Mitsubishi Galant (2004+). Manual - part 558

FUEL FILLER LID

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FUEL FILLER LID

REMOVAL AND INSTALLATION

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AC305818

AC306167

AC305819

1

2

2

3

AB

FUEL FILLER LID HEIGHT  AND 
CLEARANCE ADJUSTMENT

REMOVAL

1.

FUEL FILLER CAP

2.

FUEL FILLER LID

3.

FUEL FILLER LID DAMPER

REMOVAL (Continued)

STRUT TOWER BAR

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STRUT TOWER BAR

REMOVAL AND INSTALLATION

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WINDOW GLASS

GENERAL

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The windshield and rear window glass are attached 
by an urethane-base adhesive to the window frame. 
This adhesive provides improved glass holding and 
sealing, and also gives body openings a greater 
structural strength.

ITEMS

AC305562

1

2

2

AB

12 ± 2 N·m
102 ± 22 in-lb    

48 ± 7 N·m
36 ± 5 ft-lb    

48 ± 7 N·m
36 ± 5 ft-lb    

REMOVAL STEPS

1. STRUT TOWER BAR
2. STRUT TOWER BAR BRACKET

ITEM

APPLICATION

QUANTITY

Wire (diameter 

× length)

For cutting adhesive

Five pieces of wire 0.6 mm 

× 1 m 

(0.02 in 

× 3.3 ft)

Glass adhesive knife

For cutting adhesive

One

Sealant gun

For adhesive application

One

Wiping shop towels

-

As required

Sealer

For prevention of water and wind 
leaks after adhesive application

As required

3M AAD

 Part No. 8906 or 

equivalent

For cleaning

As required

Glass holder MB990480

For securing of window glass

Two

WINDOW GLASS

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WINDOW GLASS INSTALLATION

CAUTION

Do not apply the primer on the adhesive 
remained as the adhesion may be reduced.

AC306636

CLEANING OF ADHESION SURFACE
CUT OFF THE RESIDUAL ADHESIVE
UNTIL THE THICKNESS IS LESS THAN
2 mm (0.08 inch). CLEAN THE ADHESION
SURFACE WITH 3M™ AAD PART
NO. 8906 OR EQUIVALENT, AND LET
DRY FOR 3 MINUTES OR MORE.

CLEANING OF ADHESION SURFACE
COMPLETELY CUT OFF ALL OF THE
RESIDUAL ADHESIVE. CLEAN THE
ADHESIVE SURFACE WITH 3M™ AAD
PART NO. 8906 OR EQUIVALENT, AND
LET DRY FOR 3 MINUTES OR MORE.

CLEANING OF ADHESION SURFACE
CLEAN OFF ANY DIRT ADHERING TO
THE ADHESION SURFACE WITH 3M™
AAD PART NO. 8906 OR EQUIVALENT,
AND LET DRY FOR 3 MINUTES OR
MORE.

ATTACHING OF WINDOW SPACER
ATTACH THE WINDOW SPACER TO SET
THE POSITIONS FOR THE GLASS TO BE
INSTALLED.

GLUING OF WINDOW DAM AND WINDOW SPACER
GLUE THE WINDOW DAM AND WINDOW SPACER TO THE GLASS, FOLLOWING THE
STANDARD POSITION ALL THE WAY AROUND THE INSIDE EDGE OF THE GLASS.

APPLICATION OF ADHESIVE
WITHIN 30 MINUTES AFTER APPLYING THE PRIMER, APPLY THE ADHESIVE EVENLY
ALL THE WAY AROUND THE INSIDE EDGE OF THE GLASS.

INSTALLING THE  GLASS
AFTER APPLYING THE ADHESIVE, LIGHTY  PRESS THE GLASS
EVENLY SO THAT IT ADHERES COMPLETELY.

CLEANING
AFTER REMOVING EXCESS ADHESIVE FROM THE BODY OR
GLASS WITH A SPATULA, ETC. CLEAN OFF  WITH 3M™ AAD
PART NO. 8906 OR EQUIVALENT.

CHECKING FOR WATER  LEAKS
CARRY OUT A SHOWER TEST TO CHECK THAT NO WATER 
LEAKS THROUGH.

REPLACE  THE GLASS

REUSING THE GLASS

WINDOW GLASS INSTALLATION
PROCEDURE

BODY SIDE

WINDOW GLASS SIDE

APPLICATION OF PRIMER
DO NOT APPLY PRIMER ON RESIDUAL ADHESIVE AS DOING SO MAY AFFECT ADHESION. APPLY ENOUGH PRIMER ON ADHESION 
SURFACE EVENLY TAKING CARE NOT TO APPLY IT ON THE RESIDUAL ADHESIVE. AFTER APPLYING PRIMER, LET IT DRY FOR 
3 MINUTES OR MORE.

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WINDOW GLASS

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WINDOW GLASS DIAGNOSIS

INTRODUCTION TO WINDOW GLASS DIAGNOSIS

M1422006700254

If water emerges from the following points, there is a 
problem in the seal or body flange.

• Windshield

• Rear window glass

WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1422006800240

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 
window glass 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.

WINDOW GLASS DIAGNOSTIC TROUBLE SYMPTOM CHART

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SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Water Leak Through Windshield/Rear Window Glass

DIAGNOSIS

STEP 1. Check if the seal is faulty.

Q: Is the seal faulty?

YES : 

Repair the seal, then go to Step 3.

NO : 

Go to Step 2.

STEP 2. Check if the body flange is deformed.

Q: Is the body flange deformed?

YES : 

Replay the body flange, then go to Step 3.

NO : 

Go to Step 3.

STEP 3. Retest the system.

Q: Is any water leaking?

YES : 

Return to Step 1.

NO : 

This diagnosis complete.

SPECIAL TOOL

M1422000600301

SYMPTOM

INSPECTION 
PROCEDURE

REFERENCE PAGE

Water leak through windshield

1

P.42-14

Water leak through rear window glass

TOOL

TOOL NUMBER AND 
NAME

SUPERSESSION

APPLICATION

MB990480 Glass holder

General service tool

Removal and installation 
of window glass

MB990480