Mitsubishi Outlander (2003+). Manual - part 309

WINDOW GLASS

BODY

42-11

WINDSHIELD

REMOVAL AND INSTALLATION

M1422001000409

Pre-removal and Post-installation Operation

•

Front Deck Garnish Removal and Installation (Refer to 

GROUP 51, Windshield Wiper 

P.51-21

).

•

Roof Drip Moulding Removal and Installation (Refer to 

GROUP 51, Moulding 

P.51-15

).

•

Front Pillar Trim Removal and Installation (Refer to 

GROUP 52A, Trims 

P.52A-18

).

AC301615

AC301503

AB

Units: mm

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent

Section A – A

15

15

15

Section B – B

Section C – C

A

A

B

B

C

C 

Seal line

Ceramic line

Mark

Apply the primer and adhesive along the fictitious lines (seal line) 

between each of the marks.

Seal line 

center

Primer

Seal line

center

Primer

Seal line center

Primer

2

2

2

2

1

3

5

4

N

N

5

N

N

4

N

Removal steps
1. Harness connector (Refer to GROUP 

51, Wiper deicer 

P.51-43

).

<<A>> >>B<<

2. Windshield

>>A<<

3. Windshield moulding

>>A<<

4. Glass stopper

>>A<<

5. Windshield spacer

Removal steps (Continued)

WINDOW GLASS

BODY

42-12

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.

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.

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.

5. Use special tool window glass holder MB990480 

to remove the windshield.

ACX00474 AB

AC002060

AC207478

Glass adhesive knife

AD

ACX00475AB

MB990480

WINDOW GLASS

BODY

42-13

CAUTION

•

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/GLASS 
STOPPER/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.

ACX00476 AB

WINDOW GLASS

BODY

42-14

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.

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 
circumference. 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 and the body in the specified 
places.

3. Allow the windshield to dry for at least three 

minutes after applying primer.

AC300403AB

Glass stopper

Windshield 
spacer

Windshield center line

Windshield 
center line

Windshield 
spacer

Seal line

Ceramic line

Glass stopper and windshield spacer installation position

Windshield end line

Align the glass
stopper end with 
the windshield mark.

Seal line

Seal line

Ceramic line

Windshield

Align the windshield 
spacer end with the 
ceramic notch.

Ceramic line

Seal line

43.9 mm

43.9 mm

65 mm

18.1 mm