1991 MITSUBISHI MONTERO drain bolt

Removal
1) Remove A/C compressor. Remove pressure plate shaft bolt
using socket wrench and Clutch Stopper (07112-76060). Install Clutch
Remover (07112-66040) on pressure plate. Using clutch stopper and
socket wrench, rotate clutch remover to remove pressure plate.
2) Remove shims from pressure plate. Remove snap ring from
compressor. Tap rotor off shaft with plastic hammer. Disconnect stator
wire from housing. Remove snap ring from inside stator. Remove stator.
See Fig. 12 .
CAUTION: DO NOT damage pulley when tapping on rotor.
Installation
To install, reverse removal procedure. Ensure snap rings are
installed with beveled side up. tighten shaft bolt to 10 ft. lbs.
(14 N.m). Ensure clutch clearance is .014-.026" (.36-66 mm). adjust
clearance by adding or subtracting shims as necessary.
NIPPONDENSO 6 & 10-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR OIL CHECKING article in the AIR CONDITIONING &
HEAT section.
Removal
1) Hold clutch hub stationary and remove center nut. Screw
remover into center of hub. Turn center bolt to remove pressure plate.
2) Remove shims from shaft. Remove snap ring from inside of
pulley. Tap pulley off of shaft with plastic mallet. Be careful not to
distort pulley while removing.
3) Disconnect clutch coil wires from compressor housing.
remove snap ring inside coil and lift coil off compressor. Pry dust
seal out from around compressor shaft (if equipped).
4) Place shaft key remover on shaft and turn to remove key.
Remove drain plug (if equipped). Remove service valves-to-compressor
body bolts. Remove valves. Discard "O" rings. Drain oil out of
compressor.
5) Remove 6 through bolts from front head of compressor and
discard washers. Tap head loose from compressor; be careful not to
scratch sealing surfaces. remove snap ring (if equipped) from front
housing. Press seal plate out. Remove seal from shaft. See Fig. 14.
Installation
1) Lubricate shaft seal with clean refrigerant oil and place
on compressor shaft. Lubricate seal plate and "O" ring (if equipped)
and install in front housing. Install snap ring (if equipped).
2) Place front housing on compressor body. Install through
bolts with new washers. Tighten bolts evenly and alternately to
18 ft. lbs. (24 N.m). Install shaft key using installer and plastic
mallet. Insert dust seal into front of compressor.
3) Install drain plug with new gasket. Add correct amount of
refrigerant oil to compressor. If service valves were removed, coat
new "O" rings with refrigerant oil and install service valves.
4) Place clutch coil on compressor and install snap ring.
Install shims on shaft to adjust pressure plate-to-rotor clearance to
.016-.028" (.41-.71 mm). Tighten shaft nut to 12 ft. lbs. (16 N.m).

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.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Bearing Cap Bolt ...................... 40-47 (54-64)
Brake Caliper Bolt .................... 58-72 (79-98)
Carrier-to-Housing Tube Bolt .......... 58-72 (79-98)
Cover Bolt ............................ 11-16 (15-22)
Drain Plug ............................ 43-51 (58-69)
Fill Plug ............................. 29-43 (39-58)
Front Crossmember Bolt ............... 72-87 (98-118)
Hub Cover ............................. 13-25 (18-34)
Knuckle-to-Ball Joint Nut
Upper ............................... 43-65 (58-88)
Lower ............................ 87-130 (118-176)
Mount Bracket-to-Frame Bolt .......... 58-80 (79-108)
Mount Bracket-to-Housing Tube Bolt ... 58-72 (79-98)
Pinion Flange Nut
2.4L & 2.6L ..................... 116-159 (157-216)
3.0L ............................ 137-181 (186-245)
Drive Shaft Flange Bolt ............... 36-43 (49-58)
Right Drive Axle-to-Inner Shaft Bolt .. 36-43 (49-58)
Ring Gear-to-Case Bolt ................ 58-65 (79-88)
Tie Rod-to-Knuckle Nut ...................... 33 (45)
Wheel Lug Nuts
Montero ............................ 72-87 (98-188)
Pick-Up .......................... 87-101 (118-137)
INCH Lbs. (N.m)
Undercover-to-Frame
Bolts (Montero) ................. 84-108 (9.5-12.2)









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TESTING SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Montero & Pickup ............................ 25 (34)









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REMOVAL & INSTALLATION
AXLE SHAFTS
Removal
1) Block front wheels. Raise and support rear axle housing.
Remove brake drum. See Fig. 1. Remove parking brake cable attaching
bolts. Remove connection for parking brake cable end and rear brake
assembly. Drain brake fluid from bleeder screw at left side of rear
brake and disconnect brake tubes.
2) On all models, remove flange nuts and rear axle shaft
assembly. Use Puller (MB990241) and Slide Hammer (MB990211) if
necessary. DO NOT damage oil seal. Remove shim(s) and "O" ring.
Replace if necessary.
Fig. 1: Exploded View of Axle Shaft
Courtesy of Chrysler Motors.
Installation
1) Insert a new "O" ring and a shim of .04" (1.0 mm)

thickness into left side axle housing. Install left axle shaft
assembly into axle housing and tighten nuts to specification. See
TORQUE SPECIFICATIONS table at the end of this article.
2) Install right axle shaft assembly into axle housing
WITHOUT a shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case and rear axle housing end with a feeler gauge.
3) Select shims equal to the sum of the thickness of the
measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle
shaft and install the selected shim(s) and "O" ring into right axle
housing end. Install right axle shaft assembly into rear axle housing.
Tighten nuts in diagonal sequence to specification. See TORQUE
SPECIFICATIONS table.
4) Using dial indicator, check end play of axle shaft. End
play must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake and bleed brake system.
DIFFERENTIAL CARRIER
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support
differential carrier with jack. Remove differential carrier retaining
nuts. Remove differential carrier.
Inspection
Inspect for leakage at vent plug, differential carrier
companion flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts. Remove drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.
OVERHAUL
AXLE SHAFTS
Disassembly
1) Mount backing plate and axle shaft assembly in soft-jawed
vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench
(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall\
lock nut on axle shaft approximately 3 turns.
2) Attach Bearing Puller (MB990787-01) to rear of backing
plate to remove bearing case from axle shaft. See Fig. 2. Using equal
pressure to avoid binding, tighten puller nuts diagonally to remove
bearing case. Using hammer and drift, remove bearing outer race from
bearing case. Remove oil seal from end of axle housing with Slide
Hammer and Adapter (MB990211).

runout.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Bearing Lock Nut (Montero) .................. 130-159 (176-216\
)
Bearing Cap Bolt ..................................... 40-47 (54-64)\
Bearing Case-To-Axle Housing Bolt .................... 36-43 (49-58)\
Brake Tube Flare Nut ................................. 10-12 (14-16)\
Differential Carrier-To-Axle Housing Nut
2.4L (2WD) ......................................... 18-22 (24-30\
)
3.0L (4WD) ......................................... 29-40 (39-54\
)
Drain Plug ........................................... 43-50 (58-68)\
Filler Plug .......................................... 29-43 (39-58)\
Lock Plate Bolt ...................................... 11-16 (15-22)\
Pinion Flange Nut ................................ 137-181 (186-245)\
Drive Shaft-To-Flange Bolt ........................... 36-43 (49-58)\
Ring Gear Bolt ....................................... 58-65 (79-88)\
Side Bearing Lock Plate Bolts ........................ 11-16 (15-22)\
Wheel Lug Nut
Montero ........................................... 72-87 (98-118)\
Pickup .......................................... 87-101 (118-137)\









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Bolt loose .............. A ........... Require tightening or
replacement of bolts.
Bolt missing ............ C ... Require replacement of bolts.
Corroded, affecting
sealability ............ A .. Require repair or replacement.
Cylinder head threads
stripped ............... A ... Require repair or replacement
of cylinder head.
Gasket leaking .......... A ........... Require tightening or
replacement of gasket.
Heat stove bent ......... B ........... (1) Require repair or
replacement of stove.
Heat stove broken ....... A ......... ( 1) Require replacement
of stove.
Heat stove corroded,
affecting structural
integrity .............. 1 ......... ( 1) Suggest replacement
of stove.
Heat stove missing ...... C ......... ( 1) Require replacement
of stove.
Manifold broken ......... A .. Require repair or replacement.
Manifold cracked ........ B .. Require repair or replacement.
Manifold warped ......... A .. Require repair or replacement.
Out of specification .... B .. Require repair or replacement.
Stud broken ............. A .... Require replacement of stud.
Stud missing ............ C .... Require replacement of stud.
Stud threads damaged .... A ... Require repair or replacement
of stud.
Stud threads stripped
(threads missing) ...... A .... Require replacement of stud.
( 1) - Stove may not be available separately; this may require
replacement of manifold.









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MECHANICAL EFE DEVICES
See HEAT RISERS (MECHANICAL EFE DEVICES) .
MUFFLERS AND RESONATORS
MUFFLER AND RESONATOR INSPECTION








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Condition Code Procedure
Body shell distorted,
affecting performance or
structural integrity ... A ............ Require replacement.
Corrosion hole .......... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Mounting bracket broken . A .. Require repair or replacement.
Mounting bracket
cracked ................ B .. Require repair or replacement.
Nipple cracked .......... A .. Require repair or replacement.
Nipple loose ............ B ............ Require replacement.
Outer wrap peeling
(exhaust not leaking) .. 1 ............ Suggest replacement.
Plugged ................. A ............ Require replacement.
Puncture (other than a
drain hole) ............ A ............ Require replacement.
Rattling or knocking noise
from inside muffler .... B ............ Require replacement.
Seam open (exhaust