1991 MITSUBISHI MONTERO light

ring and carbon seal contact surface of shaft seal seat for damage.
Make sure that "O" ring contact surface on front cover is not damaged.
Make sure refrigerant oil is applied to oil seal in shaft seal seat.
Installation
1) To install, reverse removal procedure. Ensure shaft seal
contact surface is free of dirt. Lubricate with refrigerant oil. Cap
end of compressor shaft.
2) Using Guard (KV994C1143), insert shaft seal. Be sure shaf\
t
seal case is aligned with shaft. Apply force to turn seal to left and
right. Ensure shaft seal seats properly in shaft cut-out.
3) Fit "O" ring to outside groove of shaft seal seat. Ensure
"O" ring seats properly. Apply refrigerant oil on contact surfaces and
around shaft seal seat. Lightly coat surface of shaft with refrigerant
oil.
4) Install key on compressor shaft. Using snap ring pliers,
compress retainer ring and fit retainer ring into front cover. Seat
retainer ring firmly in groove. Thoroughly wipe grease or oil from
shaft surface.
5) Connect Installer (KV99412329) to shaft of compressor, an\
d
turn shaft 5 or 6 times in a clockwise direction to seat seal. See
REFRIGERANT OIL & R-12 SPECIFICATIONS chart in this section for system
capacities.
MATSUSHITA ROTARY VANE CLUTCH R & I
Removal & Installation
1) Insert two 5 mm bolts into threaded holes in armature.
Using a screwdriver as lever in between bolts, remove center bolt.
remove armature and shim from shaft.
2) Remove snap ring. Using a puller, remove pulley.
Disconnect electrical leads from field coil. Remove 3 field coil
mounting bolts. Remove field coil. See Fig. 12. To install, reverse
removal procedure.
Fig. 12: Exploded View of Rotary Vane Compressor (Matsushita)
Courtesy of Subaru of America. Inc.
NIPPONDENSO TV12 ROTARY VANE CLUTCH R & I

NOTE: Check compressor refrigerant oil level when replacing seals.
Removal
1) Secure 2 box-end wrenches, to hold armature plate, using
two 6 mm bolts 1 in. (25 mm) or longer. Holding box-end wrenches, use
a socket and ratchet to remove clutch hub nut.
2) Remove armature plate. See Fig. 17. Remove snap ring with
internal snap ring pliers. Remove clutch hub. Remove snap ring and
clutch coil.
3) Remove bolts retaining front housing. Remove front housing
and "O" ring from compressor. Remove shaft seal from shaft. Remove
snap ring from back side of front housing. Remove seal plate.
4) Use brass drift and hammer to lightly tap shaft bearing
from front housing. Remove felt seal.
NOTE: Do not touch the sealing surfaces of the shaft seal carbon
ring and shaft seal plate.
Installation
1) Lubricate shaft seal with compressor oil. Align notches on
shaft seal with notches on crank shaft. Install shaft seal plate on
the front housing. Install front seal housing to compressor.
2) Use Press Tool (MB991301) to install felt into front
housing. Make sure felt metal section faces up. Use Press Tool
(MB991301) to press bearing into front housing.
3) Align and install clutch coil. Install snap ring so that
the tapered surface is facing outward. Install clutch hub. Install
snap ring. Install armature plate, aligning raised area to notch.
4) Secure 2 box-end wrenches, to hold armature plate, using
two 6 mm bolts 1 in. (25 mm) or longer. Holding box-end wrenches, use
a socket and ratchet to tighten clutch hub nut to 12 ft. lbs. (16 N.
m).
5) Use feeler gauge to measure distance between armature and
clutch hub. If gap is not .01-.02" (.25-.51 mm), remove clutch
assembly and add or remove shims accordingly.
Fig. 17: Sanden Scroll Compressor
Courtesy of Chrysler Motors.

\003
A/C -H EA TE R S YSTE M - M AN UAL

1991 M it s u bis h i M onte ro
1991 MANUAL A/C-HEATER SYSTEMS
Chrysler Motors, Mitsubishi
Chrysler Motors: Colt Vista, Ram-50
Mitsubishi: Montero, Pickup
* PLEASE READ THIS FIRST *
CAUTION: When discharging air conditioning system, use only approved
refrigerant recovery/recycling equipment. Make every attempt
to avoid discharging refrigerant into the atmosphere.
A/C SYSTEM SPECIFICATIONS
SPECIFICATIONS TABLE








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Compressor Type
Colt Vista & Montero .................... Nippondenso 10-Cyl.
Pickup & Ram-50 ............................... Sanden Scroll
Compressor Belt Deflection
Colt Vista ............................ 11/32-7/16" (8-11 mm)
Montero ............................. 21/64-3/8" (8.5-9.5 mm)
Pickup & Ram-50 .................... 21/64-25/64" (8.5-10 mm)
Compressor Oil Capacity
Colt Vista & Montero ............................... 2.7 ozs.
Pickup & Ram-50 .................................... 5.0 ozs.
Refrigerant (R-12) Capacity
Colt Vista & Montero ................................ 32 ozs.
Pickup & Ram-50 ..................................... 30 ozs.
System Operating Pressures (1)
Colt Vista, Pickup & Ram-50
High Side .................... 130-220 psi (9.1-15.5 kg/cm
)
Low Side ........................ 20-26 psi (1.4-1.8 kg/cm)
Montero
Dual Unit
High Side .................. 142-199 psi (9.9-14.0 kg/cm
)
Low Side ...................... 16-30 psi (1.1-2.1 kg/cm)
Single Unit
High Side ................... 102-142 psi (7.1-9.9 kg/cm
)
Low Side ...................... 18-32 psi (1.3-2.2 kg/cm)
(1) - With ambient temperature at least 80
F (27C).








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DESCRIPTION
Slight variations exist among the manual A/C-heater systems
used. Either Sanden Scroll or Nippondenso 10-cylinder compressor is
used. Cycling of the compressor clutch is controlled by switches which
monitor temperatures and pressures.
Compressors will only operate within the normal operating
temperatures and pressures set for each model. An electric condenser
fan operates whenever A/C system is operating. System components used
vary depending upon model. Most systems include an A/C compressor
control unit, fan switch, evaporator, temperature sensor, high and low
(or dual) pressure switch, engine coolant temperature switch,
compressor, condenser, receiver-drier and various pipes and hoses.

OPERATION
A/C SWITCH
The A/C switch is located in the lower, center section of
control panel. See Fig. 1. When switch is pushed, air conditioning
will operate if blower motor control lever is in a position other than
OFF.
When activated, the A/C button/switch allows the A/C
compressor clutch to engage and operate the compressor. On some
models, a light on the button will glow when button/switch is
activated.
Fig. 1: A/C Switch & Control Panel
Courtesy of Mitsubishi Motor Sales of America.
AIR SELECTOR LEVER
The air selector lever is located in the upper, left corner
of control panel and moves horizontally to select the source of air
needed inside of passenger compartment. Lever moves from OFF position
on the left to the outside air mode, to the mixture of both outside
and inside air mode, and to the recirculation mode on the right. Lever
should normally be set in the recirculation mode for maximum A/C
cooling.
BLOWER MOTOR CONTROL LEVER
Blower motor control lever is located on the lower, left
corner of control panel and moves horizontally to select blower motor
speeds. As lever is moved from far left or OFF position, increasing

\003
A/C S YSTE M P R EC AU TIO NS

1991 M it s u bis h i M onte ro
AIR CONDITIONING & HEAT
A/C System Precautions
* PLEASE READ THIS FIRST *
CAUTION: When discharging air conditioning system, use only approved
refrigerant recovery/recycling equipment. Make every attempt
to avoid discharging refrigerant into the atmosphere.
BEFORE OPENING THE SYSTEM
Before disconnecting any lines or fittings, the system must
be completely discharged using approved refrigerant recovery/recycling
equipment.
DISCHARGING A/C SYSTEM
NOTE: Recent findings by the EPA indicate that R-11, R-12 and R-113
are harmful to the Earths' protective Ozone layer. Make every
attempt possible, to avoid discharging R-11, R-12 or R-113
into the atmosphere.
1) Remove service valve caps and install gauges. For high
side gauge hose, Adapter (D81L-19703-A) must be used to connect to
high side service valve.
2) Place open end of center hose in garage exhaust outlet or
in a well ventilated area. Slightly open low side gauge valve and let
refrigerant escape slowly without loosing refrigerant oil.
3) When system is nearly discharged, using approved
refrigerant recovery/recycling equipment, open high side gauge valve
to release any pressure trapped in compressor. Close valves
immediately after discharging to prevent entry of moisture.
DISCONNECTING LINES & FITTINGS
1) After system is discharged, using approved refrigerant
recovery/recycling equipment, carefully clean entire area around
coupling nut to prevent dirt entering system. Always use two wrenches
to avoid twisting or distorting lines and fittings (hold fitting with
one wrench while loosening coupling nut with second wrench).
2) Cap or plug all LINES and FITTINGS immediately to prevent
entry of air and moisture into system. Do not remove these caps until
connections are being made.
COMPONENT REPLACEMENT
When components are replaced, system oil level must be
adjusted. Add refrigeration oil to replacement component. See
Compressor oil Check article, as well as, Component Oil Replacement
Quantities" chart under "A/C SYSTEM SPECS" article in this section.
USING R-12 REFRIGERANT - SAFETY PRECAUTIONS
1) Always work in a well-ventilated, clean area. Refrigerant
(R-12) is heavier than oxygen, and will displace oxygen in a confined

ALTE R NATO R & R EG ULA TO R

1991 M it s u bis h i M onte ro
1991 ELECTRICAL
Alternators & Regulators
Colt, Colt Vista, Colt 200, Ram-50, Stealth, Summit;
Eclipse, Galant, Mirage, Montero, Pickup, Precis, 3000GT
DESCRIPTION
Mitsubishi alternators are conventional 3-phase, self-
rectifying type units containing 6 diodes (3 positive and 3 negative)
which are used to rectify current. All models use a case-mounted
Integrated Circuit (IC) voltage regulator.
Alternator relay or resistor with diode is used to ensure
charging of battery even if charging indicator light is defective. See
Figs. 1 -9.
Fig. 1: Charging System Wiring Schematic (Colt, Mirage & Summit)
Courtesy of Mitsubishi Motor Sales of America.

terminal "B" and negative lead to positive battery terminal. Reconnect
negative battery cable.
3) Start engine. Turn accessories on and adjust engine speed
until ammeter indicates 20 amps, and note voltmeter reading. If
voltmeter indicates .2 volt or less, system is okay.
4) If voltage is greater than .2 volt, wiring is defective
between alternator terminal "B", fusible link and battery positive
terminal. Disconnect negative battery cable, and remove test
equipment.
ALTERNATOR OUTPUT TEST
NOTE: During alternator output test, a slightly discharged battery
should be used as a fully charged battery may not allow full
alternator output.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Disconnect alternator output wire from terminal "B".
Install positive lead of 100-amp ammeter to terminal "B" and negative
lead to disconnected output lead.
CAUTION: Tighten each connection securely as heavy current flow will
exist. DO NOT use clips on ammeter.
2) Connect positive voltmeter lead (0-20 volts) to alternato\
r
terminal "B" and negative lead to ground. Install tachometer, and
reconnect negative battery cable.
3) Ensure voltmeter indicates battery voltage. If no voltage
exists, an open circuit is present in wire between alternator terminal
"B" and battery negative terminal. Check grounds and fusible link.
4) Turn headlights on, and start engine. Set headlights at
high beam and heater switch on HIGH. Quickly accelerate engine speed
to 2500 RPM and note alternator output current registered on the
ammeter. Minimum output should be within specification. Refer to the
ALTERNATOR MINIMUM OUTPUT SPECIFICATIONS table.
NOTE: Output voltage changes with electrical load and temperature.
Ensure proper electrical load is applied while checking
output. Nominal output may not be obtained if alternator or
ambient temperature is excessive. Allow to cool, and recheck
output. Alternator output is stamped on metal plate attached
to alternator case.
5) If minimum output is not obtained and alternator wiring is
okay, repair alternator. Disconnect negative battery cable, and remove
test equipment.
REGULATED VOLTAGE TEST
NOTE: Ensure battery is fully charged and proper drive belt
tension exists.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Install a digital voltmeter between alternator terminal
"S" and ground. See Fig. 10. Connect positive voltmeter lead to
terminal "S" of alternator. Connect negative voltmeter lead to ground.
2) Disconnect alternator output wire from terminal "B".
Install a 100-amp ammeter in series to terminal "B" and disconnected
output lead. Install positive lead of ammeter to terminal "B" and
negative lead to disconnected output wire. Install a tachometer, and
reconnect negative battery cable.
3) Turn ignition switch to ON position and ensure voltmeter
indicates battery voltage. If no voltage exists, an open circuit

exists in wire between alternator terminal "S" and positive battery
terminal or fusible link is blown.
4) Start engine. Ensure all lights and accessories are off.
Operate engine at 2500 RPM and read voltmeter when alternator output
current drops to 10 amps or less. Voltage regulator is okay if voltage
output is within specification. See REGULATOR VOLTAGE SPECIFICATIONS
table.
BENCH TESTING
RECTIFIER ASSEMBLY
1) Using ohmmeter, check for continuity between both diodes
and stator coil lead connection. See Fig. 11. Reverse leads. If
continuity exists in both directions, diode is shorted. Replace
rectifier assembly.
2) To check entire diode assembly, use an ohmmeter to check
for continuity between both ends of each diode. See Fig. 11. Switch
ohmmeter leads. Continuity should exist in one direction, but not
other. If no continuity exists or continuity exists in both
directions, diode is defective. Replace rectifier assembly.
Fig. 11: Testing Rectifier Assembly
Courtesy of Mitsubishi Motor Sales of America.
ROTOR