Mitsubishi Lancer Evolution IX. Manual - part 363

Removal steps 

<<

A

>> >>

B

<< 1. Windshield

>>

A

<< 2. Windshield moulding

>>

A

<< 3. Window dam

>>

A

<< 4. Glass stopper

>>

A

<< 5. Spacer

>>

A

<< 6. Windshield spacer

WINDOW GLASS

BODY

42-13

REMOVAL SERVICE POINT
<<A>> WINDSHIELD REMOVAL

1. To protect the body (paint surface), apply cloth 

tape to all body areas around the installed 
windshield.

2. Make mating marks on the windshield and body.

ACX00474 AB

3. Using piano wire.

(1) Using a sharp-point drill, make a hole in the 

windshield adhesive.

(2) Pass the piano wire from the inside of the 

vehicle through the hole.

CAUTION

Do not let the piano wire touch the edge of the 
windshield.

(3) Pull the piano wire alternately from the inside 

and outside along the windshield to cut the 
adhesive.

AC002060

AC207478

Glass adhesive knife

AD

CAUTION

Inserting the glass adhesive knife too deeply into 
windshield adhesive may damage windshield.
4. Using glass adhesive knife

Keep glass adhesive knife at right angles with the 
windshield edge, and put the blade at windshield 
edge and surface. Then cut away adhesive along 
the windshield edge.

ACX00475AB

MB990480

5. Use special tool glass holder (MB990480) to 

remove the windshield.

WINDOW GLASS

BODY

42-14

CAUTION

•

ACX00476 AB

Be careful not to remove more adhesive than is 

necessary.

• Be careful also not to damage the paintwork 

on the body surface with the knife. If the 
paintwork is damaged, repair the damaged 
area with repair paint or anti-rust agent.

6. Use a knife to cut away the remaining adhesive so 

that the thickness is within 2 mm around the entire 
circumference of the body flange.

7. Finish the flange surfaces so that they are 

smooth.

CAUTION

Allow the cleaned area to dry for at least three 
minutes. Do not touch any surface that has been 
cleaned.
8. When reusing the windshield, remove the 

adhesive still adhering to the windshield, and 
clean with isopropyl alcohol.

9. Clean the body side in the same way.

INSTALLATION SERVICE POINTS
>>A<< WINDSHIELD 
SPACER/SPACER/GLASS STOPPER/WIN-
DOW DAM/WINDSHIELD MOULDING 
INSTALLATION

CAUTION

Leave the degreased parts for 3 or more minutes 
to dry well, before starting on the next step. Do 
not touch the degreased parts.
1. Use isopropyl alcohol to degrease the inside and 

outside of the windshield and the body flanges.

Y0628AU

AC006029

10138AU

10139AU

Y0497AU

Glass stopper, spacer, windshield spacer and window dam installation position

17.5 mm

Glass stopper

Glass end line

Ceramic line

Align the glass
stopper end with
the ceramic notch.

Align the window
dam and with the
seal line mark.

13 mm

Glass end line

Mark

Seal line

Ceramic line

Window dam

AB

A

A

Windshield

Seal line
centre

14 mm

Windshield spacer

Section A – A

Section B – B

B

B

14 mm

Spacer

Align the spacer
and with glass
end line

Align the windshield 
spacer end with the 
ceramic notch.

WINDOW GLASS

BODY

42-15

2. The inner side of the windshield is curved, 

therefore, make a point to assemble the glass 
stopper and windshield spacer without any lifting 
and assemble in the position shown in the Figure 
of the instructions.

3. Install the windshield moulding.

>>B<<WINDSHIELD INSTALLATION

1. When replacing the windshield, temporarily set 

the windshield against the body, and place a 
mating mark on the windshield and body.

CAUTION

• The primer strengthens the adhesive, so be 

sure to apply it evenly around the entire cir-
cumference. However, a too thick application 
will weaken the adhesive.

• Do not touch the coated surface.
• Do not apply the primer on the remaining 

adhesive because of weakening the adhesive.

2. Soak a sponge in the primer, and apply evenly to 

the windshield in the specified places. If the 
adhesive does not remain on the body flange 
surface because of the panel replacement on the 
body side, apply evenly to the body side in the 
specified places. 

3. Allow the windshield to dry for at least three 

minutes after applying primer.

ACX00480

10 mm

15 mm

AB

WINDOW GLASS

BODY

42-16

4. Fill a sealant gun with adhesive. Then apply the 

adhesive evenly around the windshield within 30 
minutes after applying the primer.
NOTE: Cut the tip of the sealant gun nozzle into a 
V shape to simplify adhesive application.

5. Align the mating marks on the windshield and the 

body, and lightly press the windshield evenly so 
that it adheres completely.

6. Use a spatula or similar tool to remove any 

excessive adhesive. Clean the surface with 
isopropyl alcohol. Avoid moving the vehicle until 
the adhesive sets.

7. Bond the windshield to the body, and install the 

roof drip moulding quickly before the adhesive 
cures (Refer to GROUP51, Garnish and Moulding 

P.51-10

).

CAUTION

• Do not move the vehicle unless absolutely 

necessary.

• When testing for water leakage, do not pinch 

the end of the hose to spray the water.

8. Wait 30 minutes or more, and then test for water 

leakage.