Mitsubishi Montero (2004+). Manual - part 679

DOOR

TSB Revision

BODY

42-47

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

AC

<REAR DOOR>

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.42-29

.)

<<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.42-31

.)

6. DOOR BELTLINE INNER 

WEATHERSTRIP

DOOR BELTLINE MOLDING REMOVAL 
STEPS
7. DOOR BELTLINE MOLDING

DOOR OUTER OPENING 
WEATHERSTRIP REMOVAL  

DOOR

TSB Revision

BODY

42-48

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

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

X0538CA

AC308865

AC308866

AC309026

UNITS: mm (in)

AB

<FRONT DOOR>

DOOR INNER OPENING 
WEATHERSTRIP

COWL SIDE TRIM

CENTER PILLER 
LOWER TRIM

0 – 10 
(0 – 0.39)

0 – 3 
(0 – 0.12)

BACK DOOR ASSEMBLY

TSB Revision

BODY

42-49

Mount the door inner opening weather strip to the locations 
specified below.

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

AC308867

AC308868

AC309027

X0539CA

UNITS: mm (in)

AB

<REAR DOOR>

DOOR INNER OPENING 
WEATHERSTRIP

QUARTER LOWER 
TRIM 

CENTER PILLER 
LOWER TRIM

0 – 5 
(0 – 0.20)

0 – 3 
(0 – 0.12)

SYMPTOM

INSPECTION PROCEDURE

REFERENCE PAGE

Door hard to open

1

P.42-50

Door does not open or close completely

2

P.42-50

Uneven gap between body

3

P.42-50

BACK DOOR ASSEMBLY

TSB Revision

BODY

42-50

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Door Hard to Open

DIAGNOSIS

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

P.42-51

.)

Q: Is the latch and striker engagement adjusted?

YES : 

Go to Step 2.

NO : 

Adjust the latch and striker engagement 
(Refer to 

P.42-51

). 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.42-51

). 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.42-51

). 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.42-51

). Then check 

that the gap has been improved.