1991 MITSUBISHI MONTERO glove box

article, see appropriate HEATER SYSTEM article in the AIR
CONDITIONING & HEAT Section.
A/C SWITCH
Removal & Installation (Colt Vista)
From back side of control panel, push right control panel
clip right while pushing control panel out of dash panel. Allow
control panel to hang. Remove side bracket. Press temperature switch
control assembly left, and then remove A/C switch. To install, reverse
removal procedure.
Removal & Installation (Montero)
Remove lap heater duct. Remove glove box stoppers and glove
box. Remove heater control knobs. Remove center panel screw hole
plugs, and remove screws. Remove center panel. Disconnect center panel
wiring harness. Remove A/C switch. To install, reverse removal
procedure.
Removal & Installation (Pickup & Ram-50)
Remove heater control knobs. Remove glove box. Remove center
panel mounting screws. Use a trim stick to remove upper side of panel.
Remove A/C switch assembly mounting screws. Pull switch assembly
toward vehicle interior. Remove switch. To install, reverse removal
procedure.
COMPRESSOR
Removal & Installation (Colt Vista)
Discharge A/C system using approved refrigerant
recovery/recycling equipment. Disconnect high tension cable from
ignition coil. Remove distributor cap. Loosen idler pulley adjusting
bolt, and remove belt. Disconnect compressor electrical connector.
Remove high and low pressure lines and "O" rings from compressor.
Remove compressor mounting bolts. Remove compressor. To install,
reverse removal procedure.
Removal & Installation (Montero, Pickup & Ram-50)
DischargeA/C system using approved refrigerant
recovery/recycling equipment. Loosen idler pulley, and remove belt.
Disconnect compressor electrical connector. Disconnect high and low
pressure lines from compressor. Remove compressor mounting bolts.
Remove compressor. To install, reverse removal procedure.
CONDENSER
Removal & Installation (Colt Vista)
Discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove front grille and grille brackets.
Remove front end cover and condenser harness. Disconnect electrical
fan connector. Slowly disconnect pressure lines from condenser. Remove
2 condenser mounting bolts. Lift up and remove condenser from vehicle.
To install, reverse removal procedure.
Removal & Installation (Montero)
Discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove radiator grille. Slowly
disconnect pressure lines from condenser. Disconnect condenser fan
motor connector. Remove condenser fan mounting bolts and motor. Remove
condenser mounting bolts. Remove condenser from vehicle. To install,
reverse removal procedure.
Removal & Installation (Pickup & Ram-50)

Discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove grille. Slowly disconnect
pressure lines at condenser. Remove upper condenser mounting bolts.
Remove condenser. To install, reverse removal procedure.
EVAPORATOR ASSEMBLY
Removal & Installation (Colt Vista)
1) Discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove drain hose from evaporator.
Disconnect refrigerant line connections. Discard "O" ring seals.
2) Remove lower glove box and dash insert (or reinforcement)\
.
See Fig. 11 Remove upper glove box and duct joint. Remove defroster
ducts and duct joints from right side of evaporator. Disconnect A/C
harness connector and main harness connector. Remove evaporator
assembly. To install, reverse removal procedure.
Fig. 11: Removing Evaporator Assembly (Colt Vista)
Courtesy of Mitsubishi Motor Sales of America.
Removal & Installation (Montero)
1) Discharge A/C system using approved refrigerant

recovery/recycling equipment. Remove glove box with lower frame
attached. Loosen duct joint bolt to free duct joint. Disconnect A/C
switch harness. Disconnect evaporator drain hose.
2) Disconnect refrigerant lines at firewall side of engine
compartment. Remove evaporator top attaching bolts in passenger
compartment. Remove evaporator assembly. See Fig. 12 or 13. To
install, reverse removal procedure.
Fig. 12: Exploded View of Front Evaporator (Montero)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Exploded View of Rear Evaporator Assembly (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Removal & Installation (Pickup & Ram-50)
Discharge A/C system using approved refrigerant
recovery/recycling equipment. Disconnect liquid pipe and suction hose
connections. Remove glove box assembly. Remove air and defroster
ducts. Remove evaporator drain hose and clamp. Disconnect wiring
connectors. Remove nut from firewall evaporator assembly mounting
bracket. Remove evaporator assembly. To install, reverse removal
procedure.
WIRING DIAGRAMS

Front Behind left side of dash.
Rear Behind right side of dash,
left of blower unit.
MPI Control Relay Under right of dash, below
glove box.

Removal (Montero)
1) Move temperature control lever to WARM position. Drain
coolant from vehicle. Disconnect heater hoses from heater unit. See
Fig. 1.
2) Remove lap heater ducts. Remove hood release bracket.
Using screwdriver, release tabs and remove left and right demister
grilles. Remove glove box frame attaching screws, and remove glove
box. Remove passenger lap heater duct.
3) Using screwdriver and shop towel, carefully pry at top
center of instrument cluster cover, and remove cover. Remove 2 screws
at bottom of instrument panel and one bolt at top of instrument panel.
Gently pull instrument cluster out, and disconnect speedometer cable
and electrical connections. Remove instrument cluster.
4) Remove 4 screws, and disconnect electrical connections on
back of instrument cluster. Remove instrument cluster. Handle
instrument cluster carefully. Instrument cluster can be damaged if
dropped.
5) Remove center console knobs and side screw plugs. Remove
screws, disconnect electrical connections and remove console. Remove 6
bolts and console bracket (center dash reinforcement). Disconnect
radio connections while removing console bracket.
6) Remove horn pad and steering wheel retaining nut. Mark
steering wheel and steering shaft for reassembly reference. Using
steering wheel puller, remove steering wheel.
7) Using screwdriver, carefully pry out dash plug at upper
center of dash panel. Remove 3 upper dash mounting nuts, one upper
screw above steering column, and 2 lower mounting screws. Remove dash
panel.
8) Remove control cables at heater unit. Remove heater unit
attaching screws. Remove heater ducts. Remove heater unit. Remove
heater control lever arm.
9) Remove heater control valve cover. Remove heater pipe and
heater control valve. Disconnect control arm linkage. Remove control
arm. Remove heater core by moving it sideways.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks. Connect heater
hoses with 1-1.2" (25-30 mm) overlap on outlet.
2) When filling radiator with coolant, first open heater
control valve fully and run engine to circulate coolant and discharge
air from inside heater and engine cooling system. Stop engine, and add
coolant.
3) Adjust all control cables. When installing heater hose
grommets, apply sealer. After installing heater control assembly,
ensure each lever operates smoothly.
Removal (Pickup & Ram-50)
1) Disconnect battery ground cable. Place heater control
lever to far right. Drain coolant. Using trim stick, pry out hazard
switch and remove electrical connection. Remove 4 instrument cluster
cover screws, and remove cover. Remove 4 instrument cluster screws.
Tilt instrument cluster out, and disconnect speedometer cable and
electrical connections. Remove cluster.
2) Remove fuse box cover and fuse box assembly. Remove glove
box. Remove defroster air ducts. Disconnect heater control cables.
Using trim stick, pry under and remove speaker grilles. Remove clock
or coin box in center of dash. Remove center dash hole cover (located
above clock).
3) Remove 2 center support cover screws, and remove cover.
Remove shift knob and 6 console attaching screws. Remove console.
Ensure all electrical connections are free of dash panel. Remove 3 top
nuts, one bolt above steering column, and side and lower attaching

screws. Remove dash panel.
4) Remove blower duct, center duct and defroster ducts. See
Fig. 2. Disconnect heater wiring harness from heater unit. Remove
heater center support brackets. Remove heater unit. Remove heater core
cover plate and joint hose. Remove heater core from heater unit.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks.
2) When filling radiator with coolant, first open heater
control valve fully and run engine to circulate coolant and discharge
air from inside heater and engine cooling system. Stop engine, and add
coolant.
3) Adjust all control cables. When installing heater hose
grommets, apply sealer. After installing heater control assembly,
ensure each lever operates smoothly.
HEATER CONTROL PANEL
Removal (Montero)
1) Remove heater control knob and heater fan switch knob.
Remove center console. Remove defroster nozzle at temperature control
cable side.
2) Remove lap heater duct and glove box stopper, and push
glove box forward and down. Disconnect inside/outside control cable
from blower assembly.
3) Disconnect control cables from heater unit. Remove heater
control panel mounting screws, and pull out panel slightly. Disconnect
heater fan switch harness connectors. Remove heater control panel.
Remove heater fan switch from heater control panel.
Installation
1) Place air outlet change-over lever at closed position.
With heater side air outlet change-over damper lever in position,
connect inner cable to lever, and secure cable casing using clips.
2) Place heater control lever at OFF position. With heater
control lever in position, connect inner cable to lever, and secure
cable casing using clips.
3) Place inside/outside air change-over lever at INSIDE
position. With heater side inside/outside air change-over damper lever
in position, connect inner cable to lever, and secure cable casing
using clips.
4) Set control lever to each position to check for correct
operation. If lever does not operate correctly, adjust by moving outer
wire at clipped point. Ensure each control lever moves smoothly. If
any noise or stiff movement exists, apply multipurpose grease to all
moving parts.
NOTE: When mounting heater control panel to instrument panel,
tighten upper bolts to instrument panel so they also secure
center panel.
Removal & Installation (Pickup & Ram-50)
Remove cluster panel. Remove all control cables at heater.
Remove heater control panel. To install, reverse removal procedure.
Adjust cables as necessary.
WIRING DIAGRAMS

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* S YM PTO M C HEC K L IS T *
1 991 M it s u bis h i M onte ro
SYMPTOM CHECK LIST WORKSHEETS
* PLEASE READ THIS FIRST *
NOTE: This article is intended for general information purposes
only. It does not apply specifically to one make or model.
PURPOSE
Why Use the Symptom Check List Worksheets?
One of the most difficult and critical lines of communication
is between the service customer and the technician. The clearer the
technician understands the customer's concerns, the more likely the
problem will be "fixed right the first time".
The Symptom Check List Worksheets in this article are
designed to improve this communication. When used consistently, they
can be helpful in reducing shop comebacks, increasing technician
productivity, and producing satisfied customers. They also provide
other benefits:
* Reduce "No Trouble Found" problems
* Increase customer involvement
* Customer perceive that "they really care and listen"
* Save time during peak write-up periods
* Reduce recontacting customers for additional information
* Improve night drop information
* Insure all the right questions are asked at write-up
Making the Worksheets a Part of Your Normal Routine
The following information contains ideas that may be helpful
in forming habits that promote daily use of the Symptom Check Lists:
* HAVE THE SERVICE ADVISER FILL OUT THE FORM(S) WITH THE
CUSTOMER WHENEVER POSSIBLE.
* Place them in your night drop for the customer to fill out,
along with an instruction sheet to help them understand what
to do.
* Hand out the worksheets to customers while they wait in line
during the peak morning rush and ask them to fill it out. It
will save time for all concerned and improve the quality of
information received from the customer.
* Make sure it is attached to the hard copy when it goes to the
technician.
* Place a copy with the final repair papers and review it with
the customer at delivery.
* Put a new worksheet in the glovebox of all departing
customers.
* Require that you personally see a copy of all worksheets
filled out for shop comebacks.
* Hold a shop meeting to get employee buy-in and their ideas on
how to make it effective in your shop.
There are many other ways to utilize the concept, but as with
every other idea, successful implementation depends on employee
involvement and buy-in.
SYMPTOM CHECK LIST WORKSHEETS