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INSTALLATION INSTRUCTIONS
GRILLE GUARD
2000-2004 MITSUBISHI MONTERO SPORT
PART #8044
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GRILLE GUARD
2000-2004 MITSUBISHI MONTERO SPORT
PARTS LIST:
1 Grille Guard 2 10-1.5mm x 100mm Hex Bolts
1 Driver/Left Side Mounting Bracket 6 10mm Lock Washers
1 Passenger/Right Side Mounting Bracket 4
2 Support Brackets 4 10mm x 20mm OD x 2mm STD Flat Washers
2 600mm x 50mm x 1.0mm Adhesive Foam Strips 6 10-1.5mm Hex Nuts
2 10mm U-Bolts 2 8-1.25mm x 25mm Hex Bolts
4 12-1.75mm x 35mm Hex Bolts 2 8mm Lock Washers
4 12mm Lock Washers 4 8mm x 16mm OD x 1.6mm Flat Washers
8 12mm x 24mm x 2.5mm Flat Washers 2 8-1.25mm Hex Nuts
4 12-1.75mm Hex Nuts
10mm x 34mm OD x 3mm Large Flat
Washers
(2) Top Support Brackets
(2) 10mm U-Bolts (w/hardware)
Passenger/Right Side
Frame Mounting Bracket
Driver/Left Side Frame
Mounting Bracket
PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. ASSISTANCE IS RECOMMENDED.
2. Starting on the passenger side, locate the mounting area at the front of the frame for the Mounting
Bracket, (Figure 1). Select (1) 10mm U-Bolt, (Figure 2A). Insert the U-Bolt into one slot and out the
next slot as pictured in Figure 2B. Select the passenger side Mounting Bracket. Line up the Bracket
over the U-Bolt. Secure the Bracket to the U-Bolt with (2) 10mm Large Flat Washers, (2) 10mm Lock
Washers and (2) 10mm Hex Nuts, (Figure 3). Leave loose at this time.
3. Insert (1) 10mm x 100mm Hex Bolt with (1) 10mm Small Flat Washer into the hole toward the front of
the frame, (Figure 2B). Insert the Bolt completely through the frame and the remaining slot in the
Bracket. Secure the Bracket to the Bolt with (1) 10mm Small Flat Washer (1) 10mm Lock Washer and
(1) 10mm Hex Nut, (Figure 4). Snug but do not fully tighten hardware at this time.
4. Repeat Steps 2 – 3 to install the driver side Mounting Bracket, (Figures 5 & 6).
5. Move to the passenger side headlight assembly. Locate the factory hex bolt visible in the gap between
the bottom of the headlight assembly and the top of the bumper cover, (Figures 7A & 7B). Select (1)
Support Bracket. Apply a layer of the included Adhesive Backed Foam Tape to the flat portion of the
Bracket to protect the plastic bumper, (Figure 8). Remove the hex bolt. NOTE: To access this hex bolt,
insert wrench through opening in fender liner, (Figure 9). Insert (1) Support Bracket into opening with
the foam covered flat end out through the gap between the headlight and bumper, (Figure 10). Secure
Page 1 of 4 12-11-12 Rev1 (DP)
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GRILLE GUARD
2000-2004 MITSUBISHI MONTERO SPORT
the Support Bracket to factory threaded hole with the factory hex bolt. Snug but do not tighten hardware
at this time. Repeat this Step to install the driver side Support Bracket.
6. Carefully unpack the Grille Guard. With assistance, line up the bottom mounting tabs on the Grille
Guard with the (2) previously installed Frame Mounting Brackets. Bolt the Grille Guard to the inside of
the Frame Mounting Brackets with the included (4) 12mm x 35mm Hex Bolts, (8) 12mm Flat Washers,
(4) 12mm Lock Washers and (4) 12mm Hex Nuts, (Figure 11). Do not tighten hardware at this time.
7. Push the Grille Guard back toward the vehicle and line up the (2) tabs on the Grille Guard with the (2)
Support Brackets. Bolt the tabs to the Support Brackets with the included (2) 8mm x 25mm Hex Bolts,
(4) 8mm Flat Washers, (2) 8mm Lock Washers and (2) 8mm Hex Nuts, (Figure 11). Do not tighten
hardware at this time.
8. Level and adjust the Grille Guard properly and tighten all hardware. IMPORTANT: Make sure that the
Support Bracket is in the center of the gap between the headlight and bumper before tightening
hardware.
9. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
To protect your investment, wax this product after installing. Regular waxing is recommended to add a protective layer
over the finish. Do not use any type of polish or wax that may contain abrasives that could damage the finish.
For stainless steel: Aluminum polish may be used to polish small scratches and scuffs on the finish. Mild soap may be
used also to clean the Grille Guard.
For gloss black finishes: Mild soap may be used to clean the Grille Guard.
Passenger Side Installation Pictured
Front
Front
10mm x 100mm Hex Bolt
10mm x 20mm STD Flat Washer
(Fig 1) Passenger side pictured from under vehicle
Fig 2B
Front
Fig 2A
(Fig 3) Passenger side Bracket install pictured
10mm U-Bolt
(2) 10mm x 34mm Large Flat Washers
(2) 10mm Lock Washers
(2) 10mm Hex Nuts
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Passenger Side Installation Pictured
Fig 4
Front
(Fig 6) Driver side pictured from under vehicle
Fig 7B
Front
GRILLE GUARD
2000-2004 MITSUBISHI MONTERO SPORT
10mm x 100mm Hex Bolt
(2) 10mm STD Flat Washers
10mm Lock Washer
10mm Hex Nut
Front
Front
(Fig 5) Driver side pictured from under vehicle
Fig 7A
Locate 6mm hex bolt behind/below
side of headlight assembly. Hex bolt
is visible between top of bumper and
bottom of headlight assembly. Use
masking tape to protect the finish
during Bracket installation
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Passenger Side Installation Pictured
(2)
(Fig 8) Apply Adhesive Backed Foam Tape
to the top and bottom of the Support
Brackets to prevent damage during install
Bolt the Support Bracket in
position with the factory hex bolt
GRILLE GUARD
2000-2004 MITSUBISHI MONTERO SPORT
Front
(Fig 9) Access factory hex bolt through
opening in back of front fender
Fig 10
Front
8mm x 25mm Hex Bolt
(2) 8mm Flat Washers
8mm Lock Washer
8mm Hex Nut
Front
Fig 11
Bolt the Grille Guard to the inside
of the Mounting Brackets with :
(2) 12mm x 35mm Hex Bolts
(4) 12mm Flat Washers
(2) 12mm Lock Washers
12mm Hex Nuts
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