1991 MITSUBISHI MONTERO lock

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).

HIGH PRESSURE SWITCH
The high pressure switch, installed in refrigerant line, is
wired in series with compressor clutch. When refrigerant pressures
rise above switch control pressure point, power to compressor clutch
is cut. The high pressure switch may also be activated when airflow
through condenser is blocked or when system is overcharged.
HIGH/LOW PRESSURE CUT-OFF SWITCH
The High/Low Pressure Cut-Off (HLPCO) switch, located on
refrigerant line, is wired in series with compressor clutch. Switch
cuts off power to compressor clutch when refrigerant pressures are
above or below switch control point. When pressure returns to normal
operating range, compressor clutch operation resumes.
LOW PRESSURE SWITCH
The low pressure switch, located in receiver-drier, is wired
in series with compressor clutch. When refrigerant pressure drops
below switch control point (usually due to leak in system), power to
compressor clutch is cut.
REFRIGERANT TEMPERATURE SWITCH
The refrigerant temperature switch, located on rear of
compressor, detects refrigerant temperature discharged from
compressor. A/C Control Unit (ACCU) uses this information to control
compressor clutch cycling.
ADJUSTMENTS
NOTE: For adjustment procedures not covered in this article, see
appropriate HEATER SYSTEM article in the AIR CONDITIONING &
HEAT Section.
MODE CONTROL CABLE
Montero
Move mode selector lever to far left (DEF) position. Move
mode door lever upward in direction indicated by arrow. See Fig. 2.
Connect inner wire to lever, and secure outer housing using clip.
Operate mode control knob to ensure proper operation.
Fig. 2: Adjusting Mode Selection Cable (Montero)
Courtesy of Mitsubishi Motor Sales of America.
TEMPERATURE CONTROL CABLE

HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards

Application incorrect,
affecting air
conditioning
system performance ..... A .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bent, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Blocked, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Broken, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Cracked, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Loose, affecting air
conditioning system
performance ............ A ................. Require repair.
Loose, not affecting air
conditioning system
performance ............ 2 ................. Suggest repair.
Missing, affecting air
conditioning system
performance ............ C ............ Require replacement.









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AIR DISTRIBUTION SYSTEM
See PLENUMS.
BELTS
BELT INSPECTION








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Condition Code Procedure
Alignment incorrect ..... B .......... ( 1) Further inspection
required.
Cracked ................. 1 ............ Suggest replacement.
Frayed .................. 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Plies separated ......... A ............ Require replacement.
Serpentine belt routed
incorrectly ............ B ................. Require repair.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Worn beyond
adjustment range ....... B ............ Require replacement.

SERVICE PORT INSPECTION








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Condition Code Procedure
Application
does not match
refrigerant type ....... B ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Valve cap leaking ....... A ... Require repair or replacement
of cap.
Valve cap missing ....... C .... Require replacement of valve
cap.
Valve core sticking ..... B .. Require repair or replacement.









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SPRING LOCK COUPLINGS
SPRING LOCK COUPLING INSPECTION








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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.









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SUCTION THROTTLING VALVES (STVS)
SUCTION THROTTLING VALVE (STV) INSPECTION








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Condition Code Procedure
Connection damaged ...... B .. Require repair or replacement.
Fitting damaged ......... B .. Require repair or replacement.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.









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SWITCHES (ELECTRICAL)
SWITCH (ELECTRICAL) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.

area. Always wear eye protection when working around air conditioning
systems and R-12. The system's high pressure can cause severe injury
to eyes and skin if a hose were to burst. R-12 evaporates quickly
when exposed to atmosphere, freezing anything it contacts.
2) Use care when handling refrigerant containers. DO NOT drop
or strike containers or expose refrigerant containers to excessive
heat. Containers must never be heated more than 125
F (52C). Never
expose R-12 directly to open flame.
CAUTION: When R-12 is exposed to an open flame, drawn into a running
engine, or detected with a Halide (propane) leak tester,
poisonous phosgene gas is formed. Keep work areas ventilated
and avoid running engines near work area.
USING INDIVIDUAL R-12 CANS
Disposable refrigerant cans (referred to as one pound cans)
have a flat type seal or a screw type seal, and proper can tap must be
used for each type. Be sure sealing gasket on can tap is in good
condition. A proper safety can tap will prevent refrigerant from
flowing back into open can, as tap has a one-way flow control.
NOTE: Recent findings by the EPA indicate that refrigerant is
harmful to the Earth's protective Ozone layer. When
discharging refrigerant avoid allowing refrigerant to enter
the atmosphere. Refrigerant recovery system should be used
when discharging the system.
MULTI-CAN DISPENSING VALVES
A multi-can dispensing valve allows attachment of several
cans of refrigerant, and is a good substitute when a bulk container is
not available. Cans are installed onto each leg of multi-can
dispensing valve in the same manner as the individual cans, and each
leg has its own can tap.
CAN TAP INSTALLATION FLAT TYPE SEAL CANS
On cam-lock or one-piece can taps, first turn the handle
outward to the fully open position. Securely engage locking lugs over
the can flange, and lock them in place by turning cam lock or locking
nut. Screw tap assembly into adapter so sealing gasket is fully seated
against the can top. Turn tap inward to pierce the can and close the
tap. DO NOT open tap until ready to purge the service hose or dispense
refrigerant into the system.
On 2-piece can taps, be certain tap handle is turned fully
inward to the closed position. Check that locking base is turned to
its outer limit. Securely engage locking lugs over the can flange.
Turn entire tap assembly (without disturbing the closed setting)
downward into the locking base to pierce the can. DO NOT open tap
until ready to dispense into system.
SCREW TYPE SEAL CANS
Ensure can tap is fully closed. Screw refrigerant can into
can tap fitting until tight. This will pierce the can. Connect tap to
center hose on manifold gauge set. DO NOT open tap until ready to
dispense R-12 into system.
WARNING: DO NOT open high side hand valve while air conditioning

system is in operation. This high pressure could rupture can
or fitting at safety can valve, resulting in damage and
personal injury.
CONNECTING LINES & FITTINGS
A new "O" ring should be used in all instances when
connecting lines and fittings (dip "O" ring in clean refrigeration oil
and make certain it is not twisted during installation). Always use
two wrenches to avoid twisting or distorting lines and fittings,
tighten coupling nuts securely.
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been
completed and all connections have been made, proceed as follows:
1) Evacuate the system using a vacuum pump.
2) Charge the system with new R-12 (refrigerant) according t\
o
each individual vehicle as outlined in the
GENERAL COOLING SYSTEM SERVICING article. Also see Refrigerant
Capacity in this Section.
3) Leak test the system, with particular attention to all new
connections and components.
4) Make a performance test of the system. Never assume that a
recharging has automatically corrected a problem.
COMPRESSOR REMOVAL INFORMATION - ISOLATION METHOD
On systems which have compressors equipped with stem-type
service valves (Tecumseh), it is possible to isolate the compressor
for removal.
Isolating
Turn both high and low pressure manual valves to extreme
clockwise (front seat) position. Loosen cap on high pressure manual
valve connection to compressor and allow gas to escape until
compressor is relieved of pressure.
COMPRESSOR REMOVAL INFORMATION - DISCHARGE METHOD
This procedure is to be used on vehicles which have
compressor equipped with Schrader service valves. In these cases, the
compressor cannot be isolated and the system must be discharged, using
approved refrigerant recovery/recycling equipment, prior to compressor
removal.