INDEX

SPECIFICATIONS ............................................................................. 55-2

STRUCTURE AND OPERATION

1. Heater .......................................................................................... 55-4
2. Air Conditioner............................................................................. 55-5
3. Air Duct ....................................................................................... 55-6
4. Heater Control ............................................................................. 55-7

TROUBLESHOOTING ..................................................................... 55-10

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Recovery of Refrigerant ............................................................ 55-12
2. Recharging the System with Refrigerant ................................... 55-13
3. Checking Refrigerant Charge Level ........................................... 55-15
4. Adding Refrigerant .................................................................... 55-16

CONNECTING AIR CONDITIONER PIPING .................................. 55-17

COMPRESSOR ................................................................................ 55-18

CONDENSER, RECEIVER ............................................................... 55-20

HEATER CONTROL ......................................................................... 55-22

AIR DUCT .......................................................................................... 55-26

HEATER AND COOLING UNIT, BLOWER ....................................... 55-28

55-1
SPECIFICATIONS
<Without Air Conditioner>
Item Specifications
Mode selection Manual cable type
Damper change- Air mixing Manual cable type
System over system
Fresh/recirculation
Servomotor
changeover
Servomotor rated voltage V 12
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.
Heater unit Heating capacity W {kcal/h} 4370 ± 437 {3758 ± 376}
Temperature control system Air mixing type
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.
Blower
Blower motor voltage V 12

55-2
 55
<Air Conditioner>
Item Specifications
Type Manual type air conditioner
Type HFC134a
Refrigerant Charged quantity
650 {22.9}
g {oz}
System Mode selection Manual cable type
Damper change- Air mixing Manual cable type
over system
Fresh/recirculation
Servomotor
changeover
Servomotor rated voltage V 12
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.
Heater and cooling Heating capacity W {kcal/h} 4370 ± 437 {3758 ± 376}
unit Cooling capacity W {kcal/h} 4340 ± 434 {3732 ± 373}
Temperature control system Air mixing type
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.
Blower
Blower motor voltage V 12
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.
Model MSC90TA
3
Discharge cm {mL}/1 rotation 90 {90}
Compressor
Type SUN PAG56
Lubricant Quantity
140 +20 +1.22
0 {8.54 0 }
cm3 {cu.in.}
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.

Condenser Wide cab 7 +1.0

- 1.5
Rated current A
Standard wide cab 9.5 +1.8
- 2.0
Manufacturer MITSUBISHI HEAVY INDUSTRIES, LTD.
Receiver
Capacity cm3 {cu.in.} 350 {21.4}

55-3
STRUCTURE AND OPERATION
1. Heater

• The blower sends air to the heater unit, where the air is heated by the heater core (heat exchanger). The
warmed-up air is then sent through the ducts into the cab.
• Water (engine coolant) warmed up by the heat from the engine circulates permanently through the heater core, ir-
respective of whether the thermostat is open or closed.

55-4
 55
2. Front Air Conditioner
• The blower sends air to the heater and
cooling unit, where the air is cooled by
the evaporator. The cooled air is then
sent through the ducts into the cab.
• Refrigerant in gas form is compressed
by the compressor. The compressed
gas is then sent to the side condenser,
where it is cooled by outside air and
condenses into liquid form.
• The liquid refrigerant is sprayed into
the evaporator, where it quickly evapo-
rates into gas form while at the same
time absorbing heat from the sur-
rounding air.
• The refrigerant in gas form is again
sent to the compressor and is com-
pressed there.
• When the refrigerant pressure in the
high pressure line reaches the speci-
fied limit, the dual pressure switch
senses this and turns itself OFF. At
the same time, the magnet clutch is
turned OFF.

55-5
STRUCTURE AND OPERATION
3. Air Duct

• The blower sends outside air A or inside air B through the heater unit or heater and cooling unit to the ducts. The
flow of air is dependent on the open/closed positions of the various dampers.

55-6
 55
4. Heater Control
4.1 Mode selection

55-7
STRUCTURE AND OPERATION
4.2 Air mix selection <Air conditioner>

55-8
 55
4.3 Fresh/recirculation changeover

• The fresh/recirculation changeover damper is operated by means of motor.

55-9
TROUBLESHOOTING
Heater, Front Air Conditioner
Symptoms

No ventilation/recirculation selection

Controls require too much effort

Air volume from vents unstable
No temperature setting
Reference Gr

No mode selection
No air from vents

Draft from vents

Poor heating
Poor cooling
Possible causes
Blower motor coil open, shorted O
Blower motor relay contacts stuck closed, coil open, shorted O Gr54
Blower resistor malfunction <A/C> O
Compressor seized, malfunction <A/C> O
Refrigerant charge low <A/C> O O
Air conditioner relay contacts stuck closed, coil open, shorted
O
<A/C>
Mode damper malfunction, not fully closed O O O
Air mix damper malfunction, not fully closed O O O
Ventilation/recirculation selection damper malfunction, not fully
O O O
closed
Condenser fan motor coil open, shorted <A/C> O
Condenser relay contacts stuck closed, coil open, shorted
O
<A/C> Gr54
Dual pressure switch coil open, shorted <A/C> O
Heater control malfunction O O O O O O O
Thermostat stays open O
Gr14
Coolant level low O
Connector poor contact, harness open, faulty earth O O O O O O
Gr54
Fuse blown O O
Air conditioner piping clogged, loose, incorrectly connected
O
<A/C>
Heater piping clogged, loose, incorrectly connected O
Duct incorrectly connected O
Heater and cooling unit clogged O
Condenser clogged <A/C> O
Condenser core restricted, accumulation of foreign matter
O
<A/C>
Receiver clogged, inefficient desiccant <A/C> O
Evaporator clogged <A/C> O
Control wire jammed, incorrectly installed O O O O
Lever bent O O O O
Lever sliding section worn, out of grease O O O O

<A/C>: Air conditioner

55-10
 55
M E M O

55-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Recovery of Refrigerant

• Recover refrigerant from the air conditioning system in accordance with the following flow chart.
• Installation of the refrigerant recovery unit

Close both the low pressure and high pressure valves.

Connect the charge hose to the low pressure service valve.

Connect the charge hose to the high pressure service valve.

Connect the charge hose to the adapter valve.

Open both the low pressure and high pressure valves.

Open the adapter valve.

Run the recovery unit to collect the refrigerant.

55-12
 55
2. Recharging the System with Refrigerant

Recharge
Continue
Prepare the system
Install the Start filling recharging
the air Vacuum with refrig- Refrigerant OK
refrigerant the system Airtightness OK to the
Start conditioner filling is erant until leakage Finish
charge with test specified
for completed. saturation test
unit. vacuum. charge
recharging. pressure is
level.
reached.

NG
Retighten the NG
pipe connections.

• Recharge the system with refrigerant in accordance with the following flow chart.
• Installation of the refrigerant charge unit

Close both the low pressure and high pressure valves.

Connect the charge hose to the low pressure service valve.

Connect the charge hose to the high pressure service valve.

Connect the charge hose to the adapter valve.

Fill the system with vacuum.

Open both the low pressure and high pressure valves.

Open the adapter valve.

55-13
ON-VEHICLE INSPECTION AND ADJUSTMENT

Run the vacuum pump.

Continue to run the pump for a minimum of 10 to 15 minutes. Close the adapter valve.

Stop the vacuum pump.

CAUTION
• Make sure that the adapter valve is closed before stopping the vacuum pump.

Close both the low pressure and high pressure valves.

Wait for 5 minutes. During this interval, the readings on the gauges installed on the gauge manifold should stay where they are and should
not move towards zero.

Vacuum filling is now completed.

Recharging the system with refrigerant

With the adapter valve still closed, remove it from the vacuum pump. Connect the valve to the refrigerant container via the container valve.

Open the container valve and then the adapter valve.

Open the low pressure valve to fill refrigerant in gas form.

CAUTION
• Filling refrigerant into the system in liquid form may damage the compressor. To prevent this,
keep the refrigerant container in the upright position so that refrigerant is filled in gas form.

When the refrigerant container is empty, close the adapter valve and install a new container. Continue filling the system.

When the air conditioning system is saturated, start the engine. Turn on the air conditioner to run the compressor, and continue recharging
until the specified charge level is reached.

55-14
 55
3. Checking Refrigerant Charge Level
• To check the refrigerant charge level, observe the flow of refrig-
erant through the sight glass. If the visual inspection indicates a
low charge level, add refrigerant.
• The visual check should be performed under the following condi-
tions.
• Engine speed: 1400 rpm
• Air conditioner switch: ON
• Fan speed control dial: 4 (MAX)
• Temperature control dial: MAX COOL
• Fresh/recirculation changeover switch: Indicator lamp in the
switch (OFF Fresh)
• Doors: Fully open
CAUTION
• When no or low level of refrigerant is checked, stop the air
conditioner immediately. Running it with this condition for
long time causes the compressor to seize.

Normal level Low level No refrigerant

Sight glass
With a careful look, some- Air bubbles are seen flowing The refrigerant is almost trans-
thing like mist can be seen at all times. The refrigerant parent. Air bubbles may be
flowing. may be transparent or whitish. seen flowing, but they disap-
pear when the engine is
revved up and down.
The high pressure piping is The high pressure piping is There is almost no difference
High/low pressure piping hot while the low pressure pip- warm while the low pressure in temperature between the
ing is cold. piping is slightly cold. high and low pressure piping.

55-15
ON-VEHICLE INSPECTION AND ADJUSTMENT
4. Adding Refrigerant

• Add refrigerant in accordance with the following flow chart.

With the adapter valve closed, connect the charge hose to the low pressure service valve.

CAUTION
• If the charge hose is connected to the high pressure service valve, refrigerant may flow back,
possibly damaging the refrigerant container and charge hose.

Open and close the adapter valve to bleed air of the charge hose.
After air bleeding is completed, close the adapter valve.

Take the refrigerant container and valve assembly. With the container valve closed, connect the assembly to the adapter valve.

CAUTION
• Filling refrigerant into the system in liquid form may damage the compressor. To prevent this,
keep the refrigerant container in the upright position so that refrigerant is filled in gas form.

Open the container valve and then the adapter valve.

Start the engine.

Set the temperature control to MAX COOL. Turn on the air conditioner to run the compressor.

Continue adding refrigerant while observing the sight glass for charge level.

When “normal level” is confirmed through the sight glass,

add refrigerant further 50 g {1.76 oz}.

When charging is completed, close the adapter and container valves. Remove the charge hose and the refrigerant container
from the low pressure service valve.

If there is still some refrigerant in the container, keep it for the next opportunity. Be sure to keep the container valve closed.

55-16
CONNECTING AIR CONDITIONER PIPING 55
1 Flange (pipe end) <Flange type>
2 Flange (mating end)
<Flange type>
3 O-ring
4 Pipe
5 Pipe <Nut type>
6 Union <Nut type>
7 Nut <Nut type>

A: Refrigerating machine
oil application area
: Non-reusable parts

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut 11.8 to 14.7 {1.2 to 1.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
O-ring
Refrigerating machine oil SUN PAG56 As required
Outer periphery of pipe end (area A)

• There are 2 types of air conditioner pipe/hose connections: flange type and nut type. When connecting/tightening
the connections, observe the following precautions.
CAUTION
• The connected parts are sealed by the O-ring. Be careful not to damage the O-ring, such as by twisting.
• The O-rings are exclusively designed for HFC-134a refrigerant and are not reusable. The O-rings are
available at the MITSUBISHI HEAVY INDUSTRIES, LTD. service stations.
• Never tighten the nut-type connection by rotating the union. This will deform the piping, allowing refrig-
erant to leak out. Tighten by rotating the nut while holding the union in position.

55-17
COMPRESSOR

Disassembly sequence
1 Discharge hose (high pressure side) 5 Shaft
(See AIR CONDITIONER PIPE CONNECTING.) 6 Adjusting plate
2 Suction hose (low pressure side) 7 Clamp
(See AIR CONDITIONER PIPE CONNECTING.) 8 Compressor
3 V-ribbed belt
4 Spacer
*a: Vehicle harness

CAUTION
• Recover the refrigerant before removing the discharge hose and suction hose.
• Plug discharge hose, suction hose, and compressor after removal to keep them free from dust etc.

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• After installation, tension the V-belt to specification. (See Gr14.)

55-18
 55
Inspection procedure
Inspection: Compressor
• Check the compressor proper for malfunction and oil leakage.
• If there is anything wrong with the compressor, have it over-
hauled at a nearest MITSUBISHI HEAVY INDUSTRIES, LTD.
service station.

55-19
CONDENSER, RECEIVER
Removal sequence
1 Baffle plate
2 Baffle plate (upper)
3 EVA plate (lower)
4 Discharge pipe (compressor end)
(See the CONNECTING AIR
CONDITIONER PIPING section.)
5 Liquid pipe (heater and cooling
unit end) (See the CONNECTING
AIR CONDITIONER PIPING sec-
tion.) <Without rear air condition-
er>
6 Liquid pipe (See the CONNECT-
ING AIR CONDITIONER PIPING
section.) <Without rear air condi-
tioner>
7 Liquid pipe (condenser end) (See
the CONNECTING AIR CONDI-
TIONER PIPING section.) <With
rear air conditioner>
8 Receiver <Without rear air condi-
tioner>
9 Condenser

Installation sequence
Follow the removal sequence in reverse.

Inspection procedure
Inspection: Condenser
• If the condenser fins are clogged with dirt, dust or other foreign
matter, wash it out. Any deformed fins should be straightened
using a spatula or the like.

Inspection: Receiver
• If the need should arise to inspect the receiver, contact the MI-
TSUBISHI HEAVY INDUSTRIES, LTD. service station.

55-20
 55
M E M O

55-21
HEATER CONTROL
<Left-hand Drive Vehicle>

Removal sequence
1 Air mix control cable (BLACK)
2 Mode selection control cable (NATURAL)
3 Heater control unit

CAUTION
• Never remove the cable(s) from the heater control(s) except when the control cable(s) needs to be re-
placed. Failure to observe this may damage the claws of the cable clip.

Installation sequence
Follow the removal sequence in reverse.

55-22
 55
Work before removal
Adjustment: Temperature control knob
• Before disconnecting the control cables, turn the temperature
control knob of the heater controls to the MAX-COOL position.

Removal procedure
Removal: Control cables
• Before disconnecting the cables from the levers, put pairing
marks on each cable and its lever.
• Disconnect the control cables from the heater unit.

• In order that the control cables can be pulled back at the time of
installation, attach string to the ring parts of the cables as shown
in the illustration.

55-23
HEATER CONTROL
• Remove the heater control unit from the instrument panel.
• Use snap ring pliers to disconnect the cable(s) from the heater
control(s).

Work before installation

Adjustment: Heater control unit knobs
• At the heater controls, turn the temperature control knob to the
MAX-COOL position and turn the mode selector knob to the face
position before reconnecting the control cables.

55-24
 55
Installation procedure
Installation: Air mix control cable
• Install one end of the air mix control cable to the heater control
unit.
• Set the unit’s temperature control dial to MAX COOL.
• Pull back the control cable using the string attached at the re-
moval procedure.
• Install the other end of the air mix control cable to the lever on
the heater unit or heater and cooling unit.
• With the air mix control cable connected to the lever, pull the ca-
ble in the direction of the arrow to move the lever to MAX COOL
(upper) position. Clip the cable into the position.
• Move the temperature control knob to MAX COOL and MAX
HOT. Make sure that the lever moves to the corresponding MAX
COOL and MAX HOT positions. If not, repeat the above se-
quence to correctly install the cable. Also, make sure that the
cable being installed is in the correct color.

Installation: Mode selection control cable

• Install one end of the mode selection control cable to the heater
control unit.
• Set the unit’s mode control dial to FACE.
• Pull back the control cable using the string attached at the re-
moval procedure.
• Install the other end of the mode selection control cable to the le-
ver on the heater unit or heater and cooling unit.
• With the mode selection control cable connected to the lever,
and push the cable into the clip.
• Move the mode control knob to FACE and DEF. Make sure that
the lever moves to the corresponding FACE and DEF positions.
If not, repeat the above sequence to correctly install the cable.
Also, make sure that the cable being installed is in the correct
color.

55-25
AIR DUCT

55-26
 55
Removal sequence
1 Center duct 7 Side defroster duct
2 Driver face duct 8 Passenger foot duct
3 Center face duct 9 Center foot duct
4 Passenger face duct 10 Foot duct bracket
5 Clip ( × 7) 11 Driver foot duct B
6 Front defroster duct 12 Driver foot duct A

Installation sequence
Follow the removal sequence in reverse.

Installation procedure
Installation: Front defroster duct
• Insert the front defroster duct flanges into the instrument panel
ribs.
• Insert the instrument panel studs into the front defroster duct
holes and clip them together.

55-27
HEATER AND COOLING UNIT, BLOWER

55-28
 55
Removal sequence
1 Heater unit 5 Suction pipe (low pressure)
Heater and cooling unit <With air conditioner> (See the CONNECTING AIR CONDITIONER PIP-
2 Heater hose (outlet) ING section.)
3 Heater hose (return) 6 Fresh/recirculation changeover motor
4 Discharge pipe (high pressure) 7 Blower
(See the CONNECTING AIR CONDITIONER PIP- 8 Joint duct
ING section.)

Installation sequence
Follow the removal sequence in reverse.

Installation procedure
Installation: Fresh/recirculation changeover motor
• With the lever set to the “Fresh” position, install the motor shaft
through the lever.

55-29
HEATER AND COOLING UNIT, BLOWER
Heater Unit or Heater and Cooling Unit

Disassembly sequence
1 Cover <A/C> 6 Evaporator assembly <A/C>
2 Baffle cover <A/C> 7 Cover
3 Pipe assembly <A/C> 8 Heater core
4 Rubber insulation <A/C> 9 Heater and cooling unit case
5 Case cover
<A/C>: With air conditioner

Assembly sequence
Follow the disassembly sequence in reverse.

55-30