Mitsubishi Montero (2002-2004). Manual — part 12

DOOR

TSB Revision

BODY

42-45

REMOVAL AND INSTALLATION <REAR DOOR>

AX0540CA

AX0541CA

AX0543CA

AX0544CA

AX0545CA

AX0542CA

AC203990

ADHESIVE TAPE:
DOUBLE-SIDED TAPE [23 mm (0.9 inch) WIDTH
AND 0.8 mm (0.03 inch) THICKNESS]

1

2

3

5

6

7

4

3

:SECTIONAL VIEW OF
CLIP POSITION

:SECTIONAL VIEW OF CLIP POSITION

:SECTIONAL VIEW OF CLIP POSITION

CLIP

2

2

3

3

3

CLIP

CLIP

CLIP

CLIP

AB

DOOR INNER OPENING
WEATHERSTRIP REMOVAL STEPS

>>B<<

1. DOOR INNER OPENING

WEATHERSTRIP

• CENTER PILLAR LOWER TRIM

(REFER TO GROUP 52A, TRIMS

P.52A-8

.)

DOOR OUTER OPENING
WEATHERSTRIP REMOVAL
• REAR DOOR CHECK MOUNTING

BOLT (DOOR SIDE) (REFER TO

P.42-28

.)

<<A>>

2. DOOR OUTER OPENING

WEATHERSTRIP

3. DOOR OUTER OPENING LOWER

WEATHERSTRIP

4. DOOR OUTER OPENING FRONT

WEATHERSTRIP

DOOR WINDOW GLASS
RUNCHANNEL REMOVAL STEPS

>>A<<

5. DOOR WINDOW GLASS

RUNCHANNEL

• REAR DOOR TRIM (REFER TO

P.42-30

.)

6. DOOR BELTLINE INNER

WEATHERSTRIP

DOOR BELTLINE MOLDING REMOVAL
STEPS
7. DOOR BELTLINE MOLDING

DOOR OUTER OPENING
WEATHERSTRIP REMOVAL

DOOR

TSB Revision

BODY

42-46

REMOVAL SERVICE POINT

.

<<A>> DOOR OUTER OPENING WEATHERSTRIP
REMOVAL
Make a tool as shown and remove the door opening
weatherstrip.

INSTALLATION SERVICE POINT

.

>>A<< MOUNTING OF DOOR WINDOW GLASS CHANNEL
Remove the waterproof film when mounting the door window
glass channel.

.

>>B<< MOUNTING OF DOOR INNER OPENING WEATHER
STRIP
Mount the door inner opening weather strip to the locations
specified below.

<FRONT DOOR>

ACX00555

15 mm (0.6 in)

8 mm
(0.3 in)

AB

4 mm (0.2 in)

THICKNESS:
1 mm (0.04 in)

FABRICATED TOOL

AC204013

INSTALL SO THAT THE
END OF THE DOOR
OPENING
WEATHERSTRIP
IS ALIGNED WITH THE
NOTCH IN THE BODY.

INSTALL SO THAT THE END OF
THE DOOR OPENING
WEATHERSTRIP IS ALIGNED
WITH THE NOTCH IN THE BODY.

DOOR INNER OPENING WEATHERSTRIP

AB

BACK DOOR ASSEMBLY

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BODY

42-47

<REAR DOOR>

BACK DOOR ASSEMBLY

BACK DOOR DIAGNOSIS

INTRODUCTION TO BACK DOOR DIAGNOSIS

M1423007300047

Refer to

P.42-20

.

BACK DOOR DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1423006700053

Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
back door fault.
1. Gather information from the customer.

2. Verify that the condition described by the

customer exists.

3. Find the malfunction by following the Symptom

Chart.

4. Verify malfunction is eliminated.

SYMPTOM CHART

M1423007000273

AC204017

INSTALL SO THAT THE END OF THE DOOR
OPENING WEATHERSTRIP IS ALIGNED WITH
THE NOTCH IN THE BODY.

DOOR INNER WEATHERSTRIP

AB

SYMPTOM

INSPECTION
PROCEDURE

REFERENCE PAGE

Door hard to open

1

P.42-48

Door does not open or close completely

2

P.42-48

Uneven gap between body

3

P.42-48

BACK DOOR ASSEMBLY

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BODY

42-48

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Door Hard to Open

DIAGNOSIS

STEP 1. Adjust the latch and striker engagement.
(Refer to

P.42-49

.)

Q: Is the latch and striker engagement adjusted?

YES :

Go to Step 2.

NO :

Adjust the latch and striker engagement
(Refer to

P.42-49

). Then go to Step 4.

STEP 2. Check for possible lock rod damage.

Q: Is the possible lock rod damaged?

YES :

Repair or replace the possible lock rod, then

go to Step 4.

NO :

Go to Step 3.

STEP 3. Check door handle flexibility (amount of
movement of handle required to open door).

Q: Is the door handle flexibility good?

YES :

Go to Step 4.

NO :

Adjust the door handle flexibility (Refer to

P.42-49

). Then go to Step 4.

STEP 4. Retest the system.

Q: Does the door open easily?

YES :

The procedure is complete.

NO :

Return to Step 1.

INSPECTION PROCEDURE 2: Door does not Open or Close Completely

DIAGNOSIS

STEP 1. Check the door hinge position.

Q: Is the door hinge position correct?

YES :

Go to Step 2.

NO :

Adjust the door hinge position (Refer to

P.42-49

). Then go to Step 4.

STEP 2. Check the door.

Q: Is the door in good condition?

YES :

Go to Step 3.

NO :

Repair or replace the door, then go to Step
4.

STEP 3. Check the grease.

Q: Is the door check or door hinge grease sufficient?

YES :

Go to Step 4.

NO :

Apply the grease, then go to Step 4.

STEP 4. Retest the system.

Q: Does the door open and close correctly?

YES :

The procedure is complete.

NO :

Return to Step 1.

INSPECTION PROCEDURE 3: Uneven Gap between Body

.

DIAGNOSIS
Adjust the door fit (Refer to

P.42-49

). Then check

that the gap has been improved.