scroll through the items until #45 (In/out select damp poten (target) and #46 (In/out select damp potentiometer are displayed.

Set the Actuator Test to Recirc and click the check mark to continue. List the results below.

1. #45 ____________________ (Recirc or Fresh)

2. #46 _______ % (list the full range)

3. Describe the blower sound when the damper is fully closed. ____________________________ ______________________________________

Click X at the bottom of the screen to exit the test and confirm the damper returns to Fresh position.

On the control panel inside the vehicle, select Recirculation position and enter the results below.

4. #45 ____________________ (Recirc or Fresh)

5. #46 _______ % (list the full range)

Click X at the bottom of the screen to exit the test.

From the Actuator Test screen, click the Drop Down Arrow and select #8 Air outlet c/o damper from the list.

Activity

0

12

23

28

61

67

75

83

100

100

3


Ventilation System

55.01A

On the right side of the screen, scroll through the list until #55 (Air outlet c/o potentiometer) is displayed.

For each damper position selected during the Actuator Test, record the percentage shown for the Air outlet c/o potentiometer (data item #55).

6. Face ______ %

7. Bi-Level 1 ______ %

8. Bi-Level 2 ______ %

9. Bi-Level 3 ______ %

10. Foot ______ %

11. Def/Foot 1 ______ %

12. Def/Foot 2 ______ %

13. Def/Foot 3 ______ %

14. Defrost ______ %


From the Actuator Test screen, click the Drop Down Arrow and select #6 Air mix damper motor from the list.

On the right side of the screen, scroll through the list until #63 (Air mix potentiometer) is displayed.

15. Damper position for full heat ________ %

Set the #6 Air mix damper motor position to 0.

16. Damper position for full cool ________ %. (Feel the air temperature at the face register.)

Set the system controls to max cool, blower OFF, air discharge to floor, and disengage the compressor. Shut the engine OFF.

ON

OFF

ON

ON

ON



VENTILATION SYSTEM - i-MiEV

Turn i-MiEV key to start position. (Ensure the READY light is illuminated on instrument cluster.) Rotate the temperature selection dial to full heat and press PUSH MAX. Set high blower speed, air discharge to face, and engage the compressor. From System Select, click Air Conditioner and click the Actuator Test button.

From the Actuator Test screen, click the Drop Down Arrow and select #4 MAX Switch Output from the list.

On the right side of the screen, click the Data List (Text) button. Scroll through the items until #60 (MAX Switch Input) and #72 (MAX Switch Output) are displayed.

Set MAX Switch Input to OFF and click the check mark to continue. List the results below.

1. #60 _________

2. #72 _________

3. Describe the MAX Switch Light on the control panel. ______ (ON or OFF)


4. #60 _________

5. #72 _________

6. Describe the MAX Switch Light on the control panel. ______ (ON or OFF)

On the control panel inside the vehicle, set system to OFF.

From the Actuator Test screen, click the Drop Down Arrow and select #7 Front Blower Fan from the list.

On the right side of the screen, click the Data List (Text) button. Scroll through the items until #68 (Front Blower Fan) is displayed.

Activity

0

4.5

5.0

5.5

6.0

6.5

7.0

8.0

9.0

13.0

16.3


Ventilation System

55.01A

For each blower speed selected during the Actuator Test, record the voltage shown for the Front Blower Fan (data item #68).

7. OFF _______ V

8. 1step _______ V

9. 2step _______ V

10 3step _______ V

11. 4step _______ V

12. 5step _______ V

13. 6step _______ V

14. 7step _______ V

15. 8step _______ V

16. MAX H _______ V

17. MAX C _______ V

Set temperature dial to 9:00 o’clock position, blower OFF, air discharge to floor, and disengage the compressor. Turn key to OFF (LOCK).



The ventilation system brings filtered outside air into the vehicle directing it to the panel registers (face), floor, and defrost vents. Dampers are used to control air flow based on outputs from the controller.

After flowing through the evaporator, air can be directed to the heater core by the Air Mix Damper if a warm temperature is selected by the driver. The damper can be positioned to provide full heat (all air is directed to the heater core), full cool (all air is blocked from flowing through the heater core) or a position between the two for a blended temperature.

Depending upon its position, the Mode Damper directs airflow to the panel registers, defrost vents, and floor ducts.

The Outside/Inside Damper is opened to allow outside air into the vehicle or closed to recirculate existing passenger compartment air.

Bidirectional DC motors or stepper motors are used to position the dampers.

A blower motor forces air through the evaporator and/or the heater core and out the registers.

A power transistor or a stepped resistor is used to control blower motor speed. Battery voltage is supplied to the blower from the blower motor relay. Based on signals from the controller, the power transistor or stepped resistor varies the current to change blower speed. To dissipate heat, these components are exposed to cool air flowing within the heater case.

Current Mitsubishi vehicles use a cabin air filter to trap particles, pollen, mold, and spores. It reduces unpleasant odors and improves A/C and heater performance.

A vent is positioned at the rear of the vehicle to allow air to exit the passenger compartment.

VENTILATION SYSTEM SUMMARY

Page 11

Page 14

Page 10

Page 9

Page 10


Ventilation System

55.01A

Answer the following questions to review the material in this section. If you don’t know the answer, look it up. If you answer a question incorrectly, read the material covering the topic again until fully understand the information.

1. Blower speed is controlled by varying current flowing to the motor with a stepped resistor or power transistor. a. TRUE b. FALSE

2. The Dual Zone system allows the driver to select a different fan speed than the passenger. a. TRUE b. FALSE

3. To monitor damper position, some Mitsubishi ventilation systems use what device? a. thermistor b. potentiometer c. capacitor d. fixed value resistor

4. What damper is used to direct air over the heater core? a. mode damper b. air mix damper c. outside/inside damper d. None of these answers is correct.

5. Describe the cabin air filter. a. traps particles and pollen b. improves A/C and heater performance c. should be replaced at regular intervals d. All of these answers are correct.

6. If the mode damper is open, fresh air enters the passenger compartment. a. TRUE b. FALSE

KNOWLEDGE CHECK

Feedback

Pages 16

Page 14

Page 14

Page 4



7. Two technicians are discussing the operation of a blower motor resistor. Technician A says the thermal limiter protects the blower circuit from excessive current draw and opens at approximately 250ºF. Technician B says only HI blower speed occurs if the thermal limiter opens. Who is correct? a. Technician A b. Technician B c. Both Technician A and B are correct. d. Neither Technician A nor B is correct.

8. A stepper motor is capable of positioning a damper in incremental steps. a. TRUE b. FALSE

9. The Flow Rate Control Valve is used when the driver selects __________ . a. Max A/C b. Max heat c. Panel/Floor d. Floor

10. What device regulates the Flow Rate Control Valve? a. Mode Film Damper motor b. Air Mix Damper motor c. Max A/C Damper motor d. Water Shut-off Valve Controller

55.02A


Climate Control Components

Section DescriptionVarious heating and air conditioning components are used to control passenger compartment temperature and humidity levels. This section describes the individual elements used to heat and cool air flowing into the vehicle.

Theory Section

To Evaporator

55.02A



55.02A







Note

Caution

!





Climate Control Components55.02A

Table of Contents Section Introduction Section Goal ………………………………………………………………...…… 3 Section Objectives ………………………………………………………………. 3 Needed Materials ……………………………………………………………….. 3 Time to Complete ……………………………………………………………….. 3 Refrigeration System Components A/C Compressors ………………………………………………………………. 4 Belt Driven Scroll Compressor ………………………………………… 5 Electric Motor Driven Scroll Compressor …………………………….. 6 Swash Plate Compressor ……………………...………………………. 10 Rotary Vane Compressor ……………………………………………… 12 Compressor Clutch ……..……………………….. …………………….. 13 Refrigerant Temperature Switch ……………………………………… 17 A/C Pressure Sensor …………………………………………………… 18 Pressure Relief Valve ………………….………………………………. 20 Fin Temperature Sensor ………………………………………………………. 20 Ambient Temperature Sensor …………………………………………………. 21 Interior Temperature Sensor and Aspirator ………………………………..… 23 Photo (Sunload) Sensor ……………………………………………………….. 25 Parallel-Flow Condenser ………………………………………………………. 26 Radiator and Condenser Fan Control ………………………………………… 27 Plate & Fin Laminated Evaporator ……………………………………………. 30 Thermal Expansion Valve (TXV) Operation …………………………………. 31 Capillary Tube TXV Operation …………………………...……………. 32 Block-type TXV Operation …………………………..……………….… 34 Refrigerant Lines ……………………………………………………………..… 35 Refrigerant Hoses ………………………………………………………………. 36 Charge Ports ……………………………………………………………………. 36 “O”-Rings …………………………………………………………………….….. 37 R134a Refrigerant …………………………………………………………….… 37 Refrigerant Oils …………………………………………………………………. 38 Heating System Components Engine Cooling System ………………………………………………………… 40 Water Pump ……………………………………………………………………… 40 Thermostat ………………………………………………………………………. 41 Heater Core ……………………………………………………………………… 41 Radiator, Cooling Fan, and Radiator Cap ……………………………………. 42 Positive Temperature Coefficient (PTC) Coolant Heater (i-MiEV) ……….... 43 Electric Coolant Pump ……………………………………………………….…. 48 Positive Temperature Coefficient (PTC) Air Heater (Mirage) …………….… 49 Heated Seats …………………………………………………………………….. 52 Climate Control Components Summary ……….…………………………………….. 55 Knowledge Review Questions ………………………………………………………… 58



55.02A

SECTION GOAL

SECTION OBJECTIVES After completing this section, students will be able to perform the following tasks.

• Identify A/C system components and describe their operations.

• Identify heating system components and describe their operations.

NEEDED MATERIALS

TIME TO COMPLETE


About 2 hours

Slide 55.02A-3a

Slide 55.02A-3b

Describe the climate control components used with Mitsubishi vehicles along with their functions, and operations.



As discussed in the first section, the A/C compressor draws in low-temperature, low-pressure refrigerant from the evaporator. The compressor routes high-temperature, high-pressure gas to the condenser.

Currently Mitsubishi uses three air conditioning compressor designs depending on vehicle application and system requirements. Each of these compressor designs and their specific operation is detailed in this section.

• Scroll compressor• Swash Plate (Axial) compressor• Rotary Vane compressor

REFRIGERATION SYSTEM COMPONENTS

Slide 55.02A-4a

Compressor Designs:- Scroll- Swash Plate (axial)- Rotary Vane

This section is divided into two parts:• Refrigeration System Components• Heating System Components.

A/C Compressors

Instructor Note: • Play ScrollCompressorCutawayAnimation.avi

Instructor Note: • Pass around the compressor.



55.02A

Belt Driven Scroll Compressor

Currently, the Scroll design is the most commonly used compressor with Mitsubishi vehicles. The Mitsubishi Heavy Industries (MHI) QS90 model is shown above.

Slide 55.02A-5a

Slide 55.02A-5b

The compressor uses two scrolls; one stationary and one movable. The movable scroll is connected to the compressor shaft with a concentric and is able to orbit. As the movable spiral oscillates within the fixed spiral, a number of pockets are formed. As these pockets decrease in size, the refrigerant is pressurized and exits through a discharge valve in the rear section of the compressor.

In most applications, the movable scroll is driven by the engine’s crankshaft with a drive belt when the compressor clutch is engaged.

Discharge Valve

Orbiting Scroll

Fixed ScrollCrankshaft

Clutch Assembly

Instructor Note: • Pass around individual pieces as operation is discussed.



Electric Motor Driven Scroll Compressor.

Dampers

A/C Compressor Bracket

Chassis GroundHigh Voltage Cable

12-V System Wiring Harness

Inverter

Electric Motor

A/C Compressor High Pressure Relief Valve

However, the moveable scroll in the compressor used with the i-MiEV is driven with a high-voltage AC (alternating current) electric motor and requires no clutch. The compressor is mounted under the car, forward of the Traction Battery adjacent to the Electric Power Steering rack.

Slide 55.02A-6a

Unlike a conventional A/C system where pressures are controlled by cycling the compressor clutch, the electric motor varies the scroll speed to maintain proper pressure.

Orbiting ScrollField Winding

Armature

Slide 55.02A-6b



55.02A

Stationary Scroll Seal

Obiting Scroll Seal

Slide 55.02A-7b

Refrigerant & POE flow passages

Internal passages allow the compressor to draw refrigerant and oil through the stator windings to aid in high voltage motor cooling and lubrication.

Slide 55.02A-7a

Seals are installed in grooves in the stationary and orbiting scroll as shown above.



Slide 55.02A-8b

The electric motor’s armature drives the concentric causing the movable scroll to orbit.

Slide 55.02A-8a

High voltage DC (direct current) from the vehicle’s Traction Battery is directed to the A/C compressor inverter (shown above) which converts it to AC (alternating current) to drive the electric motor.

Compressor Specifications:• Displacement = 30cc• Maximum Speed = 6,000 RPM• Maximum Input Current = 20.5 A (at 220 VDC)

The i-MiEV A/C system is automatically engaged during Level 3 (Quick) charging or whenever the Traction Battery temperature exceeds 86º F.

Note



55.02A

(FUSE )16

CASEGROUND

A/C CONTROL UNIT

A/C COMPRESSOR

MAIN CONTACTOR

HIGH VOLTAGE FUSE

RELAY BOXTRACTION BATTERY

GROUNDINGCONNECTOR

INDICATES HIGH VOLTAGE CABLES, WIRING HARNESSES, OR CONNECTORS.

Slide 55.02A-9a

Orange cables connect the A/C compressor to the high voltage Traction Battery as shown above.

ALWAYS consult the appropriate Mitsubishi service publications for proper procedures and important precautions applicable to the high voltage system.!

Instructor Note: • Play SwashPlate.avi• Pass around the compressor.



Slide 55.02A-10a

Swash Plate Compressor

A Swash Plate compressor (also called axial) employs reciprocating pistons to compress the refrigerant. The engine drives the compressor crankshaft through a belt which drives the swash plate. Mitsubishi Swash Plate compressors are all multiple piston designs with ten pistons.

The 2006-2009 Raider uses the Denso 10S17E Swash Plate design compressor, displacing 150 cc.

Piston

Swash PlateReed Valves

Clutch

Suction

Discharge

Reed Valves

Slide 55.02A-10b



55.02A

Slide 55.02A-10a

The ten-cylinder swash plate compressor has five bores, each having two piston faces, one on each side of the wobble plate. The intake stroke on one side is the compression stroke on the other side as the pistons travel in the same bore. One complete revolution of the swash plate drives the pistons from one end of their travel to the other end and back again.

As a piston begins its stroke from one end of the cylinder, vacuum opens the intake reed valve and draws refrigerant from the Low Side into the cylinder. As the piston reverses direction and moves to the opposite end of the cylinder, the intake reed valve closes and the gas is compressed. When the gas gains enough pressure, it forces the discharge reed valve open allowing the charge to flow into the High Side of the system. As the piston reverses travel again, the discharge reed valve closes and the cycle begins again.

Reed Valve Plates

Swash plate compressors use spring steel suction and discharge reed valve plates in both the front and rear cylinder heads. The spring tension in the steel is controlled by the thickness of the steel and is calibrated to control valve timing by the suction of the piston during the intake stroke and pressure of the charge on the discharge stroke. Timing of the intake and compression charges is a function of the opening and closing of the individual reed valves on each of the plates.

Slide 55.02A-11a

Instructor Note: • Play VaneAnimation.avi• Pass around the compressor.



Rotary Vane Compressor

Slide 55.02A-12a

A Rotary Vane compressor, made by Valeo, is used on Mirage beginning with the 2014 model year.

Slide 55.02A-12b

This compressor design consists of a rotor with two vanes and a carefully shaped rotor housing. As the compressor shaft rotates, the vanes and housing form chambers. Refrigerant is drawn from the suction port into these chambers, which diminish in size as the rotor turns. The vanes are sealed against the rotor housing by centrifugal force and refrigerant oil.

Suction

Discharge

Vanes



55.02A

A compressor clutch is a stationary field electromagnetic device. The stationary field coil is attached to the compressor body with bolts. The pulley is retained with a bearing and snap ring. The front plate is mounted to the compressor shaft and held in place with a retaining nut.

When there is no current to the field coil, there is no magnetic force applied to the clutch and the pulley spins freely. The front plate and the compressor shaft remain stationary.

When current is supplied to the field coil, magnetic force pulls the front plate against the pulley and both spin as one unit, turning the compressor shaft.

When the clutch is disengaged, small, flat steel springs pull the front plate away from the pulley, allowing it to spin freely once again.

The air gap between the front plate and the pulley is adjusted by changing the number of shims located on the compressor shaft under the front plate. (Refer to the appropriate Service Manual for procedures to measure and adjust air gap.)

Slide 55.02A-13a

Compressor Clutch

Pulley Bearing

Field CoilPulley

PulleyRetainingSnap Ring

Front Plate

Air Gap Adjustment Shim

Retaining Nut

2006 - 55-129 to 55-1332007 - 55-111 to 55-1152008 - 55-108 to 55-1122009 - 55-120 to 55-124

Align dowel pin on the back of clutch coil with the hole in the front of the compressor.

Various answers

Position eyelets to the right or left of compressor’s dowel pin location.

0.014” to 0.024”

Add or subtract shims as until correct air gap is obtained.



Review the Service Manual procedures before beginning this activity.

This compressor has been diagnosed with an internal seal failure. The replacement compressor does not come with a new compressor clutch.

Information for inspecting the compressor clutch is found on what pages?________________________________________

Follow the Service Manual procedure to remove the compressor clutch.

Inspect the components for wear or damage and record the results of your inspection below.________________________________________

Reinstall the compressor clutch. What features of the compressor and clutch are used to align the clutch during installation?________________________________________________________________________________________________________________________

New snap rings must be used to retain the clutch coil to the compressor as well as pulley and bearing to the compressor. (YES or NO)

In which direction must the snap ring beveled surface face? (Inward or Outward)

To properly position the coil-to-compressor snap ring, its eyelets must be positioned ____________________________________________________________________________________________

Check the clutch air gap and record your readings. Measured: _______________________________Standard Value: ___________________________

If the measured value differed from specification, how is the air gap adjusted?________________________________________________________________________________

Activity

10S17E Swash Plate Compressor

Clutch Removal and Reinstallation

(Raider)

2014 - 55A-47 to 55A-48

None

0.010” - 0.020”


Various answers



55.02A



On what page of the Service Manual would you findinformation for inspecting the compressor clutch?________________________________________



Reinstall the clutch. What features of the compressor and clutch are used to align the clutch during installation?________________________________________________________________________________



Activity

VCR08 Rotary Vane Compressor

Clutch Removal and Reinstallation

(Mirage)

2014 - 55-133 to 55-137

Various answers

Line up the pin hole on the compressor unit with the coil projection.


0.010” to 0.017”





Information for inspecting the compressor clutch isfound on what pages?________________________________________



Reinstall the compressor clutch. What features of the compressor and clutch are used to align the clutch during installation?________________________________________________________________________________



Activity

QS90 Scroll Compressor Clutch

Removal and Reinstallation

(Lancer)



55.02A

Refrigerant Temperature Switch

Most current Mitsubishi vehicles use a Refrigerant Temperature Switch to disengage the compressor clutch when system temperatures grow excessively high.

Slide 55.02A-17a

Slide 55.02A-17b

ON → OFF: 278°FOFF → ON: 248°F

It is wired in series with the compressor clutch and opens when the temperature reaches 278º F and closes below 248º F.

Instructor Note:• Pass around the sensor.



A/C Pressure Sensor

Slide 55.02A-18a

The A/C Pressure Sensor connects to a Schrader valve on the A/C liquid line and is sealed with a rubber O-ring.

Signal Processing

CeramicDiaphragm

PressurePort

Slide 55.02A-18b

The transducer detects pressure variances by monitoring the deflection of a two piece ceramic diaphragm. Pressures under the diaphragm are converted to analog voltage signals within the sensor and sent to the A/C controller.

• ECM disengages the clutch if high side pressure rises above 460 psi and re-engages the clutch when high side pressure drops below 290 psi.

• ECM disengages the clutch if high side pressure drops below 28 psi and re-engages the clutch when high side pressure rises above 34 psi.



55.02A

The A/C-ECU (or Raider’s Front Control Module) provides 5 volts to the transducer and monitors the output voltage on the sensor circuit.

Since the A/C-ECU (or FCM) is part of the CAN bus, high side pressure is continuously monitored by the ECM.

Slide 55.02A-19a

A/CCONTROL PANEL

A/C PRESSURESENSOR

INTERIORTEMPERATURESENSOR

NOCONNECTION

VEHICLES WITH AUTOMATICAIR CONDITIONING SYSTEM

POWERDISTRIBUTIONSYSTEM

AMBIENT AIR TEMPERATURE SENSOR

37FUSIBLELINK

ETACS-ECU

ANALOGINTERFACECIRCUIT

BLOWERRELAY

POWERTRANSISTOR

BLOWERMOTOR

A/C-ECU

REFRIGERANT PRESSURE psi

OU

TPU

T VO

LTAG

E

0

1

23

54

145 290 435

Voltages representing normal system pressures range between 0.451 volts and 4.519 volts.

Slide 55.02A-19b



Climate Control Components55.02ASlide 55.02A-20a

To prevent damage to system components, compressors are equipped with a Pressure Relief Valve to vent excessively high system pressures. Pressure is vented at approximately 450 psi but differs between compressors.

If a relief valve is ordered from Mitsubishi, two valves may be included in the box (one gold & one silver). This is due to thread differences between compressors. Always use the appropriate color.

The Fin Temperature Sensor (also called Evaporator Temperature Sensor, Fin Thermo Sensor, or Air Thermo Sensor) is a thermistor used to measure the temperature of air flowing from the evaporator. Some vehicles have the sensor inserted directly into the evaporator fins (as shown above) while others have it mounted on a bracket.

Slide 55.02A-20b

High Pressure Relief Valve

Fin Temperature Sensor

Sensor

TXV

Instructor Note: TSB-10-55-05 states sensor should not be removed for voltage testing on the following vehicles.

2005−2010 Galant2006−2010 Eclipse2007−2010 Eclipse Spyder2004−2010 Endeavor



55.02ASlide 55.02A-21b

The A/C controller uses the sensor signal to optimize system performance and to protect the evaporator from freezing. As the evaporator temperature increases, the sensor circuit resistance (and voltage output to the controller) decreases. Normal operating voltage ranges from 2.1 to 2.7V.

When the evaporator outlet air temperature drops to 41º F the compressor clutch is disengaged.

RES

ISTA

NC

E (k

Ω)

TEMPERATURE ºF

8

6

4

2

0 14 32 50 68 86 104

Slide 55.02A-21a

Ambient Temperature Sensor

This thermistor is mounted at the front of the vehicle typically under the bumper. The sensor signal is hard wired to ETACS on GS and ZC platforms (FCM on Raider) where it is made available to other systems via CAN. With PS platform vehicles and the i-MiEV, the signal is routed to the A/C-ECU.

Normal operating voltage ranges from 2.1 to 2.7V.



AMBIENT AIR TEMPERATURE SENSOR

ETACS-ECU

ANALOGINTERFACE CIRCUIT

BLOWER RELAY

POWER TRANSISTOR

BLOWER MOTOR

RELAY BOX(PASSENGER COMPARTMENT)FUSIBLE LINK

GROUNDING CONNECTOR

FUSIBLELINK 37

RHEOSTAT

A/C-ECU

A/CPRESSURESENSOR

JOINTCONNECTOR (2)

AMBIENTTEMPERATURESENSOR

NOCONNECTION

REAR WINDOW DEFOGGER AND DOOR MIRROR HEATER

Slide 55.02A-22a

Slide 55.02A-22b

PS Platform Vehicles(Eclipse, Endeavor, Galant)

GS and ZC Platform Vehicles(Lancer, Outlander,

Outlander Sport)




55.02A

Used with automatic A/C systems, the sensor can be located on either side of the dash (look for grill) or directly on the A/C control panel. With some older vehicles, the sensor was located on the headliner. (A manual system may have the grill, but no sensor.) The sensor is connected to a section of flexible plastic hose as shown above.

Interior (Room) Temperature Sensor

Slide 55.02A-23b

Slide 55.02A-23a

An aspirator, typically located on the driver side of the evaporator case, is connected to the opposite end of the plastic hose leading from the sensor.

Hose from the sensor connects

here.

This end of the aspirator is left open.

The aspirator is a venturi formed by a tapered tube inside a plastic housing.

Slide 55.02A-23c

Aspirator



When the blower is running, air flow in the evaporator case creates a vacuum at the aspirator restriction.

Slide 55.02A-24b

Slide 55.02A-24a

Interior Temperature SensorHose

Evaporator Case Air Flow

Aspirator Restriction

Instrument Panel Opening

Vacuum draws passenger compartment air through slots in the instrument panel and past the Interior Temperature Sensor.

The sensor, wired directly to the A/C-ECU, provides a voltage signal indicating passenger compartment temperature. Voltage from the sensor increases as the temperature decreases and vice versa.

Instructor Note:• Show Montero condenser.



55.02A

Slide 55.02A-25b

Slide 55.02A-25a

Photo (Sunload) Sensor

A sensor used in some Mitsubishi automatic A/C systems up to 2008 is the Photo (Sunload) Sensor located on the top of the dash panel near the red anti-theft indicator light.

With bright sunlight, the A/C controller increases blower speed to maintain cool air circulation. Conversely, if the sunload is low (cloud cover), the controller reduces blower speed.

PHOTO (SUNLOAD) SENSOR

Condenser

The condenser is a series of coils and fins, which transfers heat from the high-pressure refrigerant leaving the compressor to the atmosphere. The Receiver-Drier is mounted to the condenser on most current Mitsubishi vehicles as shown above.



High Pressure Vapor


Slide 55.02A-26a

The Parallel-Flow design condenser is similar to a cross flow radiator. Instead of refrigerant travelling through one passage, it travels through numerous passages. This provides a large surface area for ambient air to contact the superheated refrigerant gas and change its state to liquid refrigerant.

Parallel-Flow Condenser

Forced Air Flow

Air flow through the radiator and condenser is vital for engine cooling as well as proper air conditioning and heater performance.

When a vehicle moves forward, air is forced through the condenser and radiator. This air flow is considered ram air because it’s forced through the condenser and radiator by vehicle movement and speed. At low vehicle speeds or periods when the vehicle is stationary, electric fans pull air through the condenser and radiator.

Slide 55.02A-26b



55.02A

The fans are surrounded by shrouds to create low pressure areas behind the condenser and radiator. This ensures cool outside air flows through the heat exchangers instead of heated air from the engine compartment.

Slide 55.02A-27a

Slide 55.02A-27b

Radiator and Condenser Fan Control

ETACS controls the radiator and condenser fans on current GS and ZC platform vehicles.



The PCM and a Fan Control Module manage the operation of both fans on Endeavor.

Based on vehicle speed, A/C demand, and engine temperature, the PCM operates the condensor and radiator fans using the Fan Control Module.

RELAYBOX

POWERTRAINCONTROL MODULE

MFI SYSTEM

MFIRELAY MFI SYSTEM

MFI SYSTEM

BATTERY

MFI SYSTEM

INPUT SIGNAL

FAN CONTROLRELAY

POWERTRAINCONTROLMODULE

VOLTAGECORRECTION

SMOOTHINGCIRCUIT

FIELD EFFECTTRANSISTORCIRCUIT

DRIVECIRCUIT

INPUT SIGNALPROCESSING

OVERCURRENTDETECTION

FAN CONTROLLER

CONDENSERFAN MOTOR

RADIATORFAN MOTOR

FUSIBLE LINK 2

·A/C-ECU

·ENGINE COOLANT TEMPERATURE SENSOR·OUTPUT SHAFT SPEED SENSOR

Slide 55.02A-28a



55.02A

JOINTCONNECTOR

RADIATORFAN RELAY

POWERTRAINCONTROLMODULE

BATTERY 2FUSIBLE LINK

FUSIBLELINK

CONDENSERFAN RELAY

FAN CONTROLRELAY

CONDENSERFAN MOTOR

RADIATORFAN MOTOR

GROUNDINGCONNECTOR

IGNITIONSWITCH (IG2)

JUNCTIONBLOCK

·A/C-ECU

·ENGINE COOLANT TEMPERATURE SENSOR

·OUTPUT SHAFT SPEED SENSOR

INPUT SIGNAL

Slide 55.02A-29a

With 2004-2012 Eclipse and Galant vehicles, the PCM controls fan operation directly.

COOLING FAN MOTOR ENGINE

CONTROL MODULE

FUSIBLE LINK 5

COOLING FAN CONTROL RELAY (LOW)

RELAY BOX

COOLING FAN CONTROL RELAY (HIGH)

(FUSE )16JOINT CONNECTOR (3)

Slide 55.02A-29b

2014 Mirage employs one fan to cool the radiator and condenser using two relays (HIGH and LOW) located in the Relay Box and controlled by the ECM.



Slide 55.02A-30a

The evaporator is a series of looped coils and fins which transfer heat from the fresh air (or in recirculation mode, air from the passenger compartment) to the refrigerant in the coils.

Similar in operation to the Parallel-Flow Condenser, the Plate & Fin Evaporator provides multiple paths for refrigerant flow creating a large surface area to absorb passenger compartment heat.

Refrigerant enters the evaporator coil as a cold low-pressure liquid. As this liquid passes through the evaporator coil, heat moves from the warm air blowing across the evaporator fins into cooler refrigerant. This air that has now been cooled is then ducted into the cabin via the blower motor.

When there is enough heat to cause a change of state, a large amount of the heat moves from the air to the refrigerant. This causes the refrigerant to change from a low-pressure cold liquid into a cold vapor.

As the warmer air blows across the evaporator fins, moisture contained in that air (humidity) will condense on the cooler evaporator fins. Condensed moisture then runs off through the drain tubes located at the underside of the evaporator case.

Plate & Fin Laminated Evaporator



55.02A

Refrigerant flow to the evaporator must be controlled to obtain maximum cooling, while ensuring that complete evaporation of the liquid refrigerant takes place. This is accomplished by the Thermal Expansion Valve (TXV).

Metering refrigerant into the evaporator is essentialto proper cooling. If too little refrigerant is admitted,the air conditioner may not cool; too much, and therefrigerant may not change state, sending liquid intothe compressor. This could damage the compressor.

The TXV performs three functions:• Throttling• Modulating• Controlling

Throttling refers to the restriction of refrigerant flowbetween the high pressure on one side of the valveand the low pressure on the other side. Since the flow of refrigerant is restricted, it is said to be “throttled”.

Modulation is the movement of the valve from fully open to fully closed.

Controlling the amount of refrigerant metered into the evaporator under the varying heat and load conditions is the primary function of the TXV. It accomplishes this by modulating the valve to regulate the amount of throttling, controlling the refrigerant flow into the evaporator.

Thermal Expansion Valve

Receiver Drier

Compressor Evaporator

Thermal Expansion

Valve

Slide 55.02A-31a

Instructor Note:• Pass around the capillary tube TXV.



The TXV uses a temperature-sensitive bulb mounted on the evaporator outlet to sense evaporator outlet temperature. The temperature bulb is attached to the TXV by a capillary tube and controls a diaphragm on the top of the TXV, which is connected to a needle valve inside the TXV.

Slide 55.02A-32a

Capillary TubeThermal Expansion Valve

Slide 55.02A-32b

As the evaporator outlet temperature rises, the refrigerant in the capillary tube exerts pressure on the expansion valve diaphragm and the TXV opens to allow more refrigerant into the evaporator.

Pressure Compensation

Tube

Capillary Tube

From Receiver Drier

To Evaporator

Refrigerant Diaphragm

Metering Orifice

Ball

Spring

TXV Open



55.02A

Refrigerant Diaphragm

Capillary Tube

Pressure Compensation

Tube

From Receiver Drier

To Evaporator

Metering Orifice

Spring

Ball

TXV Closed

As the temperature of the evaporator drops, the gas contracts and the spring pressure of the diaphragm closes the TXV to reduce refrigerant flow.

The externally equalized TXV includes a Pressure Compensation Tube connected between the lower side of the diaphragm and the evaporator outlet. This tube allows refrigerant pressure to reach the underside of the diaphragm, balancing the pressure on the upper side of the diaphragm.

2004 Montero Sport was the last Mitsubishi vehicle to use the Capillary Tube TXV. All applications from that point forward use the Block-type Thermal Expansion Valve.

Slide 55.02A-33a

Instructor Note:• Pass around the block-type TXV.• Play Block-type TXV Operation.avi



From Receiver Drier

To Evaporator

FromEvaporator

ToCompressor

To Evaporator

Metering Orifice

Refrigerant

Activating Pin

Pressure CompensationUnder Diaphragm

Sensing Element

Spring

Ball

Slide 55.02A-34a

There are two refrigerant passages which form the legs of an “H”. One passage exists in the refrigerant line between the Receiver Drier and the Evaporator and contains the spring and ball valve. The other passage exists in the refrigerant line between the Evaporator and Compressor and contains the valve’s temperature-sensing element.

With the Block-type TXV, the evaporator outlet refrigerant passes through the valve body. When the temperature of the refrigerant in the evaporator outlet passage rises, the gas in the upper chamber of the diaphragm expands, pushing the pintle down, increasing the size of the orifice.

Block-typeThermal Expansion Valve



55.02A

As the evaporator cools, two forces combine to close the valve and restrict refrigerant flow: • Spring pressure on the ball valve • Pressure differential between the top and bottom of the diaphragm.

From Receiver Drier

To Evaporator

FromEvaporator

ToCompressor

Metering Orifice

Pressure CompensationUnder Diaphragm

Sensing Element

Activating Pin

Spring

Ball

Refrigerant

Slide 55.02A-35a

Refrigerant Lines

Slide 55.02A-35b

With current vehicles, rigid aluminum tubing is used for A/C plumbing. Rubber hoses are used at vibration connections where flexibility is needed.

Different from factory installed aluminum tubing, some replacement lines may be supplied by Mitsubishi in sections to facilitate replacement without powertrain removal.

Note



Reinforcement

Rubber Nitrile

Rubber

Nylon

Owing to the smaller molecular size and higher operating pressures of R134a, hoses incorporate a nylon inner liner. This is to reduce the normal refrigerant leakage that would naturally occur through rubber hose porosity.

Most R134a hoses have a smaller outside diameter and thinner hose walls to improve flexibility and reduce noise levels within the A/C system.

Slide 55.02A-36a

Refrigerant Hoses

Charge Port

relpuoC kciuQ a431R

Hand Wheel(Open/Close

Shrader Valve)

Charge Port

Rubber SealingWasher

ShraderValve

R134a Charge Port

Slide 55.02A-36b

Charge ports enable the A/C system to be serviced and tested while under pressure. Different size ports identify the high and low sides of the A/C system. A plastic cap with a rubber seal is used to close the charge port opening and avoid leaking.

Most Schrader valves will leak slightly. Ensure the plastic protection cap is installed and tightened properly.

Charge Ports



55.02A

R134a Refrigerant

Slide 55.02A-37b

“O” Rings

The “O” ring compound used with A/C system joints, fittings, and components is a hydrogenated nitrile butadiene rubber and colored green.

Refrigerant oil is used to lubricate “O” rings during installation.

Slide 55.02A-37a

Mitsubishi uses the non-ozone-depleting R134a (CF3CFH2) because its temperature and pressure relationship at low pressures is close to R-12. Its chemical name is Tetrafluoroethane.

Light blue is the industry standard color code for a 30 pound container of R134a.

An underhood label on all vehicles shows the type of refrigerant used in the A/C system.

Instructor Note:• Pass around the oils as each is discussed.



The chart above lists refrigerant temperatures and approximate pressures in operation. For example, a gauge reading of 26 psi indicates the evaporating temperature of R-134a in the evaporator will be about 30º F.

Slide 55.02A-38a

ºF PSI ºF PSI ºF PSI-15 0.7 22 19 40 35-10 3 24 21 45 40-5 4 26 22 50 450 6 28 24 55 515 9 30 26 60 57

10 13 32 27 65 6416 15 34 29 70 7118 17 36 31 75 7820 18 38 33 80 88

Refrigerant Oil

Slide 55.02A-38b

A synthetic lubricant known as PAG (polyalkylene glycol) is used with most R134a A/C systems but not all.

Currently, Mitsubishi vehicles powered with gasoline engines only and equipped with scroll compressors use PAG-56 oil. Raider trucks equipped with a Denso swash plate compressor uses ND-8 (Polyether and Additives). Mirage vehicles equipped with a Valeo vane compressor use ZXL200PG oil (Polyalphaolefin).



55.02A

PAG oils absorb moisture from the air (hygroscopic) so any opened oil containers must be resealed immediately. This is particularly important for any fresh oil containers located on air conditioning service equipment.

As discussed earlier, the i-MiEV’s compressor is driven by a high voltage electric motor. POE (Polyol Ester) refrigerant oil exhibits high electrical resistance along with excellent insulation properties. This oil provides proper compressor lubrication and maintains the insulation integrity of the motor’s electrical windings. It prevents short circuits as the motor operates and prevents high voltage from being conducted through the compressor case to the vehicle.

The i-MiEV requires Mitsubishi MA68EV refrigerant oil. No other refrigerant oil can be used with this high voltage system unless authorized by Mitsubishi Motors. If oil other than MA68EV is used, even only a small amount, insulation properties are significantly reduced and electrical leakage can occur.

Note

!

!

Like engine oil, refrigerant oil is available in different viscosities. For example, PAG-56 and ND-8 carry an ISO viscosity rating of 46 but ZXL200PG oil is rated at 100. Technicians must always replenish any oil lost during A/C service with the specific product stipulated in Mitsubishi service publications.

Note



HEATING SYSTEM COMPONENTS

Slide 55.02A-40b

Slide 55.02A-40b

The cooling system circulates a coolant composedof ethelyne-glycol and water through the engine. The coolant flows through passages in the block and head(s) to absorb combustion heat and transfer it to the outside air.

The vehicle’s heating system, based on the engine’s cooling system, is separate from refrigeration but shares a common case and air distribution system.

Engine Cooling System

Water Pump

Thermostat

Radiator

Throttle Body TransaxleCooler

HeaterCore

Engine Driven Water Pump

Water PumpPulleyCylinder Block

Timing Case

Rotor

Coolant is drawn into the water pump from the radiator outlet (bottom hose) and circulates through the engine passages back to the top of the radiator. The thermostat at the top of the engine regulates the amount of coolant flowing through the engine where the upper radiator hose connects.



55.02A

Thermostat

A small radiator, known as a heater core is enclosed in the case as shown above. Coolant from the engine circulates through the core where heat is conducted by the coils and fins to the air flowing into the cabin. Only Sensible Heat is transferred, since there is no change-of-state for engine coolant.

Heater Core

Valve Lift

The thermostat remains closed when the engine is cold to hold heat in the engine block. This helps the engine reach operating temperature more quickly and minimizes vehicle emissions. When the enginetemperature reaches the set temperature of the thermostat, the thermostat begins to open and allows coolant from the engine to flow into the radiator.

Slide 55.02A-41a

Slide 55.02A-41b

Instructor Note:

Pressure Markings:

(1 Kg/cm2 = 14.22 psi) 0.9 = 0.9 kg/cm2 = 12.80 psi 1.0 = 1.0 kg/cm2 = 14.22 psi 1.1 = 1.1 kg/cm2 = 15.65 psi

(1 kPa = 0.145 psi) 85 kPa = 12.30 psi 100 kPa = 14.5 psi 108 kPa = 15.66 psi



Radiator, Cooling Fan, and Radiator Cap

The radiator is the heat exchanger that transfers thecombustion heat within the coolant to the outside air by conduction.

A radiator fan is required to force air across the radiator when the vehicle is operated at low speed or at a stop to improve heat transfer.

The cooling system uses a radiator cap to raise the pressure in the system. As the coolant absorbs heat, the pressure of the coolant increases. Each pound of pressure raises the boiling point about 2.5º F. A system under 16 pounds of pressure will not boil until about 250º F at sea level.

Slide 55.02A-42a

Radiator

Cooling Fan

Radiator Cap

!

The cap regulates system pressure to about 16 psi thus raising the amount of heat the coolant mixture can absorb and transfer. When system pressure rises to about 16 psi, the relief valve opens to vent excessive pressure into the coolant recovery container. Pressure ratings of Mitsubishi radiator caps are measured in either kilograms/cubic centimeter or kilopascals.

• 1 kg/cm2 = 14.22 psi• 1kPa = 0.145 psi

WARNING! Since engine coolant is pressurized, it boils instantly when the cap is removed and can cause severe burns.

Slide 55.02A-42b



55.02A

Since the i-MiEV has no gasoline engine to heat the passenger compartment, a high voltage PTC (Positive Temperature Coefficient) heater is used to warm the coolant flowing through the heater core.

The heater is located under the vehicle and powered by the high voltage Traction Battery. Its maximum output is approximately 5.0 kW and heats coolant up to 176º F.

Resistance of the PTC heater increases sharply when the specified temperature is reached and current flow to the heating elements is reduced. Because of this self-regulating property, there is no additional control necessary.

A 12V electric pump (discussed later) is used to circulate the coolant from the heater through the heater core and back to the heater.

Dia Queen Super Long Life Coolant (blue-colored) is used, part number MZ311986.

ALWAYS consult the appropriate Mitsubishi service publications for proper procedures and important precautions applicable to the high voltage system and its components.

Slide 55.02A-43a

Positive Temperature Coefficient (PTC) Coolant Heater

(i-MiEV)

!

Note

Instructor Note:* Pass around the pieces as each is discussed.



Slide 55.02A-44a

The heater is a layered assembly with coolant flow castings mounted above and below the high voltage electric heater module. Based on signals from the A/C-ECU, the PTC Controller manages the high voltage used by the heater module.

HeatingElement

Controller

Slide 55.02A-44b

Shown above are the top and bottom plates of the heater assembly. Note the coolant flow passages.



55.02A

The heater module is sandwiched between the top and bottom plates as shown above.

The high voltage module heats the aluminum plates through conduction which in turn heats the coolant flowing through the passages.

The A/C-ECU signals the PTC Controller to energize one, two, or all three heating elements depending on ambient and driver selected temperatures.

The Controller provides three functions: • Calculates capacity and control requirements• Communicates with the A/C ECU• Individually switches heater elements ON and OFF based on signals from the A/C-ECU

Slide 55.02A-45a



Coolant travels into the heater (1) and warms as it flows across the channels of the top plate (2). It exits through a passage (3) and is directed to the bottom plate (4). Coolant continues heating as it flows across the channels of the bottom plate (5) then exits the heater (6) enroute to the heater core.

Slide 55.02A-46a

1

2

3

4

5

6

(FUSE )16

CASEGROUND

A/C CONTROL UNIT

A/C COMPRESSOR

MAIN CONTACTOR

HIGH VOLTAGE FUSE

RELAY BOXTRACTION BATTERY

GROUNDINGCONNECTOR

INDICATES HIGH VOLTAGE CABLES, WIRING HARNESSES, OR CONNECTORS.

EV WATER PTC HEATER

MAIN CONTACTOR

HIGH VOLTAGE FUSE

GROUNDINGCONNECTOR

CASE GROUND

Slide 55.02A-46b

IN

OUTIN

OUT



55.02A A Heater Coolant Temperature Sensor is used to monitor system operation. Its resistance values vs. temperature is shown above.

Slide 55.02A-47a

Heater Coolant Temperature Sensor

HEATER UNIT AND BLOWER ASSEMBLY

HEATER WATER TEMPERATURE SENSOR

AMBIENT TEMPERATURE SENSOR

A/C SWITCH IND

OUTSIDE/INSIDE AIR SELECTION IND

OUTSIDE/INSIDE AIR SELECTION SWITCH

CPU

TEMPERATURE ADJUSTMENT KNOB

A/C CONTROLLER ASSEMBLY (A/C-ECU)

BLOWER KNOB

MAX SWITCH

A/C SWITCH

MAX SWITCH IND

FIN THERMO SENSOR

MODE SELECTION DAMPER CONTROL MOTOR AND POTENTIOMETER

AIR MIXING DAMPER CONTROL MOTOR AND POTENTIOMETER

MODE SELECTION KNOB

ROOM TEMPERATURE SENSOR AIR INLET

ILL

Slide 55.02A-47b

The sensor wiring diagram is shown above.

20

25

30

15

10

5

0176 212

RES

ISTA

NC

E (k

Ω)

68 10414 32TEMPERATURE ºF

140



Electric Coolant Pump

12V Wiring Harness

A 12V electric pump, controlled by the A/C-ECU, circulates the coolant from the PTC heater to the heater core and back to the heater.

Because coolant lubricates the pump, never run it if the system is empty. Running it dry, even for a few seconds, can damage the pump.

Slide 55.02A-48a

GROUNDINGCONNECTOR

FOOT AREA/TRACTION BATTERY AIR OUTLETDAMPER

A/C RELAY

HEATER WATER PUMP RELAY

HEATER WATER PUMP ASSEMBLY

FUSIBLE LINK 2

RELAY BOX

ACCONTROL UNIT

J/B

Slide 55.02A-48b

The coolant pump wiring diagram is shown above.

Note

Instructor Note:• Pass around the heater.



55.02A

Positive Temperature Coefficient (PTC) Air Heater

(Miarge)

Heater Core

PTCHeater

Slide 55.02A-49b

Unlike i-MiEV, this heater warms the air passing through the fins of the cold heater core, not the coolant flowing though the system.

The heater operates under the following conditions.• Engine: running• Blower fan: ON• Temperature setting: any except MAX cool• Outside temperature: 59º F or lower• Engine coolant temperature: 167º F or lower• Generator output is 70% or less

Slide 55.02A-49a

The 2014 Mirage uses a Denso 840 watt PTC heater to warm the passenger compartment while the engine is reaching operating temperature.



PTC HEATER CONTROL UNIT

FUSIBLE LINK 7

PTC HEATER RELAY 3

SUB RELAY BOX

PTC HEATER RELAY 2

PTC HEATER RELAY 1

PTC HEATER

JOINT CONNECTOR

The wiring diagram above shows the heating elements controlled by the individual PTC relays located in the engine compartment Sub Relay Box.

Note PTC Heater Relay #2 controls two heating elements while PTC Heater Relay #1 and PTC Heater Relay #3 each control a single element.

Slide 55.02A-50a



55.02A

Depending upon the heater control knob position (signal from A/C-ECU), outside temperature (signal from Combination Meter), coolant temperature and generator output (signals from ECM), the PTC Heater Control Unit can energize up to three relays to control the four heater elements.

Slide 55.02A-51a

ETACSCOMBINATION METER

CPU

CAN TRANSCEIVER CIRCUIT

DATA LINK CONNECTOR

INPUT SIGNAL• ENGINE COOLANT TEMPERATURE SENSOR

• GENERATOR OUTPUT

A/C-ECU

TONE ALARM

JOINT CONNECTOR (CAN1)

JOINT CONNECTOR (CAN2)

(FUSE )12

JUNCTION BLOCK

INTERFACE CIRCUIT

AMBIENT TEMPERATURE SENSOR

FUSIBLE LINK 6

(FUSE )16

A/C COMP RELAY

A/C CLUTCH

RELAY BOX

ENGINE CONTROL MODULE

A/C PRESSURE SENSOR FIN THERMO SENSOR

JOINT CONNECTOR (3)

JUNCTION BLOCK

AC/PGround

AC/TGround

5V

Ground

INPUT SIGNAL• TEMPERATURE DIAL POSITION

INPUT SIGNAL• OUTSIDE TEMPERATURE



Heated Seats

Slide 55.02A-52a

Seat HeaterElements

Electrically heated driver and front passenger seats are available for most Mitsubishi vehicles. As shown above, one heating element is located in the seat cushion, the other in the seat back.

Slide 55.02A-52b

The heaters for each seat are controlled with one 3-position switch to manage the feed and ground circuits.

When switched to HI position, thermostats control the seat temperature between 86º F and 104º F.

Instructor Note:Trace the circuits on screen with colored markers.



55.02A

12V FROMHEATED SEAT RELAY

Activity

On these worksheets, trace the feed and ground circuits for HI and LO heater operation of the Left Seat. (Heated Seat Relay is ON providing 12 volts.)

HI Heat Switch Position



12V FROMHEATED SEAT RELAY

LO Heat Switch Position



55.02A

Currently three compressor designs are used.• Scroll compressor• Swash Plate compressor• Two-Vane compressor

With a dedicated relay, the ECM controls an electromagnetic clutch to engage or disengage the compressor shaft from the belt driven pulley.

Refrigerant Temperature Switch disengages the compressor clutch when system temperatures grow excessively high.

A/C Pressure Sensor detects variances in high-side pressure by measuring the deflection of a two piece ceramic diaphragm. These changes in pressure are converted to analog voltage signals within the sensor and sent to the A/C controller.

Pressure Relief Valve prevents damage to the compressor or other components in the event of a high-side restriction or other condition causing excessive high-side pressure.

Fin Temperature Sensor is a thermistor used to measure the temperature of air flowing from the evaporator.

Ambient Air Temperature Sensor is a thermistor mounted at the front of the vehicle typically under the bumper.

Aspirator draws inside air past the Interior Temperature Sensor to signal the A/C-ECU of passenger compartment temperature.

Photo (Sunload) Sensor is located on the top of the dash panel. With bright sunlight, the A/C controller increases blower motor speed to maintain cool air circulation. Conversely, if the sunload is low (cloud cover), the controller reduces blower speed.

In a Parallel-Flow Condenser refrigerant travels through numerous passages providing a large surface area for ambient air to contact the superheated refrigerant gas and change its state to liquid refrigerant.

CLIMATE CONTROL COMPONENTS SUMMARY



Ram air is forced through the condenser and radiator by vehicle movement and speed. At low vehicle speeds or periods when the vehicle is stationary, electric fans pull air through the condenser and radiator. Depending upon the vehicle and model year, these fans are controlled by relays energized by either ETACS, Fan Control Module, or PCM.

Plate & Fin Evaporator provides multiple paths for refrigerant flow creating a large surface area to absorb passenger compartment heat.

Thermostatic Expansion Valve (TXV) meters the flow of refrigerant to the evaporator based on evaporator pressure and temperature.

Refrigerant Lines & Hoses are used to connect the A/C components together.

Charge Ports enable the A/C system to be serviced and tested while under pressure. Different size ports identify the high and low sides of the A/C system. A plastic cap with a rubber seal is used to close the charge port opening and avoid leaking.

“O” ring compound used with Mitsubishi A/C system joints, fittings, and components is a hydrogenated nitrile butadiene rubber and identified by the color green.

Mitsubishi vehicles use HFC-134a (CF3CFH2) because its temperature and pressure relationship at low pressures is close to the previously used R-12 and does not deplete the ozone layer. Its chemical name is Tetra Fluoroethane and commonly known as R134a.

Currently, Mitsubishi vehicles with gasoline engines and equipped with scroll compressors use PAG-56 oil. Raiders equipped with a Denso swash plate compressor uses ND-8. Mirage vehicles equipped with a Valeo vane compressor use ZXL200PG oil. The i-MiEV requires MA68EV refrigerant oil.



55.02A

Coolant from the engine circulates through the heater core where heat is conducted by the coils and fins to the air flowing into the cabin.

A Positive Temperature Coefficient (PTC) heater is used to warm the coolant flowing to the i-MiEV’s heater core. The heater is located under the vehicle and powered by the high voltage Traction Battery. Its maximum output is approximately 5.0 kW and heats coolant up to 176º F. A 12V electric pump, controlled by the A/C-ECU, circulates the coolant from the PTC heater to the heater core.

The 2014 Mirage uses a PTC heater to warm the passenger compartment while the gasoline engine is reaching operating temperature. Unlike i-MiEV, this heater warms the air passing through the plates and fins of the cold heater core, not the coolant flowing though the system.

Electrically heated front seats are available for most Mitsubishi vehicles. One heating element is located in the seat cushion, the other in the seat back. A 3-position switch controls the heating elements.

Page 8

Page 11

Page 31

Page 20



KNOWLEDGE CHECK Answer the following questions to review the material in this section. If you don’t know an answer, look it up. If you answer a question incorrectly, read the material covering the topic again until you fully understand the information.

1. Which design uses reed plates to control refrigerant flow entering and exiting the compressor? a. Rotary Vane b. Swash Plate c. Scroll d. Rotary Piston

2. What device changes DC voltage from the i-MiEV traction battery to AC voltage used by the air conditioning compressor? a. Battery Management Unit (BMU) b. A/C-ECU c. Inverter d. A/C Control Panel

3. In a swash plate compressor, one complete revolution of the swash plate drives the pistons from one end of their travel to the other and back to their starting points. a. TRUE b. FALSE

4. Which is NOT a function of the Thermostatic Expansion Valve (TXV)? a. Throttling b. Modulation c. Controlling d. Cycling

5. The Fin Temperature Sensor measures ______. a. Air temperature flowing through condenser b. Air temperature flowing through evaporator c. Refrigerant temperature flowing through Rotary Vane Compressor d. None of these answers is correct.

and 22

Page 25

Page 25

Page 33

Page 39

Page 43



55.02A

6. The Ambient Temperature Sensor used with Galant is wired directly to which ECU? a. A/C-ECU b. Forward Control Module c. ETACS d. A/C Control Panel

7. What A/C component is responsible for transferring passenger compartment heat to the outside atmosphere? a. Evaporator b. Compressor c. TXV d. Condenser

8. Based on the radiated heat of sunlight, what is the purpose of the Photo (Sunload) Sensor? a. Signals A/C-ECU to move the Mix Damper b. Signals ETACS to cycle the compressor OFF c. Signals A/C-ECU to change blower speed d. Signals FCM to move Outside/Inside damper

9. What is the purpose of the TXV Pressure Compensation Tube? a. Senses pressure at the evaporator inlet b. Senses pressure at the evaporator outlet c. Senses pressure above the TXV diaphragm d. Senses pressure from the capillary tube

10. To insulate the compressor case and lines from high voltage, what refrigerant oil is used with i-MiEV? a. PAG-56 b. PAG-46 c. MA68EV d. ZXL200PG

11. What is used to heat the i-MiEV passenger compartment? a. PTC air heater and heater core b. PTC coolant heater and heater core c. PTC coolant heater only d. None of these answers is correct.

Page 49

Page 49

Page 53 and 54



12. The i-MiEV’s Heater Coolant Temperature Sensor provides information to which ECU? a. A/C Control Panel b. ETACS c. Combination Meter d. A/C-ECU

13. Which of the following conditions is INCORRECT for operation of the Mirage PTC heater? a. Engine running b. Outside temperature greater than 59º F c. 70% generator output d. Engine coolant less than 167º F

14. In operation, what is the maximum power consumption of the Mirage PTC heater? a. 750 watts b. 800 watts c. 840 watts d. 900 watts

15. A heated seat switch can control either the feed or ground circuit depending upon its position. a. TRUE b. FALSE

55.03A


Electronic Control Systems

Section DescriptionThis section describes the Manual and Automatic systems used to manage passenger compartment temperatures. i-MiEV Traction Battery temperature control is also described in this section.

Theory Section

55.03A

55.03A









Note

Caution

!




55.03A



Table of Contents Section Introduction Section Goal ………………………………………………………………...…… 3 Section Objectives ………………………………………………………………. 3 Needed Materials ……………………………………………………………….. 3 Time to Complete ……………………………………………………………….. 3 A/C-ECU (Heater Control Unit) Functions ..……….………………….……………… 4 Manual System Control Panel Functions ……………………………………………. 7 Automatic System Control Panel Functions …………………..……………………... 9 i-MiEV Automatic Climate Control System Control Panel ……………………….…………………………………….……… 11 A/C-ECU Location ……………………………………………………….……… 12 Remote Climate Control Description …………………………………..……… 15 Remote Climate Control Operation …………………………………….……… 16 Traction Battery Temperature Control…………….…………………………… 17 Mirage Digital Control Panel ………………..…………………………………….……. 19 Outlander Dual Zone Digital Control Panel ………………………………………...… 19 Electronic Control Systems Summary …….…..……………………………………… 21 Knowledge Review Questions ………………………………………………………… 22



55.03A

SECTION GOAL


• Identify Manual control system components and describe their operation.

• Identify Automatic control system components and describe their operation.

• Identify the similarities and differences between the two systems.

• Identify the i-MiEV Traction Battery temperature control components and describe their operations.

• Describe the operation of the Dual Zone climate control system.

NEEDED MATERIALS

TIME TO COMPLETE

Section 55.03A only

About 1 hour

Slide 55.03A-3a

Slide 55.03A-3b

Describe the Manual and Automatic control systems used to manage passenger compartment temperatures. i-MiEV Traction Battery temperature control will also be described in this section.


Electronic Control Systems55.03A

Component MAX A/C MAX HeatAir Mix Damper Maximum Cool Maximum HeatMode Damper Panel Vents Floor OutletsOutside/Inside Damper Closed to Fresh Air Open to Fresh AirBlower Speed Maximum Maximum

Based on inputs to the control panel, the A/C-ECU (also called Heater Control Unit) manages functions either directly or together with other ECUs via CAN.(See pages 5 and 6 for network diagrams.)

• Air Mix Damper Position• Outside/inside Damper Position• Blower Speed Control• A/C Compressor ON/OFF Control• Mode Damper Position• Defroster Operation: In defrost, the ECM engages the compressor and the A/C-ECU opens the Outside/Inside damper to fresh air.• Engine Speed Increase (Idle-Up): When defrost or A/C is selected, the ECM increases engine idle speed.• Rear Window Defogger Timer Control: Rear defogger is shut OFF after 20 minutes of operation.• MAX A/C or MAX Heat Control: When the temperature is set to MAX A/C (61ºF) or MAX Heat (89ºF) with Mode and Blower Speed dials set to AUTO, the system operates as follows.

Slide 55.03A-4a

A/C-ECU(Heater Control Unit)

SYSTEM CONTROL DEVICES

• Air Bag Deployment: Climate control system is shut off when air bags are deployed.



55.03AETACS

CAN DRIVE CIRCUIT

CAN DRIVE CIRCUIT

INTERFACE CIRCUIT

COMBINATION METER

CPU

TONE ALARM

J/C(1)(FUSE )18

A/C-ECU

COMBINATION METER (ILL+)

COMBINATION METER (PWM)

HEATED SEAT SWITCH

HEATED SEAT SWITCH

J/C(CAN5)

• Refrigerant Leak Detection: A/C-ECU uses the ambient temperature sensor and the A/C pressure sensor to determine refrigerant charge. When refrigerant charge or pressure falls outside acceptable ranges, the ECM disengages the compressor to protect the system. The A/C-ECU flashes the A/C indicator light to alert the driver.

• Customizable Functions: • Automatic control of Outside/Inside damper can be overridden by holding the Outside/ Inside/ button depressed for 10 seconds. • Automatic A/C can be overridden by holding the A/C switch depressed for 10 seconds.Repeat either procedure to return the system to automatic functionality.

On certain vehicles, further customization can be accomplished using MUT-III. Refer to Group 55 for the vehilce being serviced for procedures.

Slide 55.03A-5a



A/CCOMPRESSORRELAY

J/C(CAN2)

·CRANKSHAFT POSITION SENSOR

·ENGINE COOLANT TEMPERATURE SENSOR

INPUT SIGNAL ECM

CAN DRIVE CIRCUIT

INTERFACE CIRCUIT

J/C(CAN1)

ASC-ECU

WHEEL SPEED SENSORS

INPUT SIGNAL

J/C(CAN3)

SRS-ECU

IMPACT SENSOR

INPUT SIGNAL(FUSE )11

ETACS-ECU

DATA LINKCONNECTOR

AMBIENT TEMPERATURESENSOR

INPUT SIGNAL

ETACS

Slide 55.03A-6a

Outside/Inside Damper Control Motor

Air mix Damper Control Motor *

Mode Damper Control Motor

Blower Motor

Power Transistor(Blower Speed Control)

IG (12V)+B (12V)

A/C Pressure Sensor

Interior Temperature Sensor

Fin Temperature Sensor

A/C-ECU

ETACS

· Ambient Temperature Sensor· Engine Coolant Temperature Sensor· A/C output· Rear Defogger· Ignition Status

CVT

ABS

DLC

Audio

Display

Combination Meter Engine Control Module

CAN-CMid Speed

CAN-CHi Speed

Network Communication* Vehicles with Dual Zone, two Air Mix dampers are used. On vehicles with Single Zone, only one damper is used.

2014 Outlander

Slide 55.03A-6b

Instructor Note: Play Manual Climate Control.avi

Instructor Note: TSB-10-55-007 states replacement air recirculation and/or rear defogger buttons [manual control panels only] are available separately for the following vehicles.

2006 - 2011 Endeavor2006 - 2011 Eclipse2007 - 2011 Eclipse Spyder



55.03A

Mitsubishi vehicles can be equipped with either a Manual or Automatic climate control system.

Manual System Control Panel

This system allows complete manual control over temperature, blower speed, air source and distribution, as well as compressor operation.

Slide 55.03A-7a

Momentary contact switches [A] located under each dial control Outside/Inside Damper position, Compressor ON/OFF, and Rear Defogger ON/OFF. The three dials control individual potentiometers [B] which manage Air Mix Damper position, Blower Speed, and Mode Damper position. Lights [C] indicate status of Outside/Inside Damper (open or closed), Compressor (ON or OFF), and Rear Defogger (ON or OFF).

Slide 55.03A-7b

C C C

A

B

A

B

A

B



(FUSE )8ETACS-ECU

(FUSE )12ETACS-ECU

POWERSUPPLY

A/CSWITCH

OUTSIDE/INSIDEAIR SELECTIONSWITCH

MODESELECTION DIAL

BLOWER SPEEDSELECTION DIAL

TEMPERATURECONTROL DIAL

INTERFACECIRCUIT

INTERFACECIRCUIT

RHEOSTATTONE ALARM

CPU

INTERFACE CIRCUIT

CPU

INTERFACE CIRCUIT

COMBINATIONMETER

A/CSWITCHINDICATOR

OUTSIDE/INSIDEAIR SELECTIONINDICATOR

POWERSUPPLY

(FUSE )9

INTERFACECIRCUIT

INTERFACECIRCUIT

REARDEFFOGER

INTERFACE CIRCUIT

JOINT CONNECTOR (3)

NO CONNECTION ·AUDIO SYSTEM

·HANDS-FREE CELLULAR PHONE SYSTEM·TURN-SIGNAL LIGHT AND HAZARD WARNING LIGHT

A/C CONTROL PANEL

Slide 55.03A-8a

The potentiometers and switches are shown on the wiring diagram above. (Rear Defogger circuit is not shown except for the indicator light.)

Flashing

Slide 55.03A-8b

The A/C compressor indicator light flashes to alert the driver of a malfunction. Instances where the light may be flashing are listed below.• Ambient Temperature Sensor out of range• Intermittent Compressor Clutch Operation• Evaporator Core Freezing

See Tech Talk Volume 173, July 2010 for details.

Instructor Note: Play Automatic Climate Control.avi



55.03A

Automatic System Control Panel

Slide 55.03A-9a

The functions of automatic and manual control panels are similar. By adding the Interior Temperature Sensor and additional logic, this system can be set to automatically maintain a comfortable temperature for the passenger compartment. This includes automatic selection of air source, blower speed, and mode.

If the blower speed dial is set to AUTO, the system regulates fan speed automatically depending upon the temperature dial setting. If not set in the AUTO position, the Mode Selection Dial can also be used to manually select specific airflow outlets.

If the mode selection dial is set to AUTO, the system directs airflow to the proper outlets depending upon the temperature dial setting. If not set in the AUTO position, the blower speed dial can be used to manually select blower speed.

If both blower speed and mode selection dials are set to AUTO, air flow direction, recirculation door position, blower speed, and air conditioning ON and OFF is controlled automatically.




Outside/Inside Rear Defogger

Slide 55.03A-10a

ETACS-ECU

JOINTCONNECTOR

MULTI-CENTER DISPLAY UNIT

POWERTRAIN CONTROL MODULE

TCL/ASC-ECU14

18

13

17

1

DATA LINKCONNECTOR

AMBIENTTEMPERATURESENSOR

A/C-ECU

COLUMN-ECU

LIGHTING SWITCH

COLUMNSWITCH

FRONT ECUJUNCTION BLOCK

FUSE RELAY BOX

FUSE

(G-R)

If equipped with Mitsubishi Multi Communication System (MMCS), climate control settings made on the Control Panel can be viewed on screen. This applies to both Manual and Automatic Systems on GS, PS, and ZC platform vehicles.

Slide 55.03A-10b

Climate Control and MMCS



55.03A

i-MiEV Control Panel

Slide 55.03A-11a

Only the functions of i-MiEV’s Temperature Selection Dial are different from other automatic systems.

• Numerals are not printed on the dial as with other automatic systems.

• Maximum heating or cooling, along with high blower speed, occurs when MAX switch is pressed. Operating variations are shown below.


MAX Heat or Cool LED

Temperature Selection Dial

Blower Speed Dial

Mode Selection Dial

A/C Compressor LED

Outside/Inside Damper LED

Slide 55.03A-11b

1 2 3 4 5

Dial Position Heater Compressor Blower Indicator Recirculation1 MAX OFF HIGH ON NO2 MAX OFF HIGH ON NO3 OFF OFF HIGH ON NO4 OFF MAX HIGH ON NO5 OFF MAX HIGH ON YES



If either the Temperature Selection or Blower Speed dial is rotated, the MAX function is overridden and functions return to the mode before pressing the MAX switch.

Using MAX cool or MAX heat consumes greater amounts of power from the Traction Battery and can significantly reduce the i-MiEV’s cruising range.

Note

Slide 55.03A-12a

The i-MiEV’s A/C-ECU is located under the rear seat next to the Battery Management Unit (BMU) and Electric Vehicle-ECU (EV-ECU).

A/C-ECU

BMU

EV-ECU

i-MiEV A/C-ECU Location



55.03A

Item No. Item The display contents under normal conditions15 Illumination Illumination status

19 Ambient temperature sensor 20 Air thermo sensor Temperature behind the evaporator21 Interior temperature sensor 23 Temperature dial position 24 Engine coolant TEMP. sensor 28 Air conditioning switch A/C switch status45 In/out select damper SW (input) Inside/Outside air selection switch status.

Inside/Outside air selection switch status. 46 In/out select damper SW (output) 55 Air outlet c/o potentiometer Air outlet changeover damper motor status. 56 Air outlet c/o potentiometer (Target) Air outlet changeover damper motor target value. 60 MAX switch input MAX switch status.68 Front blower fan69 Front blower fan (Target) Blower motor target value.72 MAX switch output MAX switch status.

MUT-III Data Reference Table for AIR CONDITIONER

Ambient temperature

Interior temperatureSet temperatureCoolant temperature

Blower motor status



MUT-III Data Reference Table for COMP&HEAT

Item No. Item The display contents under normal conditions. 1 Compressor speed Compressor actual speed.

2 Compressor drive history flag Compressor drive history status.3 Climate power save active flag Air conditioning power save request status.4 Cooling fan request (Climate) Cooling fan drive request status.

5 Compressor inverter input power Compressor inverter input power.6 Refrigerant pressure sensor Refrigerant pressure.7 ELC.water heater test status Electric water heater test result.8 Electric water pump output Heater water pump drive status.9 ELC.water heater power Electric water heater output power calculated value. 10 ELC.water heater inlet sensor Electric water heater inlet water temperature. 11 ELC.water heater outlet sensor Electric water heater outlet temperature.12 Battery cooling request flag Battery cooling control request status.

13 Battery cooling control mode Battery cooling control mode status.

16 In/out select damper Inside/Outside air selection damper actual position.

17 MAX SW control status MAX switch control status.18 A/C switch status A/C switch status.19 In/out select damper SW status Inside/Outside air selection switch status.

20 MAX switch status MAX switch status.21 Temperature dial position Temperature adjustment dial set position. 22 Air outlet c/o potentiometer Air outlet mode motor actual output.23 Blower fan output Blower motor actual output.24 Interior temperature sensor Interior temperature.25 Ambient TEMP. sensor (Meter) Ambient temperature (for meter).26 Ambient TEMP. sensor (CAN) Ambient temperature (for CAN output) 27 Air thermo sensor Fin thermo sensor temperature.28 Water TEMP sensor (HVAC) Heater core inlet water temperature. 29 Frost protection active flag Frost protection control status.30 Air purge mode active flag Air purge mode control active status.

31 Battery cooling active flag Traction battery cooling control active status.

33 ELC. water heater spec. judg. Specifications (5 kW) of electric water heater installed.

34 Battery heating request flag Traction battery heating control request status.

35 Battery heating active flag Traction battery heating control active status.

Instructor Note: A/C OFF means shutting climate control functions OFF.

Instructor Note: Either the time for full charge increases or state of charge decreases (if OFF timer

Instructor Note: Remote Climate Control does not function when connected to Quick Charging equipment.



55.03A

i-MiEV Remote Climate Control Description

Slide 55.03A-15a

A wireless remote system is standard with i-MiEV allowing the driver to set the charge timer, activate interior heating and cooling, activate the defroster, and view the Traction Battery state of charge.

In this course, only the Remote Climate Control functions are detailed. For a complete description of the Remote System, attend the MEVTT course or consult 2012 i-MiEV Technical Information Manual.

Selectable climate control modes are COOL, HEAT, ......, or A/C OFF. In ....., the rear defogger is also activated. If switched ON in advance, seat heaters are activated when HEAT is selected on remote.

Remote climate control operates only when the vehicle is charging on either Level 1 (120V) or Level 2 (240V) equipment and shuts off after 30 minutes. The remote’s range is approximately 328 feet from the vehicle.

The system operates regardless of control panel dial or switch positions. While in operation, dials and switches have no effect on compressor, heater, or defroster/defogger.

Because the compressor and heater consume voltage from the Traction Battery in operation, battery charging will be effected when these components are operating.

Power/Communication SwitchLong Press: ON/OFFShort Press: Send data or request latest Traction Battery level

Mode SwitchPush to select mode.ON Timer/OFF Timer/Remote Climate Control

Manual Charging SwitchPush to start regular charging(Cancel the Timer function and Remote Climate Control)

UP/DOWN SwitchIncrease or decrease the set value

Antenna

Note

Instructor Note: Demonstrate remote functions using i-MiEV Remote Simulator.exe



The following conditions must be met to operate the Remote Climate Control.• Selector lever in P (PARK) position• Electric motor switch in LOCK position• EV charging cable (Level 1 or 2) connected• Traction Battery Level: one or more bars • All doors and liftgate closed

1) Begin charging the i-MiEV.2) Press the Power/Communication switch until the i-MiEV Remote turns ON. (The remote fob generates a tone in response.)3) Press Mode switch twice. A/C OFF appears.4) Using either the UP or DOWN arrow, select COOL, HEAT, or DEF.5) Quickly press the Power/Communication switch to send the command to the vehicle. (The remote generates a tone in response.)

If the Remote Climate Control has been operating less than 30 minutes, the system can be shut OFF using any one of the following methods. (If necessary, press the Power/Communication switch until the remote turns ON.)

1) Using the UP or DOWN arrow, select A/C OFF. Quickly press the Power/Communication switch to send the command to the vehicle. (The remote generates a tone in response.)2) Toggle electric motor switch to ACC or ON.3) Disconnect the charge cable from vehicle.

i-MiEV Remote Climate Control Operation



55.03A

i-MiEV Traction Battery Temperature Control

Slide 55.03A-17a

To charge the Traction Battery faster, a Quick Charger (Level 3) can be used. To verify the vehicle is equipped with this option, look for the Quick Charge port located on the driver side. (Level 1 and 2 charge port is located on the passenger side.)

Quick Charging causes higher battery temperatures than Level 1 or 2. Between 68º and 86ºF, the battery is cooled by its own internal fan which circulates air through the assembly.

If battery temperature exceeds 86ºF, the Electric Vehicle-ECU (EV-ECU) signals the Battery Management Unit (BMU) that cold air is needed to cool the battery. The BMU sends a compressor request signal to the A/C-ECU. Refrigerated air is then directed to the battery. (ECU communication is accomplished over CAN.)

Traction Battery Cooling



Also as an option, the i-MiEV is available with a battery warming system for cold weather areas.

If the battery temperature drops into the range of -13ºF to -20ºF during Level 1 or 2 charging, the EV-ECU sends a warming request to the BMU which in turn signals the A/C-ECU to activate the electric heater. Heated air is directed to the traction battery.

Temperature Blower Compressor Battery Fan Floor Damper68ºF and less OFF OFF OFF Floor68ºF to 86ºF ON OFF ON Floor86ºF and higher ON ON ON Battery

Temperature Blower Heater Battery Fan Floor DamperUnder -22ºF-13ºF to -20ºF ON ON ON BatteryAbove -4ºF OFF OFF OFF Floor

Warming system does not operate.

Floor/BatteryDamper

Air Mix Damper

Mode SelectionDamper

To direct air from the climate control system to the battery, a Floor/Battery air damper (also called Battery Cooling Flap Motor) is used as shown above.

The system has three control modes according to battery temperature during Quick Charge.

Slide 55.03A-18a

Traction Battery Warming

Slide 55.03A-18b



55.03A

Digital Control Panels

Slide 55.03A-19a

The 2014 Mirage is equipped with a digital control panel with LCD display. It uses rocker switches to control temperature and blower speed. Compressor operation (snow flake), MODE, Outside/Inside damper, defroster, AUTOmatic operation, rear defogger, and system OFF are controlled with momentary contact switches.

The control panel, A/C-ECU, and Interior Temperature Sensor are incorporated into one assembly.

Outlander

Slide 55.03A-19b

As previously discussed, the 2014 Outlander is available with either a Single or a Dual Zone climate control system depending upon option content. The Single Zone control panel is similar to Mirage. The Dual Zone control panel is shown above.

Mirage

Fan SpeedDisplay

A/C ON Symbol

Blower Symbol

DUAL ModeIndicator

Set Temperature(Passenger Side)

Mode DisplaySet Temperature (Driver Side)

Interior Temp Sensor

Instructor Note: Play Dual Zone Climate Control.avi



Air Mix Damper Control Motor (RH)

Air Mix Damper Control Motor (LH)

Slide 55.03A-18a

Using two Air Mix dampers and stepper motors, the Outlander system allows the driver and passenger side temperatures to be set independently.

Dual Zone System Operation:The word DUAL is displayed on the LCD panel when separate temperatures are selected.

If the driver’s side temperature control switch is pressed, the system switches to synchronized mode and the passenger’s side temperature will also be controlled to the same setting temperature as the driver’s side.

If the passenger’s side temperature control switch is pressed while in synchronized mode, the system will switch to dual mode. In this case, the DUAL indicator will be displayed.

In DUAL mode, the driver’s side and the passenger’s side temperature can be set separately by using each temperature control switch.

Pressing AUTO returns the system to synchronized mode and the DUAL indicator turns OFF.



55.03A

AIR MIXING DAMPER CONTROL MOTOR(FRONT PASSENGER'S SIDE)

AIR MIXING DAMPER CONTROL MOTOR

FIN THERMO SENSOR

AIR MIXING DAMPER CONTROL MOTOR (DRIVER'S SIDE)

2 2 22

22

1

21

MODE SELECTION DAMPER CONTROL MOTOR

OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

HEATER CONTROLLERASSEMBLY (A/C-ECU)

Slide 55.03A-19a

To improve fuel efficiency, some Mitsubishi vehicles are equipped with ECO Mode which effects climate control as well as other systems.

When the ECO button is pressed:• Compressor cycles OFF at a higher temperature• Less air is delivered to vents in AUTO• Longer use of recirculated air before Outside/ Inside damper is opened to fresh air• Engine idle-up is disabled

ECO Mode Control

Slide 55.03A-19b



Based on inputs to the control panel, the A/C-ECU (also called Heater Control Unit) manages functions either directly or together with other ECUs via CAN.

The manual control system allows the driver to manage temperature, blower speed, air source and distribution, as well as compressor operation. The dials control three potentiometers mounted on the circuit board. From left to right, these potentiometers manage Air Mix Damper position, Blower Speed, and Mode Damper position. Momentary contact switches located under each dial control Outside/Inside Damper position, Compressor ON/OFF, and Rear Defogger ON/OFF.

By adding the Interior Temperature Sensor and additional logic, the automatic control system can be set to automatically maintain a comfortable temperature for the passenger compartment. This includes automatic selection of air source, blower speed, and mode.

If equipped with Mitsubishi Multi Communication System (MMCS), climate control settings made on the Control Panel can be viewed on screen. This applies to both Manual and Automatic Systems on GS, PS, and ZC platform vehicles.

The i-MiEV’s automatic system is different primarily due to the Temperature Selection Dial functionality. (Other climate control functions remain the same.)

The 2014 Mirage is equipped with a digital control panel with LCD display. The control panel, A/C-ECU, and Interior Temperature Sensor are all incorporated into one assembly.

The 2014 Outlander uses a control panel similar to the Mirage for its Single and Dual Zone systems except the Interior Temperature Sensor is not built into the assembly.

ELECTRONIC CONTROL SYSTEMS SUMMARY

Page 4

Page 5

Page 7

Page 9

Page 11



55.03A


1. The rear defogger is shut off after how many minutes? a. 10 b. 15 c. 20 d. 25

2. In addition to the A/C-ECU, what other module effects engine speed when defrost is selected? a. ECM b. BMU c. ASC d. ETACS

3. What two sensors does the A/C-ECU use for detecting a refrigerant leak? a. High Pressure Relief and Fin Temperature b. Ambient Temperature and Fin Temperature c. A/C Pressure and Interior Temperature d. A/C Pressure and Ambient Temperature

4. The momentary contact switch under the Mode dial controls what function? a. Outside/Inside Damper position b. A/C Compressor ON/OFF c. Rear Window Defogger d. Front Defroster

5. What additional sensor is used with an Automatic Climate Control system? a. Ambient Temperature b. A/C Pressure c. Interior Temperature d. Fin Temperature

6. Pressing the MAX switch on the i-MiEV control panel causes high blower speed. a. TRUE b. FALSE

KNOWLEDGE CHECK

Feedback

Pages 16

Page 20

Page 20

Page 15



7. Two technicians are discussing i-MiEV Remote Climate Control operation. Technician A says a customer can select COOL on the remote while the vehicle is Quick Charging. Technician B says the maximum time COOL will operate is 60 minutes. Which technician is correct? a. Technician A b. Technician B c. Both technicians are correct. d. Neither technician is correct.

8. Disconnecting the charge cable from an i-MiEV will shut off any climate control function selected on the remote. a. TRUE b. FALSE

9. If the driver side temperature switch is pressed, the passenger side temperature is controlled to the same setting and DUAL is displayed on the control panel. (2014 Outlander) a. TRUE b. FALSE

10. What switch is pressed to return to synchronized mode? (2014 Outlander) a. OFF b. MODE c. AUTO d. None of these answers is correct.

55.04A


Climate ControlService Equipment

Section DescriptionThe goal of this module is to provide information about technician safety responsibilities associated with A/C service and handling of refrigerant R134a. Effective use of diagnostic and service equipment to identify causes of A/C system malfunctions will be also discussed.

Theory Section

55.04A

55.04A


Climate Control Service Equipment







Note

Caution

!




55.04A



Table of Contents Section Introduction Section Goal ………………………………………………………………...…… 3 Section Objectives ………………………………………………………………. 3 Needed Materials ……………………………………………………………….. 3 Time to Complete ……………………………………………………………….. 3 Personal Safety ……………………………………….………………….……………… 4 Proper Refrigerant Handling …………………..………………………………………. 5 Technician Refrigerant Recovery and Recycling Certification ……………………... 6 Diagnostic Equipment Manifold Gauge Set …………………………………………………………..… 7 High-Side and Low-Side Components (TXV) ……………………………….. 8 High-Side and Low-Side Components (FOT) …………………………...…… 9 Temperature and Humidity ……………………………………………..……… 10 Abnormal Gauge Readings …………………………………………….……… 11 Recovery, Recycling and Recharging Station …………………………….… 17 Refrigerant Identifier ……………………………………………………………. 18 Electronic Leak Detectors ……………………………………………………… 19 MUT-III …………………………………………………………………………… 20 Climate Control Service Equipment Summary …….………………………………… 21 Knowledge Review Questions ………………………………………………………… 23



55.04A

SECTION GOAL


• Describe refrigerant safety and proper handling as well as the associated technician requirements.

• Identify abnormal gauge readings and possible reasons for those readings.

• Demonstrate proper leak detection procedures.

• Demonstrate proper use of charging and recycling equipment.

NEEDED MATERIALS

TIME TO COMPLETE

Current Mitsubishi vehicles (i-MiEV excluded)GlovesVent ThermometerA/C gauge setLeak detectorRecover/Recycling/Recharging StationMUT-III

About 1.5 hours

Slide 55.04A-3a

Slide 55.04A-3b

The goal of this module is to provide information about technician safety responsibilities associated with A/C service and proper handling of refrigerant R134a. Effective use of diagnostic and service equipment to identify causes of A/C system malfunctions will be also discussed.


Climate Control Service Equipment55.04A

Slide 55.04A-4a

Safety

CAUTIONEYE PROTECTION

REQUIREDIN THIS AREA

Always remember, you have the final responsibility for personal safety–yours and those working around you. Never neglect wearing protective clothing and using safety equipment. Always use proper tools, and follow the repair procedures as outlined in service publications provided by MMNA and service equipment manufacturers.

As R134a has a very low boiling point, care must be taken when it is been handled. The following safetyprecautions must be followed.

• Always wear eye protection with side shields.• Use blue or purple Nitrile gloves to protect your hands against automotive chemicals & oils.• Never heat refrigerant containers to speed up the charging process.• Avoid breathing refrigerant. Provide adequate ventilation when recovering and charging R134a.• Never attempt to transfer refrigerant from one container to another.

REFRIGERANT



55.04A

Proper Handling

Slide 55.04A-5a

As discussed earlier, only R134a is installed in Mitsubishi vehicles produced after 1994. Mitsubishi requires R134a for any A/C system repairs.

All refrigerant cylinders are manufactured to specifications established by the Department of Transportation (DOT). The DOT has determined refrigerants as hazardous materials that may be transported. Recovered refrigerant can be reclaimed and purified in a processing or manufacturing facilities. The refrigerant cylinders that contain new refrigerant are considered DOT 39 cylinders. Cylinders cannot be refilled under DOT and OSHA regulations, but refillable cylinders (DOT-4BA or DOT-4BW) are available for the transport of recovered refrigerant. These containers must be evacuated to a minimum of 27 in-Hg. prior to filling. Containers must be labeled and must never be overfilled by weight.

If a refrigerant is found to be escaping, the leaking cylinder must be removed from the work area immediately. Since refrigerant vapor is heavier than air and displaces oxygen, always work in a well ventilated area.

R134a is not flammable at ambient temperatures and atmospheric pressure. However, this material will become combustible when mixed with air under pressure and exposed to strong ignition sources.

See R134a MSDS information for more details.

!



Technician Certification

Slide 55.04A-6a

There are two types of certification available to the automotive service technician:• Proper Use & Handling of Refrigerants• Technical Proficiency in Conducting A/C Repairs

Although it is good to posses Technical Proficiency Certification, technicians must have Proper Use and Handling Certification to legally handle refrigerants. Technicians who repair or service motor vehicle air conditioning systems must be trained and certified by an EPA-approved program in the use of refrigerant recovery equipment.

Mobile Air Conditioning Society (MACS) established guidelines for training & testing and provides certification programs. More information can be found on their web page: https://macsworldwide.wordpress.com/tag/mobile-ac-training

Automotive Service Excellence (ASE) provides a “Refrigerant Recovery and Recycling Review andQuiz”. More information is available on ASE’s Refrigerant Recovery Program web page: http://www.ase.com/Tests/cfc.aspx



55.04A

DIAGNOSTIC EQUIPMENTManifold Gauge Set

Slide 55.04A-7a

A manifold gauge set is used for diagnosis to monitor high-side and low-side pressures in the refrigeration system.

Slide 55.04A-7b

Gauges are combined with a recovery and recycling station which recovers, recycles, evacuates, leak tests, and recharges R134Aa accurately by weight.

Refrigerant Recovery Station



The high side consists of the compressor outlet, condenser, receiver-drier, and TXV inlet. Depending upon ambient temperature and humidity, normal high side pressures range from 185 to 380 psi.

High Pressure Vapor


Slide 55.04A-8a

High Side Components(Thermal Expansion Valve System)

Low Pressure Vapor

Low Pressure Liquid

Slide 55.04A-8b

The TXV outlet, evaporator, and compressor inlet comprise the low pressure side. Normal low side pressures can range from about 25 psi to 93 psi.

Low Side Components(Thermal Expansion Valve System)



55.04A

Slide 55.04A-9b

Low Side Components(Fixed Orifice Tube System)

Low Pressure Vapor

Low Pressure Liquid

High Pressure Vapor


Slide 55.04A-9a

The compressor outlet, condenser, and fixed orifice tube inlet comprise the high pressure side. Normal high side pressures range from 150 to 400 psi.

High Side Components(Fixed Orifice Tube System)

Low side components include the fixed orifice tube outlet side, evaporator, accumulator, and compressor inlet. Pressures range from 20 - 65 psi.



The pressure ranges listed on the last few pages represent examples of normally operating TXV and FOT systems found on Mitsubishi vehicles. Generally high side pressure should be 2.2 to 2.5 times ambient temperature.

Technicians should always consult the Mitsubishi Service Manual, Group 55, for the appropriate pressures specific to the vehicle being serviced. An accurate diagnosis and determination of air conditioning system function and more importantly, malfunction, depend largely upon the ability of the technician to interpret pressure gauge readings.

Note

0 % RH

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0 °F

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Effects of Temperature and Humidity

Ambient temperature plays an important role in heat transfer. The higher the ambient temperature, the less heat the atmosphere will accept from the condenser, making the condenser less efficient at transferring heat. This keeps the temperature of the condenser higher, resulting in higher pressure.

Relative humidity also effects heat transfer. The higher the humidity (over 50%), the harder it is for the evaporator to remove passenger compartment moisture.

However, since air does not conduct heat well, the added moisture from high humidity aids heat transfer from the condenser to the atmosphere.

With relative humidity under 50%, it is easier for the evaporator to remove passenger compartment moisture, but the harder it is to transfer heat from the condenser to the atmosphere.

Slide 55.04A-10a



55.04A

ABNORMAL GAUGE READINGSLow Low-SideLow High-Side

0

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psi0

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150

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12 psi 90 psi

When both high and low pressure gauges show lower than normal readings, a low refrigerant charge is likely the cause. (This would be confirmed with low equalized gauge readings when the A/C system is OFF.) Although the system will show a pressure differential between the high and low sides, there is insufficient refrigerant in the system and heat cannot be exchanged effectively. Therefore both sides will demonstrate lower than normal readings.

Low refrigerant charge is a symptom and probably not the real problem. A refrigerant leak is most likely the cause of the low gauges readings. However, some refrigerant must exist in the system or the A/C Pressure Sensor would not have signaled the A/C-ECU to engage the compressor clutch.

Refrigerant leaks can be isolated using a visual inspection and an electronic leak detector. Once the source of the leak is discovered, follow these steps to complete the repair.

• Repair the leak. • Evacuate the system - hold vacuum a minimum of 30 minutes to remove all system moisture. • Recharge with the specified quantity of refrigerant and oil.

Slide 55.04A-11a



Normal Low-SideLow High-Side

If the Low-Side pressure is normal and the High-Side pressure is low, check for a restriction on the High-Side of the system, anywhere between the compressor discharge to the outlet of the Receiver-Drier, but before the High-Side gauge fitting.

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Slide 55.04A-12a

Cool(Should be Cold)

VERY HOT(Should be Hot)

Cool to Warm(Should be Hot)

Cool to Warm(Should be Hot)

Restriction

Slide 55.04A-12b

A restriction on the High-Side will usually result in a normally warm component being very hot before the restriction and abnormally cool (or frost formation) after the restriction.

Once again, the actual source of the restriction must be determined if it is particulate matter and follow these same procedures after repairing it

• Replace the Receiver-Drier or Accumulator • Evacuate the system - hold vacuum a minimum of 30 minutes to remove all system moisture. • Recharge with refrigerant and oil (specified for each replaced component).



55.04A

In this example, pressures are equalizing with the system running. Causes could be one of the following components.• Defective compressor• Compressor clutch slipping • Failed Refrigerant Temperature Switch • Failed A/C Pressure Sensor

When the compressor clutch is definitely engaged and the Low-Side is high and the High-Side is low, the compressor is likely failing internally and unable to pump sufficiently. Rarely an A/C clutch could be slipping but this condition is usually accompanied with belt squeal or chirp. Verify the clutch plate clearance is set to specification. Using the scan tool, verify the Refrigerant Temperature Switch and A/C Pressure Sensor operate properly.

• If diagnosis leads to it, replace the compressor. • If the compressor is replaced, replace the Receiver-Drier or Accumulator • Evacuate the System - hold vacuum a minimum of 30 minutes to remove all system moisture. • Recharge with refrigerant and oil (specified for each replaced component).

0

psi

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psi0

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70 psi 70 psi

High Low-SideLow High-Side

Slide 55.04A-13a



Very Low Low-SideNormal to Low High-Side

These gauge readings usually indicate a defective TXV, FOT, or moisture contamination.

An excessive restriction at the TXV will cause the compressor to pump most of the refrigerant into the High-Side creating a very low Low-Side pressure. A technician might think all of the refrigerant being pumped to the High-Side would cause extremely high High-Side pressure. However, since the condenser can still transfer heat, the refrigerant charge will loose a significant amount of heat (perhaps more than normal, depending on outside temperature), lowering the actual pressure so that it appears normal or only slightly low.

• A restricted FOT will show similar gauge readings to a failed TXV. When the compressor engages, the suction against the restricted orifice tube causes the compressor to cycle OFF quickly. After compressor disengagement, the rise in suction side pressure is usually very slow. Rapid compressor disengagement and slow engagement is a good indication of a clogged orifice tube. A clogged orifice tube will also starve a compressor of oil.

Consider the following areas during diagnosis.• TXV sensing bulb/capillary tube has lost its refrigerant and can’t react to evaporator temperatures. (Capillary Tube TXV only.)

• Debris is caught in the TXV or FOT from a failing compressor, rust particles, or rubber hose breakdown. If debris from a failed compressor has reached the TXV or FOT, there are probably some fragments left in the condenser as well.

• Excessive moisture in the system saturates the receiver-drier desiccant and renders it ineffective. Excess moisture moves throughout the system, carried by the refrigerant, and freezes when it reaches the pressure and temperature drop at the TXV or FOT.

To check for moisture contamination, turn the A/C system OFF for a few minutes and then turn it back ON.

0

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0-5 psi 140 psiSlide 55.04A-14a



55.04A

If the Low-Side pressure drops gradually and stays low, the problem is most likely moisture contamination. If it drops very quickly, remove the TXV or FOT and inspect for debris, using a magnet to differentiate between steel and aluminum particles. After finding and replacing the source of the contamination, follow these steps.

• Replace the Receiver-Drier since the filter is littered with particulate matter and/or the desiccant is contaminated. • Evacuate the System - hold the vacuum a minimum of 30 minutes to remove all system moisture. • Recharge with the specified quantity of refrigerant and oil.



High Low-SideHigh High-Side

A condition where the Low-Side pressure is high and the High-Side pressure is high to extremely high is probably caused by little heat exchange from the condenser to the atmosphere, which could be caused by any of the following conditions.• Lack of condenser airflow• Refrigerant or oil overcharge• Air in the system• Contaminated refrigerant

Lack of airflow across the condenser would prevent heat exchange. Look for damaged or clogged fins or a malfunctioning fan. Similarly, an overheating engine would raise the radiator and engine compartment temperatures impeding heat transfer from the condenser.

If the condenser is clear, the condenser fan operational and normal engine temperatures exists, suspect an overcharged system. Turn the system off and wait for the pressures to equalize. If the system is overcharged, higher-than-normal pressures on both sides of the system will be seen.

Excessive refrigerant in the system results from improper recharging or attempting to charge the system from gauge readings. Mitsubishi recommends charging by weight, not pressure readings.

Failure to properly evacuate a system prior to recharging is the most common cause of air in the system, but remember air could also be drawn into the system through a leaking Low-Side seal. Leaking seals can be isolated using an electronic leak detector. • Evacuate the system - hold the vacuum a minimum of 30 minutes to remove all system moisture. • Recharge with the specified quantity of refrigerant and oil.

0

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Slide 55.04A-16a



55.04A

Recovery, Recycling, and Recharging Station

Slide 55.04A-17a

Mitsubishi recommends using a recovery machine capable of performing the following functions.

• Recover refrigerant from the vehicle.* Evacuate the system of all moisture.• Test the system for leaks.• Replenish any oil removed during recovery.• Charge the system with refrigerant by weight.

As discussed previously, A/C systems using an electric compressor use POE refrigerant oil. Recovery machines must be capable of replenishing any oil removed during the recovery process with oil specified for the application. When adding oil, dedicated tools must be used to prevent contamination. This ensures electrically conductive PAG oil is never used in systems requiring the electrically insulating properties of POE.

!



Use the machine to recover the existing refrigerant and make any repairs needed. Once a system has been opened to repair a leak or replace a component, the system must be evacuated.

Evacuating the system will remove air and moisture, but not debris. If the system is contaminated, effected parts must be replaced along with the receiver-drier prior to evacuation. A minimum of 25 minutes is required to pull the system down to a vacuum of about 30 in-Hg. at sea level.

Set the machine to evacuate for 30 minutes or more. Once the machine has shut off, wait for 5 minutes. If the pressure rises, a leak is indicated. Find and repair the leak, then perform the procedure again.

If the system continues to hold a vacuum after 5 minutes, close the inlet valve and check the oil recovery bottle on the recycling machine. Determine the proper oil and add it during recharge. Remember, never mix refrigerant oils !

Recharge the system. After charging the system, turn the engine off and turn off and disconnect the recovery station.

To prevent service equipment contamination from unauthorized refrigerants, a refrigerant identifier, such as the Sentinel® by Robinair quickly identifies the purity and type of refrigerant in an A/C system.

Refrigerant Identification

Slide 55.04A-18a



55.04ASince refrigerant is heavier than air, place the leak detector probe below the refrigerant lines, fittings and components to be tested. The detector will sound when a leak is detected. Move the probe slowly along the hoses and components being careful not to touch the lines or fittings (this can set off the alarm due to low flow through the sensor).

Slide 55.04A-19b

Electronic Leak Detectors

Mitsubishi recommends the use of electronic leak detectors to isolate the source of refrigerant system leaks. Although fluorescent dyes are available for A/C system leak detection, Mitsubishi does not recommend using them. When using an electronic leak detector, set the sensitivity by following the tool manufacturer’s procedures.

Slide 55.04A-19a



MUT-III Scan Tool

Slide 55.04A-20a

As described in previous sections, current Mitsubishi vehicles include many electronic devices to manage both Manual and Automatic climate control systems. Using the scan tool, technicians can perform the following diagnosis.

• Gather Diagnostic Trouble Codes (DTCs)• Monitor Data List items• Review any available Freeze Frame Data• Operate system actuators



55.04A

You have the final responsibility for personal safety–yours and those working around you. Always use proper tools, and follow the repair procedures as outlined in service publications provided by MMNA and service equipment manufacturers. The following safety precautions must be followed.• Always wear eye protection with side shields.• Use blue or purple Nitrile gloves to protect your hands against automotive chemicals & oils.• Never heat refrigerant containers to speed up the charging process.• Avoid breathing refrigerant. Provide adequate ventilation when recovering and charging R134a.• Never attempt to transfer refrigerant from one container to another.

If refrigerant is found to be escaping, the leaking cylinder must be removed from the work area immediately. Since refrigerant vapor is heavier than air and displaces oxygen, always work in a well ventilated area. R134a is not flammable at ambient temperatures and atmospheric pressure. However, this material will become combustible when mixed with air under pressure and exposed to strong ignition sources. See R134a MSDS information for more details.

Although it is good to have the Technical ProficiencyCertification, technicians must have Proper Use and Handling Certification to legally handle refrigerants.

A manifold gauge set is used for diagnosis to monitor high-side and low-side pressures in the refrigeration system. Gauges are not appropriate for charging A/C systems. Gauges are combined with a recovery and recycling station which recovers, recycles, evacuates, leak tests, and recharges R134Aa accurately by weight.

TXV system components:• High-Side consists of the compressor outlet, condenser, receiver drier, and TXV inlet.• Low-Side consists of the TXV outlet, evaporator, and compressor inlet.

CLIMATE CONTROLSERVICE EQUIPMENT SUMMARY



FOT system components:• High-Side consists of the compressor outlet, condenser, and FOT inlet.• Low-Side consists of the FOT outlet, evaporator, accumulator, and compressor inlet.

Ambient temperature plays an important role in heat transfer. The higher the ambient temperature, the less heat it will accept from the condenser, making it less efficient at transferring heat. This keeps the temperature of the condenser higher, resulting in higher pressure.

Relative humidity also effects heat transfer. The higher the humidity (over 50%), the harder it is for the evaporator to remove passenger compartment moisture. With relative humidity under 50%, it is easier for the evaporator to remove passenger compartment moisture, but the harder it is to transfer heat from the condenser to the atmosphere.

Abnormal gauge readings can aid technicians in system diagnosis by comparing the high-side and low-side pressure readings to system specifications.

Mitsubishi recommends using a recovery machine capable of performing the following functions.• Recover refrigerant from the vehicle* Evacuate the system of all moisture• Test the system of leaks• Replenish any oil removed during recovery• Charge the system with refrigerant by weight

To prevent service equipment contamination from unauthorized refrigerants, a refrigerant identifier, such as the Sentinel® by Robinair quickly identifies the purity and type of refrigerant in an A/C system.

Use an electronic leak detector (not florescent dye) to isolate the source of refrigerant system leaks.

Technicians can perform the following the climate control diagnosis with MUT-III.• Gather Diagnostic Trouble Codes (DTCs)• Monitor Data List items• Review available Freeze Frame Data• Operate system actuators

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55.04A


1. A FOT system uses an accumulator located on the High-Side of the system. a. TRUE b. FALSE

2. Two technicians are discussing temperature and humidity. Technician A says high ambient temperatures make the condenser more efficient in transferring heat to the atmosphere. Technician B says relative humidity levels over 50% makes the evaporator more efficient at removing cabin moisture. Which technician is correct? a. Technician A b. Technician B c. Both technicians are correct. d. Neither technician A or B is correct.

3. What is the likely cause of both gauges reading low pressure in an operating system? a. Low refrigerant charge b. High-Side restriction c. Failing compressor d. Excessive moisture in the system

4. Two technicians are discussing A/C line temperatures with an operating system. Technician A says the liquid line from the receiver-drier to the evaporator should be hot. Technician B says the evaporator to compressor line should be cold and frosty. Which technician is correct? a. Technician A b. Technician B c. Both technicians are correct. d. Neither technician A nor B is correct.

5. A stuck closed TXV will show what readings? a. High Low-Side, High High-Side b. Low Low-Side, Low High-Side c. Normal Low-Side, Low High-Side d. Very Low Low-Side, Normal / Low High-Side

KNOWLEDGE CHECK

Feedback



NOTES

55.05A


Climate ControlDiagnosis and Repair

Section DescriptionThe goal of this module is to provide opportunities to practice diagnosing climate control concerns using related information, tools, and equipment.

Theory Section

55.05A

55.05A


Diagnosis and Repair







Note

Caution

!




55.05A



Table of Contents Section Introduction Section Goal ………………………………………………………………...…… 3 Section Objectives ………………………………………………………………. 3 Needed Materials ……………………………………………………………….. 3 Time to Complete ……………………………………………………………….. 3 Diagnostic Process Detailed Service Write-Up ……………………………….…………………..… 4 Technician Diagnosis …………………………………………………………... 5 Symptom Chart …………………………………..………………………...…… 6



55.05A

SECTION GOAL

SECTION OBJECTIVES Given several Mitsubishi vehicles with climate control concerns, their associated Repair Orders, diagnostic and repair information via MEDIC, and a choice of diagnostic tools & equipment, students will be able to perform the following tasks.

• Identify and describe the steps of an effective diagnosis process.• Demonstrate personal proficiency in diagnosing climate control concerns.

NEEDED MATERIALS

TIME TO COMPLETE

Current Mitsubishi vehiclesGlovesVent ThermometerA/C gauge setLeak detectorRecover/Recycling/Recharging StationMUT-III

About 1.5 hours

Slide 55.05A-3a

Slide 55.05A-3b

The goal of this module is to provide opportunities to practice diagnosing climate control concerns using related information, tools, and equipment.

DIRECTIONS These exercises are similar to typical day-to-day work at the dealership. Concerns are presented from the customer’s viewpoint on a repair order. Questions for the service advisor or customer should be directed to your instructor.

Practice the diagnostic steps as detailed in this section to identify the needed repair.


Diagnosis and Repair55.05A

Slide 55.05A-4a

DIAGNOSTIC PROCESS

A thorough understanding of the customer’s concern is essential for correct diagnosis and repair. This begins with the service advisor who gathers pertinent facts from the customer and relays them clearly to the technician on the repair order. Service write-up discussion areas with the customer should include the following. Describe the concern. • No cooling (or poor cooling) concern? • No heating (or poor heating) concern? • Air flow concern? (output location or flow) Temperature and ambient conditions • Day or night • Elapsed time after startup • Ambient temperature and humidityFrequency of occurrence • Once • Intermittent • ConstantDriving conditions • Highway • City • Vehicle speed

Detailed Service Write-Up

CSI



55.05A

Slide 55.05A-5a

After receiving a detailed description of the customer’s concern from the repair order, the technician must perform these steps to complete an effective repair.

1) Verify the Concern • Duplicate the customer’s concern. • Check for other related symptoms. • If necessary, consult the service manual description to verify normal system operation. 2) Consult Tech Talk articles and TSBs.

3) Determine Possible Causes • Consult service manual symptom charts. • Fully analyze system diagrams. • Rank possible causes in order of probability.

4) Find the Problem • Conduct systematic diagnosis. • Follow Service Manual troubleshooting steps for the vehicle being serviced. • Document the diagnosis including tests and results.

5) Complete the Repair • Verify the concern’s root cause is resolved. • Recheck system operation to confirm the concern is eliminated and no new problems have emerged during the repair.

Technician Diagnosis

CSI


Diagnosis and Repair55.05A

noitcepsnImotpmySProcedure

Reference Page

When the A/C is operation, temperature inside the passenger compartment does not decrease (Cool air is not emitted). 1 P.55A-75

2metsys ylppus rewop C/A eht fo noitcnuflaM P.55A-783.krow ton seod rosserpmoc ehT P.55A-824.nrut ton od rotom dna naf rewolB P.55A-905.degnahc eb tonnac tnuoma ria rewolB P.55A-95

P.55A-987.esaercni ton seod erutarepmet ria teltuo C/A P.55A-1018.degnahc eb tonnac tnev teltuo riA P.55A-1039.metsys ylppus rewop rotom rewolB P.55A-106

Outside to inside air changeover is not possible. 6

Slide 55.05A-6a

Shown above is the Symptom Chart for a 2014 Lancer equipped with Manual control system, taken from Service Manual Group 55A. Each symptom is associated with a specific inspection procedure, beginning on the referenced page.

Most diagnosis information is included in Group 55A. Depending upon the vehicle being repaired, an inspection or repair procedure may continue in Group 55B to check components specific to the Automatic system, then returns to Group 55A.

Depending upon the specific symptom, an inspection routine may begin with a check for DTCs and CAN network integrity using MUT-III. Other procedures begin with electrical tests of specific components and may lead to further diagnosis involving pressure readings.

The remainder of this section is dedicated to hands-on practice activities diagnosing several climate control concerns.

Each repair order includes a symptom as well as associated conditions. Among others, these further descriptors could include:• Only on hot days• At slow vehicle speeds• At high blower speed

Activity

Symptom Chart

DIAMONDPTECHNICAL TRAINING

Mitsubishi Motors North America, Inc. May 2014


Climate Control Student Guide

Documents

Transcript of Climate Control Student Guide