Mitsubishi Outlander (2003+). Manual - part 317

TAILGATE

BODY

42-43

TAILGATE

SERVICE SPECIFICATIONS

M1421000300244

SEALANTS

M1424000500076

SPECIAL TOOL

M1424000600158

TROUBLESHOOTING

M1424000700229

The tailgate system is controlled by the Smart Wiring 
System (SWS). For troubleshooting, refer to GROUP 
54B, Troubleshooting 

P.54B-15

 or GROUP 54C, 

Troubleshooting 

P.54C-4

.

Item

Standard value

Tailgate handle play  mm

2.3 to 5.9

Item

Specified sealant

Tailgate waterproof film

3M ATD Part No.8633 or equivalent

Tailgate hinge

3M ATD Part No.8531 Heavy drip check sealer, 3M 
ATD Part No.8646 Automotive joint and seam sealer 
or equivalent

Tool

Number

Name

Use

MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222

Harness set
A: Test harness
B: LED harness
C: LED harness 
adapter
D: Probe

Terminal voltage measurement
A: For checking connector pin 
contact pressure
B: For checking power supply 
circuit
C: For checking power supply 
circuit
D: For connecting a locally 
sourced tester

MB991223

A

D

C

B

AD

TAILGATE

BODY

42-44

ON-VEHICLE SERVICE

TAILGATE FIT ADJUSTMENT

M1424000900148

1. If the striker and latch mesh badly, replace the 

striker and striker installation bolts with 
replacement parts (striker: MR523105, striker 
installation bolt: MU000474).

2. Move the replaced striker forward and backward 

or to the left and right to adjust, after bolt the 
striker temporarily.

3. After adjusting, tighten the bolts to the specified 

torque [24 

±

 4 N

⋅

m].

NOTE: 

When the bolt head interferes with the rear end 
trim, rasp the interference area with a round file.

4. If uneven clearance is present between tailgate 

and body, reposition the hinge to adjust the 
clearance.

TAILGATE HANDLE PLAY CHECK

M1424002400116

1. Check the tailgate handle play.

Standard value (B): 2.3 

−

 5.9 mm

2. If it deviates from the standard value, remove the 

lower tailgate trim (Refer to GROUP 52A, tailgate 
trim 

P.52A-25

) and waterproof film (Refer to 

P.42-45

).

3. Remove the holder from the tailgate handle and 

adjust according to the tailgate latch rod and 
tailgate handle connection position.

ADJUSTMENT OF TAILGATE HEIGHT

M1424003500075

Turn the tailgate bumper using the arrow of the 
tailgate bumper as a guideline to adjust the height of 
the tailgate. The bumper height is altered by 
approximately 3mm by turning the tailgate bumper 
one rotation.

AC203659

AC203660

AB

Grind here

AC201556

AC103270

A

A

Section A – A

Rod

Holder

B

AC

AC103269

A

A

Section A – A

17.4mm

Bumper

Body

AC

TAILGATE

BODY

42-45

TAILGATE

REMOVAL AND INSTALLATION

M1424001100156

CAUTION

•

Do not disassemble or throw the tailgate gas spring into fire.

•

Punch a hole in the gas spring before disposal to release the gas inside.

•

Ensure the tailgate gas spring piston rod does not come into contact with foreign material.

Pre-removal Operation

•

Tailgate Spoiler Assembly Removal (Refer to GROUP 51, 

Tailgate Spoiler 

P.51-17

).

•

Tailgate Trim Assembly Removal (Refer to GROUP 52A, 

Tailgate Trim 

P.52A-25

).

•

Rear Wiper Motor Removal (Refer to GROUP 51, Rear 

Wiper and Washer 

P.51-30

).

Post-installation Operation

•

Tailgate Fit Adjustment (Refer to 

P.42-44

).

•

Rear Wiper Motor Installation (Refer to GROUP 51, Rear 

Wiper and Washer 

P.51-30

).

•

Tailgate Trim Assembly Installation (Refer to GROUP 

52A, Tailgate Trim 

P.52A-25

).

•

Tailgate Spoiler Assembly Installation (Refer to GROUP 

51, Tailgate Spoiler 

P.51-17

).

AC102859

7

3

1

2

3

4

5

6

7

8

12 ± 2 N·m

9.0 ± 2.0 N·m

12 ± 2 N·m

12 ± 2 N·m  

AC

Sealant: 3M ATD Part No. 8633 or equivalent

9.0 ± 2.0 N·m

7

TAILGATE

BODY

42-46

REMOVAL SERVICE POINT

<<A>> TAILGATE GAS SPRING REMOVAL

As shown in the Figure, slide the pin upward, then 
remove the tailgate gas spring in the direction of the 
arrow to unscrew the bolt.

INSTALLATION SERVICE POINTS

>>A<< TAILGATE OPENING WEATHERSTRIP 
INSTALLATION

Assemble so the tailgate opening weatherstrip 
marking is at the centre of the body.

>>B<< TAILGATE HINGE INSTALLATION

Apply the specified sealing agent to the tailgate 
hinge assembly surface to assembly the tailgate 
hinge.

Specified Adhesive: 3M ATD Part No.8531 
Heavy drip check sealer, 3M ATD Part 
No.8646 Automotive joint and seam sealer or 
equivalent

Tailgate assembly removal steps
1. Bumper
2. Rear washer hose
3. Waterproof film
4. Tailgate wiring harness

<<A>>

5. Tailgate gas spring
6. Tailgate assembly

•

Headlining (Refer to GROUP 52A, 
Headlining 

P.52A-27

).

>>B<<

7. Tailgate hinge
Tailgate opening weatherstrip removal

>>A<<

8. Tailgate opening weatherstrip

AC103607

Pin

Bolt

AD

AC103272AD

Tailgate opening 
weatherstrip

Positioning 
mark

AC104148 AC

Tailgate hinge