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Mitsubishi Montero (2002-2004). Manual - part 7

DOOR

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42-25

7. Check that wind noise occurs when the last remaining tape

is removed, and that noise does not occur when it is re-
attached.

8. When the sources of the wind noise is finally located, attach

butyl tape, body sealer or similar material to obstruct this
source as much as possible.

SPECIAL TOOLS

M1423000600036

AC203183

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990900 or
MB991164 Door
adjusting wrench

MB990900-01

Adjustment of door fit

MB990784 Ornament
remover

General service tool

Removal of trim, etc.

MB991223 Harness set

• A: MB991219 Test

harness

• B: MB991220 LED

harness

• C: MB991221 LED

harness adapter

• D: MB991222 Probe

MB991223

Measurement of terminal
voltage

• A: Connector pin contact

pressure inspection

• B: Power circuit inspection

• C: Power circuit inspection

• D: Commercial tester

connection

MB990900

MB990784

MB991223

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ON-VEHICLE SERVICE

DOOR FIT ADJUSTMENT

M1423001100131

Required Special Tool

• MB990900 or MB991164: Door Adjusting Wrench

CAUTION

• Attach protection tape to the fender and door edges

where the hinge is installed.

• Do not rotate special tool MB991164 with a torque of

over 98 N

⋅m (72 ft-lb)

1. Use special tool MB990900 or MB991164 to loosen the

hinge mounting bolts on the body side, and then adjust the
clearance around the door so that it is uniform on all sides.

2. If the door panel is not flush with the body panels, remove

the door hinges (Refer to

P.42-28

). Use a chisel or a grinder

to grind off the weld between the door hinge and the washer.
Protect the exposed metal of the ground portion using
touch-up paint. Then use special tool MB990900 or
MB991164 to temporarily tighten the door hinge mounting
bolts and nut, and align the door panel by moving it. On
completion, tighten the bolts and nut securely.
NOTE: If the replacement hinge is used or the hinge has
already been separated from the washer, use special tool
MB990900 or MB991164 to loosen the door-side door hinge
mounting bolts and nut, and align the door panel by moving
it.

3. If the door opening and closing are stiff, adjust the linking of

the striker and the door latch using the shim, while moving
the striker up and down, or left and right.

DOOR WINDOW GLASS ADJUSTMENT

M1423001000220

Check that the door glass moves while contacting the door
glass channel when it is raised and lowered fully. If not, adjust
the door window according to the following procedures.
1. Remove the door trim and waterproof film (Refer to

P.42-

2. Loosen the door glass mounting screw via the adjusting hole

with the door window glass fully closed, then lower the
window glass a little.

ACX00495

MB990900 OR
MB991164

ACX00497AB

STRIKER

SHIM

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3. Fully close the door window glass again and tighten the door

glass mounting screw firmly via the adjusting hole.

DOOR INSIDE HANDLE PLAY CHECK AND
ADJUSTMENT

M1423001500214

1. Check that the door inside handle play is within the standard

value range.

Standard value (A): 5.1 mm (0.20 inch) or more

2. If the door inside handle play is outside the standard value

range, remove the door trim (Refer to

P.42-30

3. Loosen the inside handle mounting screws, and then move

the inside handle back and forth to adjust the play.

DOOR OUTSIDE HANDLE PLAY CHECK

M1423001600039

1. Check that the door outside handle play is within the

standard value range.

Standard value (A):

Front: 2.0 mm (0.08 inch) or more
Rear: 1.7 mm (0.07 inch) or more

2. If the door outside handle play is not within the standard

value range, check the door outside handle or the door latch
assembly. Replace if necessary.

CIRCUIT BREAKER (INCORPORATED IN THE
POWER WINDOW MOTOR) INSPECTION

M1429001000024

1. Pull the power window switch to the UP position to fully

close the door window glass, and keep pulling the switch for
10 additional seconds.

2. Release the power window switch from the UP position and

immediately press it to the DOWN position. The condition of
the circuit breaker is good if the door window glass starts to
move downwards within 60 seconds.

ACX00498

FRONT

REAR

ADJUSTING HOLE

ACX00502

SECTION B B

ACX00501

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DOOR ASSEMBLY

REMOVAL AND INSTALLATION

M1423002200205

Post-installation Operation
• Door Fit Adjustment (Refer to

P.42-26

AC204039AB

26 – 4 N•m
19 – 3 ft-lb

21 – 4 N•m
16 – 2 ft-lb

4, 5

11 – 2 N•m
98 – 17 in-lb

<FRONT>

DOOR ASSEMBLY REMOVAL STEPS
1. HARNESS CONNECTOR
2. DOOR CHECK CONNECTING BOLT
3. DOOR ASSEMBLY
4. DOOR UPPER HINGE
5. DOOR LOWER HINGE

STRIKER REMOVAL STEPS
6. STRIKER
7. STRIKER SHIM
DOOR SWITCH REMOVAL STEPS
8. DOOR SWITCH CAP
9. DOOR SWITCH

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