A/C - Compressor Pressure Relief Valve ServiceNo: TSB-03-55-005REVDATE: September, 2003MODEL: See Below SUBJECT: A/C COMPRESSOR HIGH-PRESSURE RELIEF VALVE PARTS AVAILABILITY &REPLACEMENT PROCEDURES

This bulletin revises and replaces TSB-03-15-005, issued June 2003, which should be discarded. New information is included for additional affected vehicles, an added replacement part, and procedures for removing the compressor to check and refill the compressor oil level. Increased labor times are introduced for these revised procedures.

PURPOSE

The bulletin Contains information and installation instructions for the A/C compressor high-pressure relief valve.

BACKGROUND INFORMATION

The high-pressure relief valve on the A/C compressor is now available as a separate service part. There is now no need to replace the complete compressor assembly because of a faulty high-pressure relief valve. The valve can be ordered separately.

AFFECTED VEHICLES

1994-99 3000GT1994-2004 Diamante1994-2003 Galant1995-04 Eclipse (except 1995-99 2.0L, 420A engine, non-turbo)1996-04 Eclipse Spyder1997-2004 Montero Sport2002-04 Lancer2003-04 Outlander

PROCEDURE

NOTE :There are two different types of high-pressure relief valves used for 1999-2003 Galant, 2000-04 Eclipse, and 2001-04 Eclipse Spyder The relief valve will be either gold or silver One relief valve of each color will be included in service part kit MN177247 When replacing the valve, the dealer technician must confirm the color of the valve on the vehicle and then select the same colored valve from the kit.

A/C Compressor High-Pressure (HP) Relief Valve Operating Range & A/C System Diagnosis:

After HP relief valve replacement, check the high pressure reading of the system. If the reading is above the standard operating pressure of the valve (3.5 - 4.1 Mpa [508 - 595 psi]), there is another component or system failure. Use the service manual to diagnose and determine the cause of the problem. The HP valve is defective if it activates at a pressure below the standard operating pressure.

A/C Compressor High-Pressure Relief Valve Replacement Procedures

You must completely discharge the A/C system to replace the relief valve and recharge the system after replacement. Refer to section 55 in the service manual for A/C discharge and recharge information.

WARNING Wear safety goggles and gloves when servicing the refrigeration system to prevent severe damage to the eyes and hands.1. Referring to the appropriate service manual, discharge the air conditioning system, then

remove the A/C compressor.

2. Remove the high-pressure relief valve from the top of the A/C compressor. Install the new valve and tighten to 12 Nm (106 in.lb).

3. After installing the relief valve on the compressor, make the following inspections (to determine the cause by which the relief valve operated) before installing the compressor on the vehicle.a. Check the air conditioner compressor clutch relay. (Refer to Service Manual).b. Check that the compressor pulley is free to turn. If it is not free to turn, replace the

magnetic clutch.c. Perform an operational check of the air conditioner compressor clutch. (Refer to

Service Manual).

4. Before installing the compressor on the vehicle, fill it with compressor oil according to the following procedure.

5. Using the steps in the service manual, reinstall the A/C compressor and recharge the system. Check the cooling efficiency of the system to make sure it has the proper temperature drop before returning the vehicle to the customer. Check the high pressure reading of the system. If the reading is above the standard operating pressure of the valve (3.5 - 4.1 Mpa [508 - 595 psi]), there is another component or system failure. Use the service manual to diagnose and determine the cause of the problem.

PARTS INFORMATION

Use the genuine Mitsubishi Part listed.

WARRANTY INFORMATION

Repair on a customer complaint basis, only. This bulletin is for information only, not warranty authorization.

Warranty Coverage: 36 months/36,000 miles.

Special Warranty Information: Normal warranty procedures apply.