Mitsubishi Montero (2002-2004). Manual - part 17

SUNROOF ASSEMBLY

TSB Revision

BODY

42-65

DISASSEMBLY AND ASSEMBLY

M1426001400023

X1224CA

ACX02406

16

5

SECTION A   A

1

2

3

6

5

4

16

11 12

10

14

13

8

9

7

15

AB

A

A

SEALANT :
   3M  AAD PART No. 8531 OR 8646 
   OR EQUIVALENT

DISASSEMBLY STEPS

1. ROOF LID GLASS ASSEMBLY
2. WEATHERSTRIP
3. SUNROOF MOTOR ASSEMBLY
4. ROOF DRIP CHANNEL
5. SEALER
6. SUN SHADE ASSEMBLY
7. DRIVE CABLE ASSEMBLY

<<A>> >>A<<

8. SHAFT

<<A>>

9. DRIVE CABLE

<<B>>

10. ROOF WINDOW DEFLECTOR 

PANEL ASSEMBLY

<<C>>

11. DEFLECTOR

<<C>>

12. DEFLECTOR LINK
13. SET PLATE
14. FRONT COVER
15. CABLE GUIDE CASING
16. GUIDE RAIL SUB-ASSEMBLY

DISASSEMBLY STEPS (Continued)

SUNROOF ASSEMBLY

TSB Revision

BODY

42-66

REMOVAL SERVICE POINT

.

<<A>> SHAFT/DRIVE CABLE REMOVAL
Draw out the drive cable assembly as shown in the illustration, 
then remove the shaft and the drive cable.

.

<<B>> ROOF WINDOW DEFLECTOR PANEL ASSEMBLY 
REMOVAL
Pry out the roof window deflector panel assembly using a flat-
tip screwdriver as shown in the illustration.

.

X1021CA

ACX00578

GUIDE RAIL SUB-ASSEMBLY

APPROX.
200 mm (7.8 in)

SHAFT

DRIVE CABLE ASSEMBLY

AB

X1020CA

X1123CA

ACX00579

FLAT-TIP 
SCREWDRIVER

A

A

ROOF WINDOW
DEFLECTOR PANEL 
ASSEMBLY

SECTION A   A

FLAT-TIP 
SCREWDRIVER

ROOF WINDOW
DEFLECTOR PANEL 
ASSEMBLY

GUIDE RAIL SUB-ASSEMBLY

AB

SUNROOF ASSEMBLY

TSB Revision

BODY

42-67

<<C>> REMOVAL OF DEFLECTOR/DEFLECTOR LINK
Disconnect the deflector and the deflector panel using a flat-tip 
screwdriver as shown in the illustration.

INSTALLATION SERVICE POINT

.

>>A<< SHAFT INSTALLATION

Install the shaft to the drive cable from the outside of vehicle as 
shown in the illustration.

X1019CA

AX1122CA
ACX00580

A

A

FLAT-TIP
SCREWDRIVER

SECTION A   A

FLAT-TIP
SCREWDRIVER

DEFLECTOR LINK

AB

X1021CA

ACX00581

FRONT OF
VEHICLE

SHAFT

A

A

DRIVE CABLE ASSEMBLY

HOLLOW IN SHAFT

SHAFT

SHAFT 
INSERTION 
DIRECTION

INSERT THE SHAFT UNTIL ITS CONCAVE PART IS ENGAGED
WITH THE CONVEX PART OF THE DRIVER CABLE.

RAISED SECTION OF DRIVE 
CABLE ASSEMBLY

DRIVE CABLE ASSEMBLY

SECTION A   A

AB

SPECIFICATIONS

TSB Revision

BODY

42-68

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1421005300153

SERVICE SPECIFICATIONS

M1421000300181

<DOOR>

<SUNROOF>

SEALANTS

M1421000500163

<DOOR>

<WINDOW GLASS>

ITEM

SPECIFICATIONS

Hood
Hood latch bolt

9.0 

± 2.0 N⋅m (79 ± 18 in-lb)

Hood support rod bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Hood hinge bolt (hood side)

22 

± 4 N⋅m (16 ± 3 ft-lb)

Hood hinge bolt (body side)

22 

± 4 N⋅m (16 ± 3 ft-lb)

Door
Door hinge bolt (body side)

26 

± 4 N⋅m (19 ± 3 ft-lb)

Door latch assembly screw

5.9 

± 1.0 N⋅m (52 ± 9 in-lb)

Power window motor bolt

7.4 

± 1.4 N⋅m (65 ± 13 in-lb)

Speaker

4.9 

± 1.0 N⋅m (44 ± 8 in-lb)

Striker screw

11 

± 2 N⋅m (98 ± 17 in-lb)

Back door
Back door hinge bolt

21 

± 4 N⋅m (16 ± 2 in-lb)

Back door latch assembly bolt

5.9 

± 1.0 N⋅m (52 ± 9 in-lb)

Striker bolt

11 

± 2 N⋅m (98 ± 17 in-lb)

ITEM

STANDARD VALUE

Door inside handle play mm (in)

5.3 (0.21) or more

Door outside handle play mm (in) Front

2.0 (0.08) or more

Rear

1.7 (0.07) or more

ITEM

STANDARD VALUE

Roof lid glass operation current A

7 or more [20

°C (68°F)]

ITEM

SPECIFIED SEALANT 

REMARK

Waterproof film

3 M

äAAD8633 or equivalent

Ribbon sealer

ITEM

SPECIFIED SEALANT 

Back door

3 M

äAAD8609 or equivalent

Quarter window glass, garnish

3 M

äAAD8513 or equivalent

Windshield

3 M

äAAD8609 or equivalent