light MITSUBISHI MONTERO 1991 Service Manual

Fig. 8: Aligning Timing Marks (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Inspection (Montero & Pickup)
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for oil contamination, cracks, separation, worn or missing teeth
and hardened back surface. Replace belt if worn, damaged or
contaminated. Inspect belt tensioner for smooth rotation. Replace if
defective.
Installation (Montero & Pickup)
1) Install rear timing belt cover. Tighten bolts to
specification. See TORQUE SPECIFICATIONS (MONTERO & PICKUP) table at
end of article. Install camshaft sprockets (if removed). Using holder,\
hold camshaft and tighten retaining bolt to specification.
2) Install belt tensioner and spring. Ensure spring is
secured on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing from cylinder block.
3) Rotate belt tensioner counterclockwise as much as
possible, and temporarily tighten bolt. Align all timing marks with
No. 1 cylinder at TDC of compression stroke. See Fig. 8.
4) Install timing belt on crankshaft sprocket and then left
camshaft sprocket with all slack removed from tension side of belt.
Route timing belt onto water pump pulley, right camshaft sprocket and
tensioner. Remove any slack from belt by rotating left and then right
camshaft sprockets counterclockwise.
5) Ensure belt is installed in original direction of rotation
and all timing marks are aligned. Install flange on crankshaft. Loosen
belt tensioner bolts slightly, and allow tensioner to apply belt
tension.
6) Using Crankshaft Socket (MD998716), rotate crankshaft 2

Inspect belt tensioner for smooth rotation. Replace if defective.
Installation
1) Install rear timing belt cover. Tighten bolts to
specification. See TORQUE SPECIFICATIONS (3000GT) table at end of
article. Install camshaft sprockets (if removed). Using holder, hold
camshaft and tighten camshaft sprocket bolt to specification.
2) Install belt tensioner and spring. Ensure spring is
secured on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing from cylinder block.
3) Rotate belt tensioner counterclockwise as much as
possible, and temporarily tighten bolt. Align all timing marks with
No. 1 cylinder at TDC of compression stroke. See Fig. 8.
4) Install timing belt on crankshaft sprocket, rear cylinder
bank camshaft sprocket, water pump pulley, front cylinder bank
camshaft sprocket and timing belt tensioner. Ensure belt is installed
in original direction of rotation and all timing marks are aligned.
Install flange on crankshaft. Loosen belt tensioner bolts slightly,
and allow tensioner to apply belt tension.
5) Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise. Realign all
timing marks. Tighten belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS (3000GT) table. Using belt tension gauge,
measure belt tension halfway between crankshaft sprocket and camshaft
sprocket on side opposite belt tensioner.
6) Belt tension should be 46.3-63.3 lbs. (21-29 kg). To
install remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers and engine support bracket.
See Figs. 9 and 10. Tighten bolts to specification. See TORQUE
SPECIFICATIONS (3000GT) table.
NOTE: Engine support bracket reamer bolt must be tightened slowly
while spraying lubricant on bolt.
Fig. 11: Identifying Timing Belt Cover Bolt Length (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Removal (DOHC)
1) Remove lower splash shields. Remove cruise control

Oversize In. (mm) Size Mark Bore Size In. (mm)
.002 (.05) ............ 5 ... .4744-.4751 (12.050-12.068)
.010 (.25) ............ 25 .. .4823-.4830 (12.251-12.269)
.020 (.51) ............ 50 .. .4921-.4928 (12.500-12.518)









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VALVE SEAT (SOHC)
1) Valve seat sinkage should be checked after valve and valve
seat have been reconditioned and lightly lapped. With valve assembly
installed, measure installed height of valve spring between spring
seat and retainer. Valve seat must be replaced if measurement exceeds
1.63" (41.4 mm).
2) Grind seat wall thickness until seat can be removed.
Machine cylinder head to accommodate an oversize valve seat. See
OVERSIZE VALVE SEAT SPECIFICATIONS (SOHC) table. Heat cylinder head to\
approximately 480
F (250C), and install valve seat. Grind valve seat
using 45-degree stone. Use 30-degree and 60-degree stones to set seat
height.
OVERSIZE VALVE SEAT SPECIFICATIONS TABLE (SOHC)









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Application In. (mm)
Intake
Bore Depth
.012" (.3 mm) Oversize ............ .311-.319 (7.9-8.1)
.024" (.6 mm) Oversize ............ .323-.331 (8.2-8.4)
Bore Diameter
.012" (.3 mm) Oversize .. 1.7440-1.7451 (44.300-44.325)
.024" (.6 mm) Oversize .. 1.7559-1.7569 (44.600-44.625)
Exhaust
Bore Depth
.012" (.3 mm) Oversize ............ .311-.319 (7.9-8.1)
.024" (.6 mm) Oversize ............ .323-.331 (8.2-8.4)
Bore Diameter
.012" (.3 mm) Oversize .. 1.5079-1.5089 (38.300-38.325)
.024" (.6 mm) Oversize .. 1.5197-1.5207 (38.600-38.625)









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VALVE SEAT (DOHC)
Grind seat wall thickness until seat can be removed. Machine
cylinder head to accommodate an oversize valve seat. See OVERSIZE
VALVE SEAT SPECIFICATIONS (DOHC) table. Chill cylinder head with
liquid nitrogen, and install valve seat. Grind valve seat using 45-
degree stone. Use 30-degree and 60-degree stones to adjust seat
height.
OVERSIZE VALVE SEAT SPECIFICATIONS TABLE (DOHC)









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Application In. (mm)
Intake
Bore Depth
.012" (.3 mm) Oversize ............ .295-.303 (7.5-7.7)
.024" (.6 mm) Oversize ............ .307-.315 (7.8-8.0)
Bore Diameter
.012" (.3 mm) Oversize .. 1.4291-1.4301 (36.300-36.325)
.024" (.6 mm) Oversize .. 1.4409-1.4419 (36.600-36.625)
Exhaust
Bore Depth

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A/C C O M PR ESSO R O IL C HEC KIN G

1991 M it s u bis h i M onte ro
1991 GENERAL SERVICING
Compressor Refrigerant Oil Checking
ISOLATING COMPRESSOR
NOTE: Only compressors with stem-type service valves can be
isolated.
1) Connect service gauge set to the compressor service valves
and open compressor valves slightly (turn in clockwise). Start engine
and operate air conditioning. Slowly turn compressor suction valve
clockwise toward closed (front-seated) position.
2) When suction pressure is reduced to zero or less, turn off
engine and compressor and quickly turn suction valve stem in to full
front-seated position. Suction pressure should be slightly above zero.
Turn discharge valve into front-seated position.
3) To check oil level, slowly open compressor crankcase plug
to relieve any remaining pressure. After oil level is corrected, cap
service gauge ports on both valves. Back-seat suction service valve to
allow refrigerant to enter compressor. Open discharge valve halfway.
4) Loosen discharge service valve cap, allowing refrigerant
pressure to force air out of compressor. Back-seat service valve and
tighten cap. Compressor is now ready for operation.
REFRIGERANT OIL
Only new, pure, moisture-free refrigerant oil should be used
in the air conditioning system. This oil is highly refined and
dehydrated to a point where moisture content is less than 10 parts per
million. The oil container must be tightly closed at all times when
not in use, or moisture will be absorbed into the refrigerant oil from
the air.
SERVICING PRECAUTIONS
NOTE: Recent findings by the EPA indicate that refrigerant is
harmful to the earth's protective Ozone layer. When
discharging refrigerant, DO NOT allow refrigerant to enter
the atmosphere. If available, use refrigerant
recovery/recycle systems when discharging system. Always
follow manufacturer's instructions.
DISCHARGING SYSTEM PRECAUTIONS
If compressor has stem-type service valves, it can be
isolated and removed without discharging entire system. See ISOLATING
COMPRESSOR at the beginning of this article. Otherwise, discharge
system completely before loosening any fittings.
DISCONNECTING LINES & FITTINGS TEST
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when tightening or
loosening fittings to avoid twisting or distorting lines. Cap or plug
all openings as soon as lines are removed. DO NOT remove caps until
immediately before connections are made. This will keep entry of air

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A/C C O M PR ESSO R S ER VIC IN G

1991 M it s u bis h i M onte ro
1991 GENERAL SERVICING
Compressor Service
* 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.
ISOLATING COMPRESSOR
NOTE: Only compressors with stem-type service valves can be
isolated.
1) Connect service gauge set to the compressor service valves
and open compressor valves slightly (turn in clockwise). Start engine
and operate air conditioning. Slowly turn compressor suction valve
clockwise toward closed (front-seated) position.
2) When suction pressure is reduced to zero or less, turn off
engine and compressor and quickly turn suction valve stem in to full
front-seated position. Suction pressure should be slightly above zero.
Turn discharge valve into front-seated position.
3) To check oil level, slowly open compressor crankcase plug
to relieve any remaining pressure. After oil level is corrected, cap
service gauge ports on both valves. Back-seat suction service valve to
allow refrigerant to enter compressor. Open discharge valve halfway.
4) Loosen discharge service valve cap, allowing refrigerant
pressure to force air out of compressor. Back-seat service valve and
tighten cap. Compressor is now ready for operation.
REFRIGERANT OIL
Only new, pure, moisture-free refrigerant oil should be used
in the air conditioning system. This oil is highly refined and
dehydrated to a point where moisture content is less than 10 parts per
million. The oil container must be tightly closed at all times when
not in use, or moisture will be absorbed into the refrigerant oil from
the air.
DISCHARGING SYSTEM PRECAUTIONS
CAUTION: When discharging air conditioning system, use only approved
refrigerant recovery/recycling equipment. Make every attempt
to avoid discharging refrigerant into the atmosphere.
If compressor has stem-type service valves, it can be
isolated and removed without discharging entire system. Otherwise,
discharge system completely using approved refrigerant
recovery/recycling equipment before loosening any fittings.
DISCONNECTING LINES & FITTINGS TEST
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when tightening or
loosening fittings to avoid twisting or distorting lines. Cap or plug
all openings as soon as lines are removed. Do not remove caps until

Removal
1) Hold clutch plate and remove shaft nut. Using Clutch Plate
Remover (64 5 00), remove clutch plate. Using snap ring pliers, remove\
circlip and remove pulley assembly.
2) If pulley bearing is being replaced, remove circlip at
rear of pulley. Press bearing and spacer from pulley. Press in new
bearing with spacer and replace circlip.
Installation
1) Clean all surfaces. Install pulley assembly on compressor
and install circlip. Ensure clutch plate shim is in place on shaft.
Install clutch plate and nut. Tighten nut to 13-14 ft. lbs. (18-20 N.
m).
2) Using a feeler gauge, check clutch plate-to-pulley
clearance. Clearance should be .028-.051" (.7-1.3 mm). If clearance is\
not correct, remove clutch plate and replace clutch plate shim. See
Fig. 2 .
BOSCH 6-CYL SHAFT SEAL R & I
Removal & Installation
1) Remove clutch plate. Remove shaft key and circlip. Using
Seal Seat Remover/Installer (64 5 030), remove seal seat.
2) Using Seal Remover/Installer (64 5 040), remove shaft sea\
l
by turning seal slightly clockwise to disengage tangs and pull out
shaft seal. Remove "O" ring seal.
3) Coat new "O" ring seal with refrigerant oil and install.
Coat new shaft seal with refrigerant oil and install shaft seal on
Seal Remover/Installer (64 5 040). Ensure alignment of shaft seal and
shaft machine surfaces. Insert shaft seal and turn slightly
counterclockwise to secure on shaft.
4) Using sleeve from Seal Seat Remover/Installer (64 5 030),\
push seal seat into compressor and install circlip. Install shaft key
and clutch plate. Check compressor oil level before charging system.
Fig. 2: Bosch 6-Cylinder Compressor Clutch
Courtesy of BMW of North America, Inc.
CALSONIC V5 CLUTCH R & I

Removal
1) Clamp Holding Fixture (J-25008-A) in a vise and attach
compressor to holding fixture with thumb screws. Use Clutch Hub Holder
(J-33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-\
9399).
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with a wrench and turn center screw
into remover body to remove clutch plate and hub assembly. Remove
shaft key and retain for assembly. See Fig. 5.
NOTE: DO NOT drive or pound on clutch hub or shaft.
Installation
1) Install shaft key into hub key groove. Allow key to
project approximately 1/8" out of key way. Shaft key is curved
slightly to provide an interference fit in hub key groove.
2) Ensure frictional surface of clutch plate and clutch rotor
are clean before installing clutch plate and hub assembly. Align shaft
key with shaft key way and place clutch plate and hub assembly onto
compressor shaft.
3) Hold hex portion of Installer (J-9480-B) with a wrench.
Tighten center screw to press hub into shaft until there is .020-.040"
(.5-1.0 mm) air gap between frictional plate and clutch rotor.
4) Install new shaft nut with small diameter boss of nut
against crankshaft shoulder. Use Thin Wall Socket (J-9399) and Clutch
Hub Holder (J-25030). Tighten shaft nut to 10 ft. lbs. (14 N.m). Spi\
n
pulley rotor by hand to ensure rotor is not rubbing on clutch drive
plate.
HARRISON R4 4-CYL SHAFT SEAL R & I
Removal
1) Clamp Holding Fixture (J-25008-A) in a vise and attach
compressor to holding fixture with thumb screws. Use Clutch Hub Holder
(J-33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-\
9399).
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with a wrench and turn center screw
into remover body to remove clutch plate and hub assembly. Remove
clutch plate and shaft key. Pry out dust seal (if equipped). Remove
seal seat snap ring. Thoroughly clean compressor neck area and "O"
ring groove surrounding shaft. Any dirt or foreign material may cause
compressor damage.
3) Use Seal Remover/Installer (J23128-A), remove seal with a\
twisting motion. Use "O" Ring Remover (J-9553-01) to remove "O" ring.
Installation
1) Coat new shaft seal with refrigerant oil and install shaft
seal on remover/installer. Align compressor shaft machined surface
with shaft seal and install. Turn remover/installer slightly
counterclockwise to secure shaft seal tangs.
2) Using Seal Installer (J-33011), install "O" ring and coat\
with refrigerant oil. Coat seal seat with refrigerant oil and install
using seal seat remover/installer. Install snap ring. Install dust
seal (if supplied in seal kit). See Fig. 7.

Fig. 7: Harrison R-4 Radial Compressor
Courtesy of Isuzu Motor Co.
HARRISON V5 5-CYLINDER CLUTCH R & I
Removal
1) Clamp Holding Fixture (J-34992) in vise and attach
compressor to holding fixture with thumb screws. Use Clutch Hub Holder
(J-33027) to hold clutch. Remove shaft nut using Shaft Nut Socket
(J-33022).
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with a wrench and turn center screw
into remover body to remove clutch plate and hub assembly. Remove
shaft key and retain for installation.
Installation
1) Install shaft key into hub key groove. Allow key to
project approximately 1/8" (3.2 mm) out of key way. Shaft key is
curved slightly to provide an interference fit in hub key groove.
2) Ensure frictional surface of clutch plate and clutch rotor
are clean before installing clutch plate and hub assembly. Align shaft
key with shaft key way and place clutch plate and hub assembly onto
compressor shaft.
NOTE: DO NOT drive or pound on clutch hub or compressor shaft,
as compressor could be damaged internally.
3) Hold hex portion of installer (J-33013) with a wrench.
Tighten center screw to press hub into shaft until there is .015-.025"
(.38-.64 mm) air gap between frictional plate and clutch rotor.
4) Install new shaft nut with a small diameter boss of nut

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.