Mitsubishi Montero (2004+). Manual — part 667

REFRIGERANT LINE

TSB Revision

AUTOMATIC AIR CONDITIONING

55B-157

REFRIGERANT LINE

REMOVAL AND INSTALLATION

M1552006400491

Refer to GROUP 55A, REFRIGERANT LINE

P.55A-146

.

OTHER PARTS

OTHER PARTS MAINTENANCE SERVICE POINTS

M1554004000103

The following maintenance service points are the
same as for the manual A/C.

ITEM

REFERENCE
PAGE

ON-VEHICLE
SERVICE

REFRIGERANT
LEVEL TEST

P.55A-112

A/C
COMPRESSOR
CLUTCH TEST

P.55A-112

RECEIVER
DRIER TEST

P.55A-112

DUAL
PRESSURE
SWITCH
CHECK

P.55A-112

COMPRESSOR
DRIVE BELT
ADJUSTMENT

P.55A-113

REFRIGERANT
LEAK REPAIR

P.55A-115

COMPRESSOR
NOISE CHECK

P.55A-116

POWER RELAY
CONTINUITY
CHECK

P.55A-117

IDLE-UP
OPERATION
CHECK

P.55A-118

BLOWER MOTOR
DISASSEMBLY AND ASSEMBLY

P.55A-126

INSIDE/OUTSIDE AIR
CHANGEOVER DAMPER
MOTOR

P.55A-128

REAR A/C SWITCH AND FRONT
REAR FAN SWITCH

P.55A-131

COMPRESSOR AND TENSION
PULLEY

P.55A-140

CONDENSER AND
CONDENSER FAN MOTOR

P.55A-144

VENTILATORS

P.55A-149

ITEM

REFERENCE
PAGE

SPECIFICATIONS

TSB Revision

AUTOMATIC AIR CONDITIONING

55B-158

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1554006100054

SERVICE SPECIFICATIONS

M1554000300049

LUBRICANTS

M1554000400035

ITEM

SPECIFICATION

A/C pipe mounting bolt (heater/cooler unit side)

9.8

± 2 N⋅m (87 ± 18 in-lb)

A/C pipe mounting nut (condenser side)

9.8

± 2 N⋅m (87 ± 18 in-lb)

Discharge hose mounting bolt (compressor side)

9.8

± 2 N⋅m (87 ± 18 in-lb)

Discharge hose mounting nut (condenser side)

9.8

± 2 N⋅m (87 ± 18 in-lb)

Suction hose mounting bolt (compressor side)

9.8

± 2 N⋅m (87 ± 18 in-lb)

Liquid pipe A and liquid pipe B joint nut

14

± 0.5 N⋅m (124 ± 4 in-lb)

Liquid pipe B and liquid pipe C joint nut

14

± 0.5 N⋅m (124 ± 4 in-lb)

Liquid pipe C and liquid pipe D joint nut

14

± 0.5 N⋅m (124 ± 4 in-lb)

Liquid pipe D and rear heater unit joint nut

14

± 0.5 N⋅m (124 ± 4 in-lb)

Suction pipe A and suction flexible hose joint nut

33

± 1 N⋅m (24 ± 1 ft-lb)

Suction pipe A and suction pipe B joint nut

33

± 1 N⋅m (24 ± 1 ft-lb)

Suction pipe B and suction pipe C joint nut

33

± 1 N⋅m (24 ± 1 ft-lb)

Suction pipe C and rear heater unit joint nut

33

± 1 N⋅m (24 ± 1 ft-lb)

ITEM

STANDARD VALUE

Air mix damper potentiometer resistance k

Ω

1.2

− 4.8

Air outlet changeover damper potentiometer resistance k

Ω

0.96

− 5.76

Resistor (for rear blower motor)

Ω

LOW

2.79

MEDIUM LOW

1.49

MEDIUM HIGH

0.36

ITEM

SPECIFIED LUBRICANT

QUANTITY

Compressor refrigerant unit lubricant cm

3

(floz)

SUN PAG 56

140 (4.7)

Each connection of refrigerant line

SUN PAG 56

As required

42-1

GROUP 42

BODY

CONTENTS

HOOD. . . . . . . . . . . . . . . . . . . . .

42-3

HOOD DIAGNOSIS . . . . . . . . . . . .

42-3

INTRODUCTION TO HOOD DIAGNOSIS

42-3

HOOD DIAGNOSTIC TROUBLESHOOTING
STRATEGY . . . . . . . . . . . . . . . . . . . . . .

42-3

SYMPTOM CHART . . . . . . . . . . . . . . . .

42-3

SYMPTOM PROCEDURES . . . . . . . . .

42-3

HOOD. . . . . . . . . . . . . . . . . . . . . . .

42-5

REMOVAL AND INSTALLATION . . . . .

42-5

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-7

FENDER. . . . . . . . . . . . . . . . . . .

42-7

REMOVAL AND INSTALLATION .

42-7

FUEL FILLER LID . . . . . . . . . . .

42-8

REMOVAL AND INSTALLATION .

42-8

WINDOW GLASS . . . . . . . . . . .

42-10

GENERAL DESCRIPTION . . . . . . . . . . . . .

42-10

WINDOW GLASS DIAGNOSIS . . .

42-11

INTRODUCTION TO WINDOW GLASS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-11

WINDOW GLASS DIAGNOSTIC

TROUBLESHOOTING STRATEGY . . .

42-12

SYMPTOM CHART . . . . . . . . . . . . . . . .

42-12

SYMPTOM PROCEDURES . . . . . . . . .

42-12

SPECIAL TOOL. . . . . . . . . . . . . . .

42-12

WINDSHIELD. . . . . . . . . . . . . . . . .

42-13

REMOVAL AND INSTALLATION . . . . .

42-13

QUARTER WINDOW GLASS . . . .

42-16

REMOVAL AND INSTALLATION. . . . . .

42-16

BACK DOOR WINDOW GLASS . .

42-18

REMOVAL AND INSTALLATION. . . . . .

42-18

DOOR . . . . . . . . . . . . . . . . . . . .

42-20

GENERAL DESCRIPTION . . . . . . .

42-20

CENTRAL DOOR LOCKING SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-20

POWER WINDOW DIAGNOSIS . . . . . .

42-20

DOOR DIAGNOSIS . . . . . . . . . . . .

42-20

DOOR DIAGNOSIS . . . . . . . . . . . . . . . .

42-20

INTRODUCTION TO GLASS AND DOOR
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-20

GLASS AND DOOR DIAGNOSTIC

TROUBLESHOOTING STRATEGY . . . .

42-20

SYMPTOM CHART . . . . . . . . . . . . . . . .

42-21

SYMPTOM PROCEDURES . . . . . . . . . .

42-21

HOW TO LOCATE WIND NOISES . . . .

42-24

SPECIAL TOOLS . . . . . . . . . . . . . .

42-25

ON-VEHICLE SERVICE . . . . . . . . .

42-26

DOOR FIT ADJUSTMENT . . . . . . . . . . .

42-26

DOOR WINDOW GLASS ADJUSTMENT

42-27

DOOR INSIDE HANDLE PLAY CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . .

42-28

DOOR OUTSIDE HANDLE PLAY CHECK

42-28

CIRCUIT BREAKER (INCORPORATED
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-28

DOOR ASSEMBLY. . . . . . . . . . . . .

42-29

REMOVAL AND INSTALLATION. . . . . .

42-29

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-30

Continued on next page

42-2

DOOR TRIM AND WATERPROOF
FILM . . . . . . . . . . . . . . . . . . . . . . . .

42-31

REMOVAL AND INSTALLATION . . . . .

42-31

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-36

DOOR GLASS AND REGULATOR

42-38

REMOVAL AND INSTALLATION . . . . .

42-38

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-40

DOOR HANDLE AND LATCH. . . .

42-41

REMOVAL AND INSTALLATION . . . . .

42-41

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-43

WINDOW GLASS RUNCHANNEL
AND DOOR OPENING
WEATHERSTRIP. . . . . . . . . . . . . .

42-46

REMOVAL AND INSTALLATION . . . . .

42-46

BACK DOOR ASSEMBLY . . . .

42-49

BACK DOOR DIAGNOSIS . . . . . .

42-49

INTRODUCTION TO BACK DOOR
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . .

42-49

BACK DOOR DIAGNOSTIC

TROUBLESHOOTING STRATEGY . . .

42-49

SYMPTOM CHART . . . . . . . . . . . . . . . .

42-49

SYMPTOM PROCEDURES . . . . . . . . .

42-50

SPECIAL TOOL. . . . . . . . . . . . . . .

42-51

ON-VEHICLE SERVICE. . . . . . . . .

42-51

BACK DOOR FIT ADJUSTMENT . . . . .

42-51

BACK DOOR HANDLE PLAY CHECK .

42-51

BACK DOOR ASSEMBLY . . . . . .

42-52

REMOVAL AND INSTALLATION . . . . .

42-52

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-53

BACK DOOR TRIM AND
WATERPROOF FILM . . . . . . . . . .

42-54

REMOVAL AND INSTALLATION . . . . .

42-54

BACK DOOR HANDLE AND LATCH

42-55

REMOVAL AND INSTALLATION . . . . .

42-55

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-55

KEYLESS ENTRY SYSTEM . .

42-56

GENERAL DESCRIPTION . . . . . . .

42-56

KEYLESS ENTRY SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . .

42-56

SPECIAL TOOLS . . . . . . . . . . . . . .

42-57

ON-VEHICLE SERVICE . . . . . . . . .

42-58

HOW TO REPLACE THE TRANSMITTER
BATTERY . . . . . . . . . . . . . . . . . . . . . . . .

42-58

ENABLING/DISABLING THE ANSWERBACK
FUNCTION . . . . . . . . . . . . . . . . . . . . . . .

42-58

HOW TO REGISTER SECRET CODE .

42-59

SUNROOF ASSEMBLY . . . . . .

42-63

GENERAL DESCRIPTION . . . . . . .

42-63

SUNROOF DIAGNOSIS . . . . . . . . .

42-63

SPECIAL TOOLS . . . . . . . . . . . . . .

42-63

ON-VEHICLE SERVICE . . . . . . . . .

42-63

WATER TEST . . . . . . . . . . . . . . . . . . . .

42-63

SUNROOF FIT ADJUSTMENT . . . . . . .

42-64

OPERATION CHECK. . . . . . . . . . . . . . .

42-64

SUNROOF ASSEMBLY . . . . . . . . .

42-66

REMOVAL AND INSTALLATION. . . . . .

42-66

INSPECTION . . . . . . . . . . . . . . . . . . . . .

42-69

DISASSEMBLY AND ASSEMBLY . . . . .

42-70

SPECIFICATIONS . . . . . . . . . .

42-73

FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . .

42-73

SERVICE SPECIFICATIONS . . . . .

42-73

SEALANTS . . . . . . . . . . . . . . . . . . .

42-73

COMPONENT IDENTIFICATION . .

42-74