Mitsubishi Montero (1991+). Manual - part 13

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 seal

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. Remove

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.