Mitsubishi Montero Sport (2004+). Manual — part 487

SUNROOF ASSEMBLY

TSB Revision

BODY

42-203

<<F>> SUNROOF DRIVE CABLES REMOVAL
1. Tilt the sunroof guide assembly and then remove the

sunroof guide rail rod holder.

2. Close the sunroof guide assembly and disconnect the

sunroof drive cable end from the sunroof guide assembly.

.

<<G>> SUNROOF GUIDE ASSEMBLY REMOVAL
1. Slide the roof drip rear channel backward, and then remove

the guide assembly screws, the rear screw and spacer.

2. Slide the rear of the guide assembly toward center of the

vehicle and remove the guide assembly.

.

<<H>> DRAIN HOSE REMOVAL
Remove the grommet. Tie a cord to the end of the drain hose,
wind plastic tape around it so that there is no unevenness, and
pull the drain hose out into the wheel house.

AC004061AB

SUNROOF GUIDE ASSEMBLY

SUNROOF GUIDE
RAIL ROD HOLDER

AC004062

SUNROOF DRIVE CABLE END

AB

AC004063

AC004064

AB

FRONT

REAR

DRAIN HOSE

CORD

CORD

DRAIN
HOSE

SUNROOF ASSEMBLY

TSB Revision

BODY

42-204

INSTALLATION SERVICE POINTS

.

>>A<< DRAIN HOSE INSTALLATION
1. Tie the cord that was used during removal to the end of the

drain hose, and wind the plastic tape around it so that there
is no unevenness.

2. Pull the cord to pull through the drain hose.

3. Make the protrusion from the drain hose grommet as shown

in the illustration.

.

>>B<< SUNROOF DRIVE CABLES INSTALLATION

CAUTION

If cables are kinked, replace them. Always replace the
cables in pair and grease them before installation.
Close the sunroof guide assembly and install the sunroof drive
cable end to the sunroof guide assembly.

.

>>C<< FRONT SUNROOF SUNSHADE/REAR SUNROOF
SUNSHADE INSTALLATION
1. Install the front sunroof sunshade first by inserting the slide

blocks on the right side of the sunshade into the lower slide
position of the right guide assembly.

2. Push the sunshade slide blocks on the left side of the

sunshade into the sunshade to allow the front sunroof
sunshade to drop into position. Once in position, engage the
slide blocks into the lower channel of the left guide
assembly.

AC004065AB

FRONT

REAR

AC004066

GROMMET

FRONT 25 - 30 mm
(1.0 - 1.2 in)
REAR 70mm (2.8in)

AB

AC004062

SUNROOF DRIVE CABLE END

AB

AC004067

SUNROOF ASSEMBLY

TSB Revision

BODY

42-205

3. Push the front sunroof sunshade to full forward position.
4. Position the rear sunroof sunshade so that the stop tabs are

against the stop bumpers on the guide assembly. Engage
the right side slide blocks of the upper half of the sunshade
into the upper channel on the right guide assembly. Engage
the slide blocks on the left side of the sunshade into the
upper channel in the left guide assembly.

5. Slide the sunshade back and forth to check that it functions

smoothly.

.

>>D<< SUNROOF-ECU INSTALLATION
1. Look into the "viewing windows" while turning the rotating

wheel. Turn the rotating wheel until the white timing marks
appear. When the white timing marks appear in the "viewing
windows" at the same time, stop turning the rotating wheel.

2. Close the sunroof fully. Install the timed sunroof control unit.

Make sure that the sunroof cable is properly inserted into the
control unit.

3. Insert a flat-tipped screwdriver, place it on the tab, and press

it to the right, being careful not to pinch the wiring.

.

>>E<< SUNROOF GLASS SEAL INSTALLATION
1. Starting at the rear center of the sunroof glass, begin

installing the seal by pushing it onto the edge of the glass
panel and gently pulling on it while installing.

2. Approximately 102 mm (4.0 inches) before completing the

installation, lay the end of the seal over top of the beginning
of the seal. Cut the seal so there is an extra 3.18 mm (0.125
inch) of the seal past the point where the seal lines up with
the beginning of the seal

3. Apply Loctite R 410 Black Toughened Instant Adhesive or

equivalent to the splice joint area where two ends of the seal
meet.

4. With the approximately 102 mm (4.0 inches) of the seal

unattached, push two ends of the seal together at glue joint.

5. Install the remainder of the seal by pushing the seal onto the

edge of the glass panel. The 3.18 mm (0.125 inch) of extra
seal material should strengthen the seal at the splice joint.

.

AC004066

GROMMET

FRONT 25 - 30 mm
(1.0 - 1.2 in)
REAR 70mm (2.8in)

AB

AC004069AB

TIMING MARKS

ROTATING WHEEL

VIEWING
WINDOWS

AC004070

SUNROOF-ECU

AB

AC004071

REAR CENTER
POINT

GLASS
SEAL

GLASS
PANEL

AB

SUNROOF ASSEMBLY

TSB Revision

BODY

42-206

>>F<< SUNROOF GLASS INSTALLATION
1. Position the sunroof glass onto the guide assemblies and

align the mounting holes.

2. Apply Loctite R Small Screw Thread locker 222 or

equivalent to the sunroof glass attaching screws and install
them, going to the next step before tightening.

SUNROOF MOTOR CHECK

M1426002500045

Check the rotation direction of the drive gear when the battery
is connected to the connector.

SUNROOF SWITCH CONTINUITY CHECK

M1426001600094

Operate the sunroof switch and check for the continuity
between each of the terminals.

AC004072

TESTER CONNECTION

DRIVE GEAR
OPERATION

• Connect terminal 2 to the

positive battery terminal

• Connect terminal 1 to the

negative battery terminal

The drive gear rotates
clockwise

• Connect terminal 1 to the

positive battery terminal

• Connect terminal 2 to the

negative battery terminal

The drive gear rotates
counterclockwise

2

1

AC003809

LEFT
ROTATION

DRIVE GEAR

RIGHT
ROTATION

AB

SWITCH POSITION TESTER

CONNECTION

SPECIFIED
CONDITION

At the Open position 3

− 4

Less than 2 ohms

At the Off position

1

− 4

3

− 4

Open circuit

At the Close position 1

− 4

Less than 2 ohms

5

4

6

3

2

1

AC003808