1991 MITSUBISHI MONTERO Service Manual

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).

Fig. 14: Nippondenso 6-Cylinder Compressor
Courtesy of Chrysler Motors.
PANASONIC ROTARY VANE CLUTCH R & I
Removal
1) Insert two 5 mm bolts into threaded holes in armature.
Using screwdriver as a lever in between bolts, remove center bolt.
Remove armature and shims from shaft.
2) remove snap ring. Using puller, remove pulley. Disconnect

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

Removal & Installation
Remove clutch and coil. Remove seal plate snap ring. Using
seal plate remover, engage seal and remove seal plate. Using seal
remover, engage seal ears and remove seal. See Fig. 16. To install,
reverse removal procedure. Coat new seal plate and seal with clean
refrigerant oil before installing. DO NOT touch seal surfaces with
fingers.
Fig. 16: Removing Rotary Vane Compressor Shaft Seal (Panasonic)
Courtesy of Chrysler Motors.
SANDEN SCROLL CLUTCH & 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.

Fig. 18: Sanden 5-Cylinder Compressor
Courtesy of Chrysler Motors.
SANDEN 7-CYL CLUTCH COIL & BEARING R & I
Removal
1) Hold clutch hub stationary and remove shaft nut. Remove
clutch plate using Clutch Plate Puller (09977-21110). Remove clutch
shims and bearing dust cover. Remove external front housing snap ring.
2) Install puller, and pull drive pulley assembly off. Detach
clutch coil lead from compressor housing. Remove clutch coil snap ring
and clutch coil. If necessary, invert drive pulley assembly and remove
snap ring and bearing.
Installation
1) Ensure clutch coil protrusion aligns with hole in
compressor housing, and install clutch coil snap ring. Install drive
pulley assembly using Drive Pulley Installer (09977-21811).
2) install external bearing snap ring. Using Seal Installer
(09977-21800), install bearing dust cover. After dust cover

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).