1991 MITSUBISHI MONTERO check oil

HITACHI 5 & 6-CYL CLUTCH R & I
Removal
1) Using Clutch Holder (KV99412302), hold clutch hub. Remove\
shaft nut from shaft. Using Clutch Hub Remover (KV994C5780), remove
clutch hub.
2) Pry inner snap ring off. Remove pulley and bearing
assembly. If assembly cannot be removed by hand, use Pulley and
Bearing Removers (KV994C5781 and KV994C5782).
3) Remove clamping screws that secure coil assembly leads.
Remove inner snap ring from coil assembly. Remove coil assembly from
front cover. See Fig. 9.
Inspection
Check friction surfaces of clutch for damage due to excessive
heat, or excessive grooving due to slippage. Replace compressor
components as necessary. Oil or dirt on friction surfaces should be
cleaned with a solvent and a dry rag. Check coil for binding, shorted
or open leads.
Installation
1) Install coil assembly on compressor. Properly position
terminals. Using snap ring pliers, install snap ring. Using a plastic
mallet, drive pulley and bearing assembly onto neck of front cover.
Turn pulley, making sure that there is no noise and that rotation is
free. Ensure there is no pulley play.
2) Using snap ring pliers, install inner snap ring. Remove
all oil from clutch pulley. Fit key and clutch hub to shaft. Select
adjusting spacer which gives the correct clearance between pulley and
clutch hub.
3) Coat shaft nut with Loctite and install. Using a feeler
gauge, measure clutch hub-to-pulley clearance. Clearance should be .
020-.031" (.5-.8 mm). If specified clearance is not obtained, replace
adjusting spacer and readjust.
4) When replacing compressor clutch assembly, DO NOT forget
break-in operation. This is accomplished by engaging and disengaging
clutch 30 times.

Fig. 9: Hitachi 6-Cylinder Compressor (5-Cylinder Similar)
Courtesy of Nissan Motor Co., U.S.A.
HITACHI 5 & 6-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR REFRIGERANT OIL CHECKING article in this
section.
Removal
1) Drain oil from suction port, measure oil drained and
discard oil. Remove clutch hub, pulley, bearing assembly and coil
assembly. See HITACHI 5 & 6-CYLINDER CLUTCH R & I in this article.
2) Using snap ring pliers, remove retainer ring. Remove key
and plug low and high pressure openings of compressor with Plugs
(KV994C4531, KV994C4532 and KV994C4559).
3) Insert Adapter (KV994C1552) into hole in middle of blind

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).

electrical leads from field coil. Remove 3 field coil mounting bolts.
Remove field coil.
Inspection
Check friction surfaces for damage from excessive heat or
grooving caused by slippage. Replace parts as necessary. Check coil
winding for shorted or open winding. Clean surfaces with solvent and
dry rag.
Installation
To install, reverse removal procedure. Tighten field coil
retaining screws to 30-56 INCH lbs. (3.4-6.4 N.m). Ensure pulley-to-
armature gap is .016-.024" (.4-.6 mm). If gap is not as specified,
adjust by adding or removing shims. Tighten center bolt to
96-108 INCH lbs. (11-13 N.m). See Fig. 15.
Fig. 15: Exploded View of Rotary Vane Compressor (Panasonic)
Courtesy of Chrysler Motors.
PANASONIC ROTARY VANE SHAFT SEAL 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.

SANDEN 5-CYL CLUTCH R & I
Removal
1) Hold clutch hub stationary and remove shaft nut. Remove
clutch plate using puller. Remove external front housing snap ring and
internal bearing snap ring. See Fig. 16.
2) Install puller and pull rotor assembly off. remove 3
screws and clutch coil. Use driver and hammer to drive bearing out
from hub.
Installation
1) Install new bearing; ensure installer contacts outer race
of bearing. Install snap ring and ensure bearing turns freely. Install
clutch coil on compressor.
2) Support compressor on rear mounting ears. Align rotor on
front housing hub. Use adapter and press to install rotor (or drive
into place with soft mallet). After rotor is seated, install front
snap ring.
SANDEN 5-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
Removal
1) Hold clutch hub stationary and remove shaft nut with thin
wall socket. Use clutch plate puller to remove clutch plate. Tap key
out of slot in crankshaft.
2) Remove seal retainer with seal remover and 3/4" socket
wrench. Use seal seat remover tongs to pull seal seat off compressor
shaft. Insert seal remover into front housing and turn to engage tangs
on seal. Lift seal out. Remove seal "O" ring from front housing, being
careful not to scratch shaft.
Installation
1) Coat "O" ring with refrigerant oil and install into
groove. Load a new seal onto installer, being careful not to touch
carbon sealing surface with fingers. Install shaft protector. Dip seal
in refrigerant oil and install on shaft. Rotate seal clockwise until
seal fits into flats on shaft. Remove seal installer by turning
counterclockwise.
2) Coat seal seat with refrigerant oil and install with
tongs. Reinstall seal seat retainer (with flat side down). Install
shims and shaft key. Rotate shaft several times to help break in seal.
3) Use a press to install clutch plate. Make sure that air
gap is .016-.031" (.41-.79 mm). Hold plate stationary and install
shaft nut.

installation, ensure there is no contact between cover and front
housing.
3) Install clutch shims and clutch plate. Tighten shaft nut
to 12-14 ft. lbs. (17-19 N.m). Using a dial indicator, apply voltage
to clutch coil to check air gap between clutch plate and drive pulley
assembly. Ensure air gap is .016-.032" (.41-.80 mm).
SANDEN 7-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
Removal
1) Hold clutch hub stationary and remove shaft nut. Remove
clutch plate using Clutch Plate Puller (09977-21110). Tap shaft key
out of slot in compressor shaft. Remove clutch shims.
2) Remove seal retainer felt ring. Remove shaft seal seat
snap ring with snap ring pliers. Insert Seal Seat Remover/Installer
(09977-21400) into front housing and turn to engage tangs on seat.
Lift seal seat out.
3) Insert seal Remover/Installer (09977-21510) into front
housing and turn to engage tangs on seal. carefully lift seal seat out
without scratching compressor shaft.
Installation
1) Install Shaft Seal Guide Sleeve (09977-21700) over
compressor shaft. Dip seal in refrigerant oil and install seal on
sleeve. Using seal remover/installer, rotate seal clockwise until seal
is engaged. Remove seal remover/installer by turning it
counterclockwise.
2) Coat seal seat with refrigerant oil and install seal with
seal seat remover/installer. Remove shaft seal guide sleeve. Install
snap ring. Install seal retainer felt ring using seal seat
remover/installer. Install clutch shims and shaft key.
3) Install clutch plate. Tighten shaft nut to 12-14 ft. lbs.
(17-19 N.m). Using dial indicator, apply voltage to clutch coil to
check air gap between clutch plate and drive pulley assembly. Ensure
air gap is .016-.032" (.41-.80 mm).

Check blower switch and relay. Check A/C compressor clutch coil.
2) Ensure system is properly charged with correct amount of
refrigerant. Add refrigerant or evacuate and recharge system as
necessary. Ensure receiver-drier is not clogged. Check compressor belt
for proper tension. Check for clogged expansion valve. Check
compressor operation. Repair or replace compressor as necessary.
INSUFFICIENT AIRFLOW
Check for air leakage at air duct joint. Check for frost on
evaporator. Ensure blower motor is operating properly. Check for
obstructed air intake.
INSUFFICIENT COOLING
Ensure system is properly charged with correct amount of
refrigerant and free of air and moisture. Add refrigerant or evacuate
and recharge system as necessary. Ensure receiver-drier is not
clogged. Ensure sufficient airflow through condenser exists. Check
compressor belt for proper tension. Check compressor operation. Repair
or replace compressor as necessary. Check for clogged expansion valve.
Replace expansion valve as necessary.
INTERMITTENT COOL AIR
Check for air or moisture in system. Evacuate and recharge
system as necessary. Check for expansion valve malfunction. Replace
expansion valve if necessary. Check compressor belt for proper
tension.
TESTING
A/C SWITCH
1) Disconnect A/C switch harness connector. Using appropriate
wiring diagram as a guide, jumper appropriate terminals of A/C switch
wiring harness connector. See Fig. 4.
2) Turn blower on and momentarily turn ignition on without
starting engine. Listen for compressor clutch engagement. If
compressor clutch does not engage, check fuse and other components
wired in series with compressor clutch.
Fig. 4: A/C Switch Connector ID
Courtesy of Mitsubishi Motor Sales of America.
AIR THERMO & AIR INLET SENSORS