Mitsubishi Montero (2002-2004). Manual — part 13

BACK DOOR ASSEMBLY

TSB Revision

BODY

42-49

SPECIAL TOOL

M1423000600252

ON-VEHICLE SERVICE

BACK DOOR FIT ADJUSTMENT

M1423001700025

1. If the striker and latch mesh badly, move the striker forward

and backward or right and left to adjust.

2. If uneven clearance is present between back door and body,

reposition the hinge and striker and/or change the thickness
of shim (change the number of shim) to adjust the
clearance.

BACK DOOR HANDLE PLAY CHECK

M1423007600048

1. Check the Back Door handle play.

Standard value (B): 2.3 mm (0.09 inch)

2. If the back door handle play is not within the standard value,

check the back door handle and door latch assembly.
Replace if necessary.

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990784
Ornament remover

General service tool

Removal of back door
trim

MB990784

X1113CA

X11114CA

ACX00559AC

AC203483AB

B

A

A

SECTION A A

BACK DOOR ASSEMBLY

TSB Revision

BODY

42-50

BACK DOOR ASSEMBLY

REMOVAL AND INSTALLATION

M1423005200055

Pre-removal Operation
• High-mounted Stop Light Removal (Refer to GROUP 54A

P.54A-79

.)

• Spare Tire Removal

Post-installation Operation
• High-mounted Stop Light Installation (Refer to GROUP

54A

P.54A-79

.)

• Spare Tire Installation

• Back Door Fit Adjustment (Refer to

P.42-49

.)

X0123CA

ACX00561

X1118CA

1

2

3

4

5

6

7

8

8

3,5

11

12

10

9

1

21 – 4 N•m
16 – 2 ft-lb

21 – 4 N•m
16 – 2 ft-lb

11 – 2 N•m
102 – 13 in-lb

AB

21 – 4 N•m
16 – 2 ft-lb

REMOVAL STEPS
• BACK DOOR TRIM AND

WATERPROOF FILM (Refer to

P.42-

52

.)

1. HARNESS CONNECTOR
2. BACK DOOR ASSEMBLY
3. BACK DOOR UPPER HINGE
4. SHIM
5. BACK DOOR LOWER HINGE

6. SHIM
7. DAMPER MALE
8. BACK DOOR STOPPER

>>B<<

9. STRIKER

>>A<<

10. BACK DOOR OPENING

WEATHERSTRIP

11. DOOR SWITCH
12. BACK DOOR BUMPER FEMALE

REMOVAL STEPS (Continued)

BACK DOOR ASSEMBLY

TSB Revision

BODY

42-51

INSTALLATION SERVICE POINTS

.

>>A<< BACK DOOR OPENING WEATHERSTRIP INSTAL-
LATION
Align the marking section on the back door opening
weatherstrip with the center of the body.

.

>>B<< STRIKER INSTALLATION
Install the striker so that the striker center does not deviate
more than 1.5 mm (0.06 inch) from the latch center.

INSPECTION

M1421007600387

BACK DOOR SWITCH CHECK

ACX00564

CENTER OF STRIKER

STRIKER

+1.5 mm (0.06 in)

CENTER OF
LATCH

LATCH

-1.5 mm (0.06 in)

AC

SWITCH
POSITION

TESTER
CONNECTION

SPECIFIED
CONDITION

Open (ON)

1

− switch body, 2 −

switch body

Less than 2 ohms

Depressed (OFF)

Open circuit

1 2 3

ACX01865AB

ON

OFF

BACK DOOR ASSEMBLY

TSB Revision

BODY

42-52

BACK DOOR TRIM AND WATERPROOF FILM

REMOVAL AND INSTALLATION

M1423005500056

INSTALLATION SERVICE POINT

.

>>A<< DOOR PULL HANDLE INSTALLATION
Mount the door pull handle with its arrow mark at the back
pointing upward.

X0124CA

AX1543CA

AX0127CA

AC204018

7

7

5

3

6

10

4

8

9

5

2

3

1

A

A

A

A

CLIP

AB

SECTION A A

: CLIP POSITIONS

ADHESIVE TAPE:
3M ADD PART No. 8625 OR
EQUIVALENT

BACK DOOR TRIM REMOVAL
STEPS

1. HIGH MOUNTED STOPLIGHT

COVER

• HIGH MOUNTED STOPLIGHT

(REFER TO GROUP 54

P.54A-79

.)

>>A<<

2. DOOR PULL HANDLE
3. BACK DOOR UPPER TRIM
4. TOOL BOX ASSEMBLY

5. BACK DOOR UPPER TRIM (LH)
6. TOOL BOX BRACKET LOWER (RH)
7. WATERPROOF FILM
8. BACK DOOR LID
9. WASHER TANK LID
10. TOOL BOX BRACKET UPPER

BACK DOOR TRIM REMOVAL
STEPS (Continued)