Mitsubishi Montero (2004+). Manual - part 673

DOOR

TSB Revision

BODY

42-23

STEP 3. Check the 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.42-28

 and 

P.42-28

). 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 6: 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.42-26

). 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 7: Uneven Gap between Body

.

DIAGNOSIS
Adjust the door fit (Refer to 

P.42-27

). Then check 

that the gap has been improved.

INSPECTION PROCEDURE 8: Wind Noise around Door

DIAGNOSIS

STEP 1. Check the weatherstrip for holding 
condition.

Q: Is the weatherstrip installed properly?

YES : 

Go to Step 2.

NO : 

Repair or replace the weatherstrip. Then go 
to Step 5.

STEP 2. Check the weatherstrip for installation 
condition.

Q: Is the weatherstrip installed properly?

YES : 

Go to Step 3.

NO : 

Repair or replace the weatherstrip. Then go 
to Step 5.

STEP 3. Check the clearance.

Q: Is the clearance between the door glass and the 

door weatherstrip holder proper?

YES : 

Go to Step 4.

NO : 

Adjust the clearance (Refer to 

P.42-27

). 

Then go to Step 5.

DOOR

TSB Revision

BODY

42-24

STEP 4. Check the door.

Q: Is the door deformed?

YES : 

Repair or replace the door. Then go to Step 

5.

NO : 

Go to Step 5.

STEP 5. Retest the system.

Q: Has the wind noise been improved?

YES : 

Return to Step 1.

NO : 

This diagnosis complete.

HOW TO LOCATE WIND NOISES

M1421004200186

1. Attach cloth tape to every place, such as panel seams, 

projections, molding seams, glass and body seams, etc. 
which might conceivably be the source of wind noise.

2. Then make a road test to check that the places not covered 

by tape are not sources of wind noise.

3. Remove the strips of tape one by one, making a road test 

after each is removed, until a wind noise source is 
discovered.

4. When such a place is found, cover it again and repeat the 

procedure to check if there are any other noise source.

5. If no others are found, the last remaining tape is the only 

source.

6. Cut the remaining piece of tape into smaller pieces, attach it 

again as it was before, and then remove the pieces one by 
one to narrow down the source.

AC203179

AC203179

AC203181

AC203182

DOOR

TSB Revision

BODY

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

M1423000600371

AC203183

TOOL

TOOL NUMBER AND 
NAME

SUPERSESSION

APPLICATION

MB990900 or 
MB991164 Door 
adjusting wrench

MB990900-01

Adjustment of door fit

MB990925 Bearing and 
oil seal installer set

A: MB990939 Remover 

bar

MB990925-01 or 
General service tool

Adjustment of door striker

MB990211 Slider 
hammer

MB990211-01

MB990241 Axle shaft 
puller

A: MB990243 Body 

puller

MB990241-01 or 
General service tool

MB991223 Harness set

A: MB991219 Test 

harness

B: MB991220 LED 

harness

C: MB991221 LED 

harness adapter

D: MB991222 Probe

General service tools

Measurement of terminal 
voltage

A: Connector pin contact 

pressure inspection

B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester 

connection

MB990900

MB990925AD

A

MB990211

MB990241

A

AC

MB991223

A

AB

B

C

D

DOOR

TSB Revision

BODY

42-26

ON-VEHICLE SERVICE

DOOR FIT ADJUSTMENT

M1423001100238

Required Special Tools:

• MB990211: Slide Hammer

• MB990243: Body Puller

• MB990900 or MB991164: Door adjusting Wrench

• MB990939: Brass Bar

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 a door is not flush with its surrounding panels, loosen the 

door-side door hinge mounting bolts and adjust the door as 
necessary.
NOTE: If the door hinge mounting bolt washers are welded, 
grind off the welding according to the procedure below 
beforehand.

.

1. Remove the door hinge. (Refer 

P.42-29

.)

2. Use a chisel or grinder to release the door hinge mount-

ing bolt washer, which is welded to the door hinge.

3. On completion, paint the affected area with touch-up 

paint to prevent corrosion.

4. Install the door hinge. (Refer 

P.42-29

.)

3. If the door is stiff to lock and unlock:

MB990784 Ornament 
remover

General service tool

Removal of trim, etc.

TOOL

TOOL NUMBER AND 
NAME

SUPERSESSION

APPLICATION

MB990784

AC000592

MB990900

OR

MB991164

AB

AC206498

WASHER

BOLT

WASHER

DOOR HINGE

AD

WELD POINT

WELD POINT