oil MITSUBISHI MONTERO 1991 Owner's Guide

When inspecting system for oil loss, look for signs of
leaking (shiny, wet spots on components or underside of hood). If oil
leak is noted or component replacement is required, use the following
procedure as indicated:
NO OIL LEAK
Discharge system and change components as necessary. See
SERVICING PRECAUTIONS at the beginning of this article. Add
refrigerant oil to components as necessary.
OIL LEAK
1) Slowly discharge system. Repair or replace faulty
components. If equipped with a drain plug, remove plug, drain and
discard oil. If not equipped with a drain plug, remove compressor from
vehicle and pour oil out suction and discharge ports.
2) Replace drain plug (if equipped). Add 1.5 ounces of new
refrigerant oil through suction port. Use new gaskets or "O" rings
when replacing suction and discharge lines.
COMPRESSOR FAILURE OR SYSTEM CONTAMINATED
If either situation exists, discharge system and remove
compressor, receiver-drier and expansion valve. Clean expansion valve
screen. Flush entire system. Install new compressor and receiver-
drier. New compressors contain correct amount of oil. If installing
overhauled compressor, add 1.5 ounces of new refrigerant oil through
suction port.
PANASONIC ROTARY VANE DRAIN & REFILL
1) Before checking and adjusting oil level, operate
compressor at 1000-1500 engine RPM, and set controls at maximum
cooling and high blowing speed for about 10 minutes to return oil to
compressor.
2) Stop engine. Discharge refrigerant and remove compressor
from vehicle. See SERVICING PRECAUTIONS at the beginning of this
article. Drain oil from compressor through suction and discharge
ports. Measure amount of oil drained. If amount drained is more than
2.4 ounces, fill with same amount using new oil. If amount drained is
less than 2.4 ounces, fill with 2.4 ounces. Install compressor and
recharge.
3) If A/C components are replaced, add refrigerant oil to
system. Add 1.4 ounces if condenser is replaced. Add 2 ounces if the
evaporator is replaced. Oil does not need to be added if receiver-
drier is replaced.
SANDEN SCROLL DRAIN & REFILL
Discharge system. Remove compressor from vehicle. Drain oil
from compressor through inlet and outlet holes. Refill compressor with
2.8 ounces of oil through suction port. When replacing condenser, add
.5 ounce. When replacing evaporator, add 1.7 ounces. When replacing
other A/C components, add .5 ounce per component replaced.
SANDEN 5-CYL DRAIN & REFILL
1) Discharge system. Remove compressor belt and loosen

mounting bolts. Rotate compressor in brackets until filler plug is at
top. Clean area around filler plug and remove plug slowly. Rotate
front hub plate so notch in lobe is 110 degrees from the bottom. This
rotates ball end of top piston to align with oil fill port and allows
clearance for dipstick. See Fig. 1.
2) Insert compressor dipstick diagonally from right to left
until stop on dipstick contacts filler plug surface. Remove dipstick
and note oil fill level. Each increment on dipstick represents one
ounce of oil. Add oil if necessary to reach 3-4 ounce level.
Fig. 1: Sanden 5-Cylinder Oil Level Checking
Courtesy of Sanden International U.S.A, Inc.
SANDEN 7-CYL DRAIN & REFILL
1) Before checking and adjusting oil level, operate
compressor at engine idle speed, and set controls at maximum cooling
and high blowing speed for 20-30 minutes to return oil to compressor.
2) Stop engine. Discharge refrigerant and remove compressor
from vehicle. See SERVICING PRECAUTIONS at the beginning of this
article. Remove oil drain plug and drain oil. Measure amount of oil
drained. Install drain plug with new "O" ring.
3) If amount drained is more than 3 ounces, fill with same
amount using new oil. If amount drained is less than 3 ounces, fill
with 3 ounces. Install filler plug. Install compressor and recharge
system.

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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

immediately before connections are made. This will keep entry of air
and moisture to a minimum.
CONNECTING LINES AND FITTINGS
A new gasket or "O" ring should be used in all instances when
connecting lines or fittings. Dip "O" ring in new refrigerant oil and
ensure it is not twisted during installation. Always use 2 wrenches to
prevent damage to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and
all connections have been made, evacuate system thoroughly with a
vacuum pump. Charge system with proper amount of refrigerant and
perform a leak test. See REFRIGERANT OIL & R-12 SPECIFICATIONS chart
in this section for system capacities. Be sure to check all fittings
that have been opened. After system has been leak tested, make a
system performance check.
NOTE: Air conditioning systems will not normally need addition of
refrigerant oil unless definite oil loss has occurred due to
ruptured lines, leaking compressor seals, compressor
overhaul or component replacement.
ATSUGI ROTARY VANE CLUTCH R & I
Removal
When replacing compressor clutch, be careful not to scratch
shaft or bend pulley. When removing center bolt, hold clutch disc with
Clutch Holder (KV99231010). Using Hub Puller (KV998VR001 &
KV99231010), remove clutch disc. When removing pulley, remove lock nut
with Hub Socket (KV99235160).
Installation
Wipe oil off clutch surface. Adjust disc pulley clearance to
.012-.024" (.3-.6 mm). Tighten center bolt to 80-104 INCH lbs. (9.1-
11.8 N.m). Tighten clutch lock nut to 22-29 ft. lbs. (29-39 N.m). See\
Fig. 1 .
Fig. 1: Atsugi Rotary Vane Compressor
Courtesy of Nissan Motor Co., U.S.A.
BOSCH 6-CYL CLUTCH R & I

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) Remove shaft nut while holding armature plate with clutch
disk wrench. Install clutch disk puller and remove clutch plate.
Remove snap ring from center of clutch pulley.
2) Use a universal gear puller to remove clutch pulley. See
Fig. 3 .Remove screw securing clutch coil ground lead. Use puller to
remove clutch coil.
Installation
1) To install clutch coil, reverse removal procedure.
Carefully press clutch coil into place. Ensure that coil lead and
connector are positioned on same side as removed coil.
2) Install a NEW clutch pulley snap ring, being careful not
to damage shaft seal. Press clutch plate into place. Install shaft nut
and torque to 0.9-1.4 INCH lbs. (0.10-.12 N.m).
3) Use a feeler gauge to check clutch plate-to-pulley
clearance. Clearance should be .012-.024" (0.3-0.6 mm). If clearance
is too large, remove shaft nut and again press in clutch plate. If
clearance is too small, increase gap by pulling up clutch plate. Do
not remove shaft nut.
Fig. 3: Explode View of Compressor Clutch (Calsonic V5)
Courtesy of Nissan Motor Co. U.S.A.
DIESEL KIKI ROTARY VANE CLUTCH R & I

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.

Removal & Installation
1) Remove clutch coil assembly. Remove retainer and felt.
Discard retainer and felt. Using internal snap ring pliers, remove
seal seat snap ring. Remove seal seat and discard. Using a seal pick,
remove "O" ring from inside groove of shaft seal housing. Discard "O"
ring.
2) To remove shaft seal, push down and turn clockwise on seal
remover to engage tangs. Slowly draw seal from bore. Discard seal.
Check shaft and inside of compressor neck for dirt or foreign material
and ensure these areas are perfectly clean before installing new seal.
3) To install, reverse removal procedure. Coat "O" ring,
shaft seal, and seal seat with new refrigerant oil.
Fig. 5: Diesel Kiki 6-Cylinder Compressor
Courtesy of Mitsubishi Motor Sales of America.
FORD FX-15 CLUTCH R & I
Removal
1) Using Clutch Holder (00 41 0812 05), remove clutch plate
retaining bolt and discard. Using an 8 mm bolt threaded into clutch
plate, remove clutch plate and shim(s). See Fig. 6.
2) Remove snap ring and pulley assembly. Install Shaft
Protector (49 UN01 47) over shaft seal opening. Use a 2-jaw puller to
remove clutch coil from compressor.
Installation
1) Ensure clutch coil mounting surface is clean. Use Coil

Installer (49 UN01 046) and 2-jaw puller engaged to rear side of
compressor front mounts to press coil into place.
2) Install pulley assembly. Install pulley assembly snap ring
with bevel side of snap ring facing out. Install shim(s) and clutch
plate. Install a NEW clutch plate retaining bolt and tighten to
96-120 INCH lbs. (11-14 N.m).
3) Use a feeler gauge to check clearance between clutch plate
and pulley assembly. Clearance should be .018-.033" (.46-.84 mm). If
clearance is incorrect, add or remove shims as necessary.
FORD FX-15 SHAFT SEAL R & I
Removal
1) Using Clutch Holder (000 41 0812 05), remove clutch plate\
retaining bolt and discard. Using an 8 mm bolt threaded into clutch
plate, remove clutch plate and shim(s). See Fig. 6.
2) Remove shaft felt seal. Thoroughly clean seal area of
compressor. Remove shaft seal retaining snap ring. Position Shaft Seal
Remover (49 UN01 044) over compressor shaft.
3) Push shaft seal remover downward against seal. Ensure end
of shaft seal remover is engaged with inside of seal. Rotate shaft
seal remover clockwise to expand remover tip inside seal. Pull shaft
seal from compressor.
Installation
1) Lubricate shaft seal protector and shaft seal with
refrigerant oil. Install shaft seal on shaft seal protector so lip
seal is toward compressor (large end of shaft seal protector).
2) Install shaft seal protector on compressor shaft. Using
shaft seal installer (49 UN01 043), push shaft seal down seal
protector until seal is seated.
3) Remove shaft seal installer and protector. Install a NEW
shaft seal retaining snap ring and shaft seal felt. Install shim(s)
and clutch plate. Install a NEW clutch plate retaining bolt and
tighten to 91-120 INCH lbs. (11-14 N.m).
4) Use a feeler gauge to check clearance between clutch plate
and pulley assembly. Clearance should be .018-.033" (.46-.84 mm). If
clearance is incorrect, add or remove shims as necessary.
Fig. 6: Exploded View of Compressor Clutch (Ford FX-15)
Courtesy of Mazda Motors Corp.
HARRISON R4 4-CYL 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.