Mitsubishi Montero (2002-2004). Manual - part 71

COMPRESSOR ASSEMBLY

TSB Revision

HEATER, AIR CONDITIONING AND VENTILATION

55A-147

REMOVAL SERVICE POINTS

.

<<A>> DRIVE BELT REMOVAL

CAUTION

When reusing the drive belt, mark an arrow which indi-
cates the turning direction (right turn) on the back of the 
drive belt with a chalk, etc.
Insert the socket-wrench handle into the tool hole for auto-ten-
sioner and turn it to the arrow direction. Reduce the drive belt 
tension and remove the drive belt.

.

<<B>> DISCHARGE HOSE/SUCTION HOSE REMOVAL

CAUTION

Seal the hoses completely, otherwise the compressor oil 
and receiver will absorb water vapor easily, possibly dam-
aging the compressor and deteriorating performance.
Plug the disconnected hose and compressor nipple to prevent 
foreign matter from getting into them.

.

<<C>> COMPRESSOR REMOVAL
When removing the compressor, be careful not to spill the com-
pressor oil.

INSTALLATION SERVICE POINT

.

>>A<< COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of oil 
according to the procedures described below, and then install 
the compressor.
1. Measure the amount [X cm

3

 (X floz)] of oil within the 

removed compressor.

2. Drain (from the new compressor) the amount [Y cm

3

 (Y 

floz)] of oil calculated according to the following formula, and 
then install the new compressor.

<Vehicles without rear A/C>
 New compressor oil amount = 120cm

3

 (4.2 floz) 

<Vehicles with rear A/C>
 New compressor oil amount = 140cm

3

 (4.9 floz) 

<Vehicles without rear A/C>
120 cm

3

 

− X cm

3

 = Y cm

3

 (4.2 floz 

− X floz = Y floz) 

<Vehicles with rear A/C>
140 cm

3

 

− X cm

3

 = Y cm

3

 (4.9 floz 

− X floz = Y floz) 

NOTE: Y cm

3

 (Y floz) indicates the amount of oil in the refriger-

ant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same times as 
the compressor, subtract the rated oil amount of the each part 
from Y cm

3

 (Y floz) and discharge from the new compressor.

Quantity:

• Evaporator: 60 cm

3

 (2.0 floz)

• Condenser: 15 cm

3

 (0.5 floz)

ACX00838 AC

COMPRESSOR ASSEMBLY

TSB Revision

HEATER, AIR CONDITIONING AND VENTILATION

55A-148

• Suction hose: 10 cm

3

 (0.3 floz)

• Receiver: 10 cm

3

 (0.3 floz) 

INSPECTION

M1552004500168

AIR CONDITIONING COMPRESSOR CLUTCH 
OPERATION INSPECTION

Connect the positive battery terminal to the air conditioning 
compressor clutch connector terminal 3, and ground the nega-
tive battery terminal to the body of the compressor. The condi-
tion is normal if the sound of the magnetic clutch (click) can be 
heard.

COMPRESSOR

M1552004600284

DISASSEMBLY AND ASSEMBLY

ACX01440AB

AC002662

1

2

3

4

5

6

7

14 ± 3 N·m
120 ± 24 in-lb

AB

DISASSEMBLY STEPS

>>C<<

•

AIR GAP ADJUSTMENT

1. LOCK SENSOR

<<A>>

2. ARMATURE PLATE

>>B<<

3. SNAP RING

4. ROTOR
5. SNAP RING

>>A<<

6. CLUTCH COIL
7. SHIMS

DISASSEMBLY STEPS 

COMPRESSOR ASSEMBLY

TSB Revision

HEATER, AIR CONDITIONING AND VENTILATION

55A-149

DISASSEMBLY SERVICE POINT

.

<<A>> ARMATURE PLATE REMOVAL
1. Remove the armature plate mounting nut.
2. Tighten the M10 bolt into the armature plate bolt hole and 

disconnect the serration of the shaft and the armature plate.

ASSEMBLY SERVICE POINTS

.

>>A<< CLUTCH COIL INSTALLATION
Install the clutch coil to the compressor, mating the compressor 
body slot to the clutch coil projection.

.

>>B<< SNAP RING INSTALLATION
Install the snap ring taking care not to enlarge the inner diame-
ter too much. When the inner diameter is over 30.5 mm (1.2 
inch) resulting from being enlarged too much, replace the snap 
ring with a new one.

.

>>C<< AIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the stan-
dard value.

Standard value: 0.35 

− 0.65 mm (0.014 − 0.026 inch)

NOTE: If there is a deviation of the air gap from the standard 
value, make the necessary adjustment by adjusting the number 
of shims.

ACX00841AC

M10 BOLT

ACX00842

CLUTCH COIL
PROJECTION

NOTCH ON 
COMPRESSOR 
BODY

AC

1

2

3

ACX01441

CONDENSER AND CONDENSER FAN MOTOR

TSB Revision

HEATER, AIR CONDITIONING AND VENTILATION

55A-150

CONDENSER AND CONDENSER FAN MOTOR

REMOVAL AND INSTALLATION

M1552006700276

REMOVAL SERVICE POINT

.

<<A>> DISCHARGE HOSE/LIQUID PIPE A REMOVAL

CAUTION

Seal the hoses completely, otherwise the compressor oil 
and receiver will absorb water vapor easily, possibly dam-
aging the compressor and deteriorating performance.
Plug the disconnected hose, pipe and condenser nipple to pre-
vent foreign matter from getting into them.

ACX00844AD

2

9.8 ± 2.0 N·m
87 ± 17 in-lb

7

6

4

8

1

3

N

N

9

5

5

CONDENSER REMOVAL STEPS

1.

RADIATOR BRACKET

2.

RELAY

<<A>>

3.

DISCHARGE HOSE

<<A>>

4.

LIQUID PIPE A

5.

O-RING

6.

CONDENSER

7.

CONDENSER BRACKET

CONDENSER FAN REMOVAL 
STEPS

8.

CONDENSER FAN ASSEMBLY

9.

MOTOR ASSEMBLY

CONDENSER REMOVAL STEPS