clutch MITSUBISHI MONTERO 1991 Service Manual

* Wrap shop towels around fuel return and high pressure hoses
to prevent fuel splashing on engine. Disconnect fuel return
hose and high pressure fuel hose to drain any residual fuel.
ENGINE
Removal (Montero & Pickup)
1) Remove hood. Drain cooling system, and remove radiator.
Remove skid plate and splash shields. Release fuel system pressure.
See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect
negative battery cable.
2) Remove air cleaner ducts. Remove accessory drive belts.
Remove and support A/C compressor and power steering pump. DO NOT
disconnect hoses from compressor or pump. Disconnect oil cooler hoses.
Cover fuel hose using shop towel, and disconnect high pressure fuel
hose and "O" ring. Remove fuel return hose.
3) Label and disconnect all vacuum hoses. Disconnect cooling
system hoses. Label and disconnect all electrical connections from
engine. Remove heat shield from motor mounts. Remove motor mount
bolts. Ensure all hoses and wires are disconnected and set aside.
4) Disconnect exhaust pipe from exhaust manifolds. Remove
starter. Attach engine hoist to engine. Support transmission.
Disconnect engine from transmission. See appropriate article in
CLUTCHES or TRANSMISSION SERVICING. Remove engine.
Installation (Montero & Pickup)
To install, reverse removal procedure. Install new "O" ring
on fuel line. Install new exhaust gaskets and nuts. See TORQUE
SPECIFICATIONS (MONTERO & PICKUP) table at end of article. Adjust
fluid levels.
Removal (3000GT)
1) Release fuel pressure. See FUEL PRESSURE RELEASE under
REMOVAL & INSTALLATION. Remove hood. Remove cruise control vacuum pump
and linkage. On turbo models, remove necessary turbo air intake hoses
and pipes. On all other models, remove air cleaner hoses.
2) On all models, drain cooling system. Drain engine oil and
transaxle oil. Remove heater hoses and radiator hoses. Remove
transaxle assembly. See appropriate article in CLUTCHES or
TRANSMISSION SERVICING.
3) Remove radiator. Label and disconnect all vacuum hoses.
Label and disconnect all electrical connections and harnesses from
engine. Remove accessory drive belts.
4) Remove and support A/C compressor and power steering pump.
DO NOT disconnect hoses from compressor or pump. Cover fuel hose using
shop towel, and disconnect high pressure fuel hose and "O" ring.
Remove fuel return hose.
5) On turbo models, disconnect oil cooler and vacuum hoses.
On all models, remove motor mount bolts and brackets. Ensure all hoses
and wires are disconnected and set aside. Attach engine hoist to
engine. Remove engine.
Installation
To install, reverse removal procedure. Install new "O" ring
on fuel line. Install new exhaust gaskets and nuts. See TORQUE
SPECIFICATIONS (3000GT) table at end of article. Adjust fluid levels.
UPPER INTAKE MANIFOLD
Removal (Montero & Pickup)
1) Remove air intake hose. See Fig. 1. Remove accelerator
cable adjusting bolts. On models equipped with automatic transmission,
remove throttle control cable. On all models, remove accelerator

install, reverse removal procedure using new gaskets and "O" rings.
Coat "O" ring with fuel before installation.
2) Install lower intake manifold gasket with adhesive side
toward intake manifold and gasket protrusions facing outboard of
engine. Tighten bolts and nuts to specification. See appropriate
TORQUE SPECIFICATIONS table at end of article. Check for fuel leaks.
TURBOCHARGER
Removal (Front)
1) Drain coolant, and remove radiator. Disconnect exhaust
pipe from turbo. Remove all air intake pipes. Note match marks and
installation depth on air pipes and hoses for reinstallation. Remove
serpentine drive belt. Remove alternator. Remove A/C compressor and
bracket, and support aside.
2) Remove O2 sensor. Remove dipstick assembly and turbo heat
shield. Disconnect turbo coolant feed and return lines. Disconnect
turbo oil feed and return lines. Remove turbocharger assembly.
Removal (Rear)
1) Drain coolant. Remove battery. Disconnect accelerator
cable at bracket and throttle body. Disconnect exhaust pipe from
turbo. Remove all air intake pipes and heat shields. Disconnect
accelerator cable at pedal.
2) Remove clutch booster vacuum hose. Remove O2 sensor.
Remove EGR pipe and turbo heat shield. Disconnect turbo coolant feed
and return lines. Disconnect turbo oil feed and return lines. Remove
turbocharger assembly.
CAUTION: DO NOT allow foreign material into turbocharger air intakes
or coolant and oil passages.
Inspection (Front & Rear)
1) Inspect turbocharger for oil leakage. Check turbine and
compressor wheels for cracks and other damage. Both wheels should turn
easily by hand.
2) Apply 6.8 psi (61 kPa) vacuum to wastegate diaphragm.
Ensure wastegate operates and diaphragm holds vacuum pressure. Use
care when cleaning gasket surfaces so no foreign material enters
turbocharger oil, coolant and air passages.
Installation (Front & Rear)
Refill turbocharger with clean engine oil through oil pipe
installation hole. To complete installation, reverse removal
procedure. Align match marks, and install air pipes and hoses to
proper depth.
EXHAUST MANIFOLDS
Removal (Montero & Pickup)
1) Remove splash shields. Remove O2 sensor. Remove exhaust
pipe-to-manifold nuts. Lower exhaust pipe, and remove gasket. Remove
heat protector. To remove right exhaust manifold, remove air duct,
engine lift bracket and alternator bracket.
2) To remove left exhaust manifold, remove EGR pipe and
gasket. Remove front intake manifold plenum bracket. Remove exhaust
manifolds and gaskets.
Inspection (Montero & Pickup)
Clean all gasket mating surfaces. Inspect for damage and
cracks on all mounting surfaces. Check mounting surfaces of manifold
and cylinder head for warpage. Repair or replace components if warpage
exceeds .012" (.30 mm).

TIMING BELT under REMOVAL & INSTALLATION. Remove intake camshaft
sprockets.
4) Remove coolant manifold and coolant inlet pipe. Using
Socket (MD998051), remove cylinder head bolts. Remove cylinder head
and camshaft assemblies. Note direction of washer installation on head
bolts.
Inspection (DOHC)
Check cylinder head height. Check warpage at gasket and
manifold surfaces. Resurface head if warpage exceeds specification.
See CYLINDER HEAD (DOHC) table under ENGINE SPECIFICATIONS at end of
article. After resurfacing, recheck cylinder head height. Replace
cylinder head if it is not within specification.
Installation (DOHC)
1) Ensure mating surfaces are clean and dry. Note
identification mark located on front of head gasket. Identification
marks are: "R" for SOHC, "2DN" for DOHC non-turbocharged and "2DT" for
DOHC turbocharged engine. Install head gasket with identification mark
toward timing belt side of engine and facing upward. Ensure all holes
are aligned.
NOTE: Install head gasket with identification mark toward timing
belt side of engine and facing upward. Ensure all holes
align. Install washers on head bolts with chamfered side
toward bolt head.
2) Install cylinder head and bolts. Ensure washers are
installed on head bolts with chamfered side toward bolt head. Using
proper sequence, tighten bolts to specification in 2-3 steps. See
Fig. 5 . See TORQUE SPECIFICATIONS (3000GT) table at end of article. On
turbocharger equipped engines, back off head bolts once, and repeat
tightening procedure.
3) To reinstall camshaft sprocket, hold hexagonal area of
camshaft using wrench while tightening sprocket bolt. Tighten rocker
cover bolts in a crisscross pattern. Start at 4 corners of rocker
cover and move toward center.
NOTE: Rocker cover bolts are color coded. Front cylinder bank
bolts are black; rear cylinder bank bolts are green.
4) To complete installation, reverse removal procedure.
Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS
(3000GT) table.
FRONT CRANKSHAFT OIL SEAL
Removal & Installation
Remove timing belt and crankshaft sprocket. See TIMING BELT
under REMOVAL & INSTALLATION. Pry oil seal from oil pump. To install,
coat seal lip with grease. Using Seal Installer (MD998717), install
seal in oil pump. Install remaining components. See appropriate TORQUE
SPECIFICATIONS table at end of article.
TIMING BELT
Removal (Montero & Pickup)
1) Drain cooling system. Disconnect upper radiator hose.
Remove upper radiator shroud. Remove cooling fan and fan clutch
assembly. Remove cooling fan pulley. Remove all drive belts. Remove
power steering pump with pressure and return hoses connected, and set
aside.
2) Remove power steering pump brackets. Remove A/C tensioner

and No. 2. Install bearing caps with front mark arrow facing the same
direction as similar mark on cylinder head beside bearing journal.
Note bearing cap number and identification mark ("I" for intake
camshaft and "E" for exhaust). See Fig. 22.
3) Install front and rear bearing caps. Tighten bearing cap
bolts to specification. See TORQUE SPECIFICATIONS (3000GT) table at
end of article. Coat camshaft oil seal area with oil. Using Seal
Installer (MD998761), install camshaft oil seal. Using Circular
Packing Installer (MD998761), install circular packing.
4) Install crankshaft angle sensor adapter. To complete
installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
REAR CRANKSHAFT OIL SEAL
Removal
Remove transaxle/transmission. See appropriate article in
TRANSMISSION SERVICING or CLUTCHES. Remove flywheel or drive plate.
Remove rear oil seal case. Pry seal from seal case.
Installation
To install, coat seal lip with oil. Using Seal Installer
(MD998718), install seal in seal case. Apply sealant to sealing
surface of seal case. Install seal case. Install flywheel or drive
plate. Tighten bolts to specification. See appropriate TORQUE
SPECIFICATIONS table at end of article. To complete installation,
reverse removal procedure.
WATER PUMP
Removal
Drain cooling system. Remove timing belt and crankshaft
sprocket. See TIMING BELT under REMOVAL & INSTALLATION. Remove coolant
pipes to water pump (if required). Remove water pump bolts, noting
length and location for reassembly reference. Remove water pump.
Installation
To install, reverse removal procedure using new gasket and
"O" rings. Coat all "O" rings with water before installation. Install
water pump and gasket. Tighten bolts to specification. See appropriate
TORQUE SPECIFICATIONS table at end of article.
OIL PAN
Removal (Montero)
1) Remove hood. Remove skid plate and lower covers. Raise and
support vehicle. Disconnect and remove exhaust pipe from exhaust
manifolds. Drain engine oil. Remove starter cover and starter. Remove
oil pressure sending unit connector. Remove front suspension
crossmember.
2) Remove transmission stays. Remove ground cable and motor
mount heat shields. Attach engine hoist. Remove motor mount bolts.
Raise engine, and insert a 1" wood spacer between front insulator and
mounts. Lower engine onto wood blocks.
3) Raise vehicle using a hoist. Remove oil pan bolts. Using
Seal Cutter (MD998727), separate oil pan from cylinder block. Remove
pan from vehicle.
Removal (Pickup)
1) Remove skid plate and lower covers. Raise and support
vehicle. Drain engine oil. Using Steering Linkage Puller (C-3894-A or
MB990635), disconnect relay rod from idler arm and steering box.
2) Remove oil pan bolts. Using Seal Cutter (MD998727),

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