1991 MITSUBISHI MONTERO break

Removal
1) Using Clutch Holder (KV99231010), hold clutch disc. Remov\
e
center bolt retaining clutch assembly to shaft. Thread Hub Remover
(KV99232232) into bore of clutch hub. Hold hub remover with wrench and\
thread center bolt inward until clutch disc is removed.
2) Remove clutch disc, collar and adjusting shims. Remove
snap ring and plate. Remove pulley and bearing assembly. If assembly
cannot be removed by hand, use a puller and adapter.
3) Be careful not to scratch shaft or bend pulley. Using an
impact driver, loosen 6 coil mounting screws. Remove key and clutch
coil. See Fig. 4.
Installation
1) Install key. Position coil assembly on compressor body. Be
sure that electrical terminals are installed in original position.
Install and tighten coil mounting screws to 35-52 INCH lbs. (4-6 N.m).\
2) Press pulley assembly onto neck of coil assembly using
Pulley Installer (KV99234160). Wipe oil thoroughly off clutch surface.\
Select adjusting shims which give correct clearance between pulley and
clutch disc.
3) Using a plastic mallet, tap clutch disc in place on drive
shaft. Do not use excessive force with plastic mallet or press. Place
spring washer and center bolt onto drive shaft. Tighten center bolt to
drive clutch wheel onto drive shaft. Tighten center bolt to 11-13 ft.
lbs. (15-18 N.m).
4) Hold clutch with Clutch Holder (KV99231010). Check
clearance around entire outer edge of clutch disc. Clearance should be
.012-.024" (.3-.6 mm). If specified clearance is not obtained, replace\
adjusting shims as required.
5) When replacing compressor clutch assembly, break-in
procedure must be performed. This is accomplished by engaging and
disengaging clutch 30 times.
DIESEL KIKI 6-CYL CLUTCH COIL R & I
Removal & Installation
Using clutch holder to prevent clutch disc rotation, remove
bolt. Using clutch holder and puller, remove clutch disc. Remove shims
from compressor drive shaft or clutch disc. Remove snap ring with
external snap ring pliers and then remove pulley. Using a gear puller,
remove pulley. Remove coil lead wire and 6 screws. Remove coil. To
install, reverse removal procedure. Adjust clutch disc-to-pulley
clearance to .010-.020" (.3-.6 mm). See Fig. 4.

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.

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.

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* A /C -H EA TE R S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES

Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ (2) Require replacement.
Insulation overheated ... A ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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BLOWER SWITCHES
See SWITCHES.
CABIN AIR FILTERS
CABIN AIR FILTER INSPECTION








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Condition Code Procedure
Air flow obstruction .... A ............. Require cleaning or
replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.









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CIRCUIT BREAKERS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSOR CLUTCH ASSEMBLY INSPECTION








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Condition Code Procedure
Air gap incorrect ....... B .. Require repair or replacement.
Bearing seized .......... A .. Require replacement of bearing
or assembly.
Bearing worn, affecting
performance ............ A .. Require replacement of bearing
or assembly.
Coil shows signs of
overheating ............ 1 .... Suggest replacement of coil.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,

(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted internally ... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.









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EXPANSION VALVES
EXPANSION VALVE INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require 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.
Corroded internally ..... 1 ............ Suggest replacement.
Filter screen torn ...... A .. Require replacement of screen.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Expansion valve operation may be affected by capillary
tube location, corrosion, and insulation tape.
Inoperative includes intermittent operation.









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FUNCTION SELECTORS
See CONTROL HEADS (FUNCTION SELECTORS) .
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Blown ................... A ........ ( 1) Require replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Inoperative ............. A ... ( 2) Require replacement.
Insulation damaged,

conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... (1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to replacement
of part.
( 2) - Inoperative includes intermittent operation.









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FUSIBLE LINKS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
GASKETS
GASKET 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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HEATER CASES
See PLENUMS.
HEATER CONTROL VALVES
HEATER CONTROL VALVE INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require 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

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F - B ASIC T E STIN G

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Basic Diagnostic Procedures
Chrysler; Colt, Colt 200, Colt Vista, Ram-50, Stealth,
Summit
Mitsubishi; Eclipse, Galant, Mirage, Montero, Pickup, 3000GT
INTRODUCTION
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no start
condition. First step in diagnosing any driveability problem is
verifying customer's complaint with a test drive under conditions
problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns, poor electrical connections or
damaged/misrouted vacuum hoses. Before condemning computerized system,
perform each test listed in article.
NOTE: Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM)\
with a minimum 10-megohm input impedance, unless stated
otherwise in test procedure.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Visually inspect all electrical wiring, looking for chafed,
stretched, cut or pinched wiring. Ensure electrical connectors fit
tightly and are not corroded. Ensure distributor cap and rotor are
free of cracks, carbon trails or contamination. Ensure vacuum hoses
are properly routed and not pinched or cut. See M - VACUUM DIAGRAMS
article in the ENGINE PERFORMANCE Section to verify routing and
connections (if necessary). Inspect air induction system for possible
vacuum leaks.
MECHANICAL INSPECTION
Compression
Check engine mechanical condition with a compression gauge,
vacuum gauge, or an engine analyzer. See engine analyzer manual for
specific instructions.
WARNING: DO NOT use ignition switch during compression tests. Use a
remote starter to crank engine. Fuel injectors on many models
are triggered by ignition switch during cranking mode, which
can create a fire hazard or contaminate engine's oiling
system.
COMPRESSION SPECIFICATIONS TABLE (1)









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Application Specification
psi (kg/cm)
1.5L (VIN X) .............................. 137 (9.6)
1.6L (VIN Y) ............................. 171 (12.0)
1.8L (VIN T) .............................. 131 (9.2)