Mitsubishi Montero Sport (2004+). Manual - part 439

WINDOW GLASS

TSB Revision

BODY

42-11

WINDOW GLASS

WINDOW GLASS DIAGNOSIS

INTRODUCTION TO WINDOW GLASS DIAGNOSIS

M1422006700209

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

WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1422006800206

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 that the malfunction is eliminated.

SYMPTOM CHART

M1422006900214

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Water Leak Through Windshield/Water Leak Through Quarter Window 
Glass/Water Leak Through Liftgate 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 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 procedure is complete.

SPECIAL TOOL

M1422000600204

SYMPTOM

INSPECTION 
PROCEDURE

REFERENCE PAGE

Water leak through windshield

1

P.42-11

Water leak through quarter window glass
Water leak through back 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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42-12

WINDOW GLASS

GENERAL INFORMATION

M1422000100243

The windshield, quarter window and liftgate glass are 
attached by an urethane-base adhesive to the win-
dow frame. This adhesive provides improved glass 
holding and sealing, and also permits use of body 
openings having a greater structural strength.

ITEM

APPLICATION

QUANTITY

Wire (dia. 

× length)

For cutting adhesive

Five pieces of wire 0.6 mm 

× 1 m 

(0.02 in 

× 3.3 ft)

Sealant gun

For adhesive application

One

Wiping shop towels

−

As required

Sealer

For prevention of water leaks and 
gathering after adhesive application

As required

3M

TM

 AAD Part No. 8880 or 

equivalent

For cleaning

As required

Glass holder MB990480

−

2

Windshield molding (service 
part)

−

1

Dam (service part)

−

As required

Tectyl 506T (Valvoline oil 
company)

−

As required

WINDOW GLASS

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42-13

WINDOW GLASS INSTALLATION

CLEANING OF ADHESION SURFACE
CUT OFF THE RESIDUAL ADHESIVE
UNTIL THE THICKNESS IS LESS THAN
2 mm (0.88 inch). CLEAN THE ADHESION
SURFACE WITH 3M™ ADD PART
NO. 8880 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. 8880 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. 8880 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 PRIMER
APPLY TO THE ADHESION SURFACE OF
THE BODY, AND LET DRY FOR 3 
MINUTES OR MORE.

APPLICATION OF PRIMER
APPLY SUFFICIENT PRIMER EVENLY TO THE ADHESION SURFACE SO THAT THERE
IS NO PATCHINESS.
AFTER APPLICATION, LET DRY FOR 3 TO 30 MINUTES.

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 ADHEDIVE, 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. 8880 OR EQUIVALENT.

CHECKING FOR WATRER  LEAKS
CARRY OUT A SHOWER TEST TO CHECK THAT NO WATER WILL
LEAK THROUGH

REPLACE  THE GLASS

REUSING THE GLASS

WINDOE GLASS INSTALLAITON
PROCEDURE

BODY SIDE

WINDOW GLASS SIDE

AC006000AB

TION

WINDOW GLASS

TSB Revision

BODY

42-14

WINDSHIELD

REMOVAL AND INSTALLATION

M1422001000380

Required Special Tools:

• MB990449: Window Molding Remover

• MB990480: Glass Holder

Pre-removal and Post-installation Operation
• Front Deck Garnish Removal and Installation (Refer to 

GROUP 51, Windshield Wiper and Washer 

P.51-16

.)

• Front Pillar Trim Removal and Installation (Refer to 

GROUP 52A, Trims 

P.52A-41

.)

• Headlining Removal and Installation (Refer to GROUP 

52A, Headlining 

P.52A-42

.) 

• Inside Rear Vew Mirror Removal and Instllation(Refer to 

GROUP 52A,Insaide Rear Vew Mirror  

P.52A-43

.) 

AC003762

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

10(0.4)

15(0.6)

PRIMER

PRIMER

21(0.8)

PRIMER

11.5(0.45)

21(0.8)

AB

5

4

4

1

3

3

4

14(0.6)

10(0.4)

15(0.6)

15(0.6)

4

4

2

UNIT: mm(in)

200(7.9)

200(7.9)

2

100(3.9)

ADHESIVE TAPE: 
DOUBLE-SIDED TAPE[6 mm (0.24 in) 
WIDE AND 0.125 mm (0.0040 in) THICK]

REMOVAL STEPS

<<A>> >>A<<

1. WINDSHIELD
2. WINDSHIELD MOLDING
3. WINDOW SPACER
4. GLASS STOPPER

>>A<<

5. DUAL LOCK FASTENER