Mitsubishi Montero (2004+). Manual - part 670

WINDOW GLASS

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WINDOW GLASS INSTALLATION

WINDOW GLASS DIAGNOSIS

INTRODUCTION TO WINDOW GLASS DIAGNOSIS

M1422006700221

If water leaks from the windshield, the quarter win-
dow glass, the back door glass, or the seal or body 
flange may be faulty.

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.

AB

WINDOW GLASS

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WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1422006800046

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.

SYMPTOM CHART

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SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Water Leak through Windshield/Water Leak through Quarter Window 
Glass/Water Leak through Back Door 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 : 

Repair or replace 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

M1422000600323

SYMPTOM

INSPECTION 
PROCEDURE

REFERENCE PAGE

Water leak through windshield

1

P.42-12

Water leak through quarter window glass
Water leak through back door window glass

TOOL

TOOL NUMBER AND 
NAME

SUPERSESSION

APPLICATION

MB990480 Glass holder

General service tool

Removal and installation of 
window glass

MB990480

WINDOW GLASS

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WINDSHIELD

REMOVAL AND INSTALLATION

M1422001000391

Required Special Tool:

• MB990480: Glass Holder

REMOVAL SERVICE POINT

.

<<A>> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth tape to all 

body areas around the installed windshield.

Pre-removal and Post-installation Operation
• Front Deck Garnish Removal and Installation (Refer to GROUP 51, Windshield Wiper and Washer 

P.51-26

.)

• Front Pillar Trim Removal and Installation (Refer to GROUP 52A, Trims 

P.52A-8

.)

• Headlining Removal and Installation (Refer to GROUP 52A, Headlining 

P.52A-10

.) 

ACX00469

ACX02416

ACX0470

1

2

3

4

A

A

B

B

C

C

SECTION A – A

SECTION B – B

SECTION C – C

UNIT: mm(in)

ADHESIVE: 3M™ AAD PART NO. 8609 SUPER FAST URETHANE AND 3M™ AAD PART NO. 8608 SUPER FAST
URETHANE PRIMER OR EQUIVALENT

7.7(0.30)

9.8(0.38)

PRIMER

PRIMER

32.5(1.3)

PRIMER

2.0(0.08)

8.0(0.31)

PRIMER

AB

REMOVAL STEPS

<<A>> >>B<<

1. WINDSHIELD

>>A<<

2. WINDSHIELD MOLDING

>>A<<

3. WINDOW SPACER

>>A<<

4. GLASS STOPPER

WINDOW GLASS

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2. Using a sharp-point drill, make a hole in the windshield 

adhesive.

3. 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.
4. Pull the piano wire alternately from the inside and outside 

along the windshield to cut the adhesive.

5. Make mating marks on the windshield and body.

6. Use special tool MB990480 to remove the windshield.

CAUTION

• Be careful not to remove more adhesive than is neces-

sary.

• Be careful also not to damage the paintwork on the 

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

7. Use a knife to cut away the remaining adhesive so that the 

thickness is within 2 mm (0.08 inch) around the entire 
circumference of the body flange.

8. 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.
9. When reusing the windshield, remove the adhesive still 

adhering to the windshield, and clean with 3M

 AAD Part 

number 8906 or equivalent.

10.Clean the body side in the same way.

INSTALLATION SERVICE POINTS

.

>>A<< GLASS STOPPER/WINDSHIELD SPACER/WIND-
SHIELD MOLDING 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 3M

 AAD Part number 8906 or equivalent to degrease 

the inside and outside of the windshield and the body 
flanges.

ACX00474 AB

ACX00475AB

MB990480

ACX00476 AB