Mitsubishi Montero Sport (2004+). Manual - part 488

UNDER COVER

TSB Revision

BODY

42-207

UNDER COVER

REMOVAL AND INSTALLATION

M1421002800041

AC003810

1

2

3

4

AB

1. TRANSFER CASE PROTECTOR

UNDER SKID PLATE REMOVAL 
STEPS

2. UNDER COVER
3. UNDER SKID PLATE
4. SKID PLATE BRACKET

SPECIFICATIONS

TSB Revision

BODY

42-208

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1426003000087

ITEM

SPECIFICATION

Body mounting 
Body mounting self jam nut

27 

− 31 N⋅m (20 − 23 ft-lb)

Door
Door hinge bolt

26 N

⋅m (19 ft-lb)

Door hinge nut

26 N

⋅m (19 ft-lb)

Power window motor bolt

5.4 

± 0.5 N⋅m (48 ± 4 in-lb)

Striker screw

12 N

⋅m (106 in-lb)

Door latch assembly screw

6 N

⋅m (53 in-lb)

Hood
Hood latch bolt

9 N

⋅m (80 in-lb)

Hood support rod bolt

9 N

⋅m (80 in-lb)

Hood hinge bolt (hood side)

12 N

⋅m (106 in-lb)

Hood hinge bolt (body side)

22 N

⋅m (16 ft -lb)

Hood hinge nut (body side)

12 N

⋅m (106 in-lb)

Keyless entry system
Keyless entry receiver-ECU

5 N

⋅m (44 in-lb)

Liftgate
Liftgate hinge nut

14 N

⋅m (124 in-lb)

Liftgate hinge bolt

12 N

⋅m (106 in-lb)

Striker bolt

9 N

⋅m (80 in-lb)

Joint ball

12 N

⋅m (106 in-lb)

Liftgate gas spring bolt

5 N

⋅m (44 in-lb)

Liftgate latch assembly bolt

9 N

⋅m (80 in-lb)

Sunroof
Sunroof assembly bolt

5 N

⋅m (44 in-lb)

Sunroof assembly nut

5 N

⋅m (44 in-lb)

Sunroof glass bolt

5 N

⋅m (44 in-lb)

Sunroof guide assembly bolt

3 N

⋅m (27 in-lb)

Set bracket bolt

5 N

⋅m (44 in-lb)

Set bracket nut

5 N

⋅m (44 in-lb)

SPECIFICATIONS

TSB Revision

BODY

42-209

SERVICE SPECIFICATIONS

M1426000300078

<DOOR>

<LIFTGATE>

SEALANTS AND ADHESIVES

M1426000500072

<DOOR>

<LIFTGATE>

<WINDOW GLASS>

<SUNROOF>

ITEM

STANDARD VALUE

Door outside handle play mm (in)

2.8 (0.11)

Power window operation current A

7 or more [20

°C (68°F)]

Door inside handle play mm (in)

7.3 (0.29) or more

Glass pad and glass holder 
installation position mm (in)

Distance (A) between glass 
holder and rear edge of glass

106.7 

− 108.2 (4.20 − 4.26)

Distance (B) between glass 
holders

417.5 

− 420.5 (16.44 − 16.56)

Distance (C) between glass 
holder and rear edge of glass

<Vehicles with power windows>127 

− 

131 (5.0 

− 5.2) <Vehicles without 

power windows> 62 

− 66 (2.4 − 2.6)

ITEM

STANDARD VALUE

Liftgate handle play mm (in)

1.5 

− 5.5 (0.06 − 0.22)

ITEM

SPECIFIED SEALANT 

REMARK

Waterproof film

3 M

 AAD8633 or equivalent

Ribbon sealer

ITEM

SPECIFIED SEALANT 

REMARK

Waterproof film

3 M

 AAD8633 or equivalent

Ribbon sealer

ITEM

SPECIFIED SEALANT 

Liftgate window glass

3 M

AAD8609 or equivalent

Quarter window glass

3 M

AAD8513 or equivalent

Windshield

3 M

AAD8609 or equivalent

ITEM

SPECIFIED SEALANT 

Sunroof glass attaching screws

Loctite

 Small Screw Threadlocker 222 or equivalent

Sunroof glass sealing

Loctite

 410 Black Toughened Instant Adhesive or equivalent

SPECIFICATIONS

TSB Revision

BODY

42-210

COMPONENT IDENTIFICATION

M1421005400194

DOOR HINGES

DOOR CHECK

DOOR OUTER OPENING WEATHERSTRIP

APPLICABLE LOCATION

IDENTIFICATION MARK

Front left side door

Upper hinge

F1

Lower hinge

E1

Front right side door

Upper hinge

E1

Lower hinge

F1

Rear left side door

Upper hinge

A1

Lower hinge

B1

Rear right side door

Upper hinge

B1

Lower hinge

A1

APPLICABLE LOCATION

IDENTIFICATION MARK

LH

Front door

19L

Rear door

25L

RH

Front door

19R

Rear door

25R

APPLICABLE LOCATION

IDENTIFICATION COLOR

Right door

Brown or yellow

Left door

Natural (white)