Mitsubishi Montero (1991+). Manual - part 15

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

against crankshaft shoulder. Use Thin Wall Socket (J-9399) and Clutch

Hub Holder (J-25030). Tighten shaft nut to 96-192 INCH lbs.

(11-22 N.m). Spin pulley rotor by hand to ensure rotor is not rubbing

on clutch drive plate. See Fig. 8.

         HARRISON V5 5-CYLINDER SHAFT SEAL R & I

         Removal

         Discharge refrigerant from system using approved refrigerant

recovery/recycling equipment. See SERVICING PRECAUTIONS at beginning

of article. Remove clutch plate assembly. Remove shaft seal snap ring.

Thoroughly clean inside of compressor neck area around shaft and seal.

Engage tangs of Seal Remover/Installer (J-23128-A) into recessed

portion of seal and remove seal. Remove and discard seal "O" ring from

compressor neck. Thoroughly clean inside of compressor neck and "O"

ring groove.

         Installation

         1) Coat new "O" ring with refrigerant oil and install on "O"

ring installer (J-33011). Install "O" ring into groove in compressor

neck. Attach new seal to Seal Remover/Installer (J-23128-A). Dip seal

in clean refrigerant oil.

         2) Place Seal Protector (J-34614) over compressor shaft. Push

new seal over shaft protector. Install new snap ring with flat side

against seal. Install clutch plate assembly.

Fig. 8:  Exploded View of Harrison V5 5-Cylinder Compressor

Courtesy of General Motors Co.

         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.

Fig. 9:  Hitachi 6-Cylinder Compressor (5-Cylinder Similar)

Courtesy of Nissan Motor Co., U.S.A.

         HITACHI 5 & 6-CYL SHAFT SEAL R & I

NOTE:    Check compressor refrigerant oil level when replacing seals.

         See COMPRESSOR REFRIGERANT OIL CHECKING article in this

         section.

         Removal

         1) Drain oil from suction port, measure oil drained and

discard oil. Remove clutch hub, pulley, bearing assembly and coil

assembly. See HITACHI 5 & 6-CYLINDER CLUTCH R & I in this article.

         2) Using snap ring pliers, remove retainer ring. Remove key

and plug low and high pressure openings of compressor with Plugs

(KV994C4531, KV994C4532 and KV994C4559).

         3) Insert Adapter (KV994C1552) into hole in middle of blind