Mitsubishi Outlander manuals

Mitsubishi Outlander: Window Glass

SPECIFICATIONS

ADHESIVE

Mitsubishi Outlander. Body

LUBRICANT

Mitsubishi Outlander. Body

GENERAL

The windshield glass, quarter window glass and liftgate 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

Mitsubishi Outlander. Body

WINDOW GLASS INSTALLATION

CAUTION Do not apply primer on the adhesion surface, as adhesion may be reduced.

Mitsubishi Outlander. Body

WINDOW GLASS DIAGNOSIS

INTRODUCTION TO WINDOW GLASS DIAGNOSIS

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

WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGY

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

Mitsubishi Outlander. Body

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Water Leak Through Windshield Glass/Water Leak Through Quarter Window Glass/Water Leak Though Liftgate 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 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

Mitsubishi Outlander. Body

WINDSHIELD

REMOVAL AND INSTALLATION

Pre-removal and post-installation operation

Mitsubishi Outlander. Body

Mitsubishi Outlander. Body

Removal steps

  1. Windshield glass
  2. Windshield molding
  3. Glass stopper
  4. Windshield spacer

Required Special Tool:

REMOVAL SERVICE POINT

WINDSHIELD GLASS REMOVAL

1. To protect the body (paint surface), apply cloth tape to all body areas around the installed windshield glass.

2. Make mating marks on the windshield glass 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 glass.

  1. Pull the piano wire alternately from the inside and outside along the windshield glass to cut the adhesive.

Mitsubishi Outlander. Body

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

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

Mitsubishi Outlander. Body

Mitsubishi Outlander. Body

5. Use special tool MB990480 to remove the windshield glass.

Mitsubishi Outlander. Body

CAUTION

6. 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.

7. Finish the flange surfaces so that they are smooth.

Mitsubishi Outlander. Body

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 glass, remove the adhesive still adhering to the windshield glass, and clean with 3M  AAD Part No. 8906 or equivalent

9. Clean the body side in the same way.

INSTALLATION SERVICE POINTS

WINDSHIELD SPACER/GLASS STOPPER/ WINDSHIELD 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 glass and the body flanges.

Mitsubishi Outlander. Body

2. Install the windshield spacer and glass stoppers to the specified positions so that there are no adrift or warped surfaces inside the windshield glass.

Mitsubishi Outlander. Body

3. Install the double-sided tapes to the windshield glass.

4. Install the windshield molding to the windshield glass.

WINDSHIELD GLASS INSTALLATION

1. When replacing the windshield glass, temporarily set the windshield glass against the body, and place a mating mark on the windshield glass and body.

CAUTION

2. Soak a sponge in the primer, and apply evenly to the windshield glass and the body in the specified places.

3. Allow the windshield glass to dry for at least three minutes after applying primer.

4. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield glass 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 glass and the body, and lightly press the windshield glass evenly so that it adheres completely.

6. Use a spatula or similar tool to remove any excessive adhesive. Clean the surface with 3M AAD Part number 8906 or equivalent. Avoid moving the vehicle until the adhesive sets.

Mitsubishi Outlander. Body

CAUTION

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

QUARTER WINDOW GLASS

REMOVAL AND INSTALLATION

Pre-removal and post-installation operation

Mitsubishi Outlander. Body

Mitsubishi Outlander. Body

Removal steps

  1. Quarter window glass assembly
  2. Clip
  3. Fastener

Required Special Tool:

REMOVAL SERVICE POINT

QUARTER WINDOW GLASS ASSEMBLY REMOVAL

1. In order to protect the body (paint surface), apply the protective tape to all body areas around the installed quarter window glass assembly.

2. Stick the protective tape to avoid the quarter window glass assembly from dropping.

Mitsubishi Outlander. Body

3. Use glass adhesive knife to cut away adhesive.

Mitsubishi Outlander. Body

4. Working inside the vehicle, insert the tip of a windshield knife into the sealed part of the quarter window glass assembly.

CAUTION If you lever the windshield knife, the quarter window glass assembly may be damaged.

5. Holding the tip of the windshield knife and the body flange at right angles, align the blade of the windshield knife with the body flange, and pull the blade parallel to the body flange to separate the adhesive.

Mitsubishi Outlander. Body

6. Use a piano wire to separate the clips.

Mitsubishi Outlander. Body

7. Make mating marks on the quarter window glass assembly and body, and use the special tool MB990480 to remove the quarter window glass assembly.

Mitsubishi Outlander. Body

CAUTION

8. 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.

9. Finish the flange surfaces so that they are smooth.

Mitsubishi Outlander. Body

CAUTION Allow the cleaned area to dry for at least three minutes. Do not touch any surface that has been cleaned.

10.When reusing the quarter window glass, remove the adhesive still adhering to the quarter window glass, and clean with 3M AAD Part number 8906 or equivalent.

11.Clean the body side in the same way.

INSTALLATION SERVICE POINTS

FASTENER/CLIP INSTALLATION

1. If the quarter window glass assembly is reused, follow the procedure below:

  1. Engage the clip with the body.
  2. Separate the convex portion of the quarter window glass assembly clip installation position.

NOTE: If the quarter window glass assembly is installed without separating the convex portion of the quarter window glass assembly clip installation position, improper installation may result.

CAUTION Before the next operation, leave the decreased parts for 3 minutes or more to dry. Do not touch the degreased parts.

2. Use 3M AAD Part number 8906 or equivalent to degrease the inside circumference of the quarter window glass assembly and the body flanges.

Mitsubishi Outlander. Body

3. Install the fasteners to the specified positions on the body flange.

4. Install the fasteners to the quarter window glass assembly at the positions which correspond to the fasteners on the body flange.

Mitsubishi Outlander. Body

5. Apply the double-sided tape to the specified position on the body flange.

QUARTER WINDOW GLASS ASSEMBLY 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 quarter window glass and the body flanges.

2. Install the quarter window glass using the same procedures as for the windshield glass.

Mitsubishi Outlander. Body

LIFTGATE WINDOW GLASS

REMOVAL AND INSTALLATION

Pre-removal and post-installation operation

Mitsubishi Outlander. Body

Mitsubishi Outlander. Body

Removal steps

  1. Liftgate window glass
  2. Fastener
  3. Glass stopper
  4. Liftgate dam upper
  5. Liftgate dam side
  6. Liftgate dam lower

REMOVAL SERVICE POINT

LIFTGATE WINDOW GLASS REMOVAL

Remove the liftgate window glass by the same procedures as for the windshield glass.

NOTE: Use a piano wire to remove the liftgate window glass.

INSTALLATION SERVICE POINTS

LIFTGATE DAM LOWER/LIFTGATE DAM SIDE/LIFTGATE DAM UPPER/GLASS STOPPER/ FASTENER INSTALLATION

Mitsubishi Outlander. Body

1. As shown in the figure, divide the liftgate dam lower into three pieces.

2. By referring to the illustration, cut the end of the liftgate dam lower (liftgate dam lower center, liftgate dam lower side) and liftgate dam side.

Mitsubishi Outlander. Body

Mitsubishi Outlander. Body

3. Cut both ends of the liftgate dam lower center to 67º.

Mitsubishi Outlander. Body

4. Cut both ends of the liftgate dam lower side (LH) to 30º and 67º.

Mitsubishi Outlander. Body

5. Cut both ends of the liftgate dam lower side (RH) to 67º and 30º.

Mitsubishi Outlander. Body

6. Cut one side of the liftgate dam side (LH) end to 62º.

Mitsubishi Outlander. Body

7. Cut one side of the liftgate dam side (RH) end to 62º.

CAUTION

8. To both ends of the liftgate dam lower center, adhere the liftgate dam lower side (LH, RH) according to the procedure below.

NOTE: When the liftgate dam lower center and the liftgate dam lower side (LH, RH) are attached together, the liftgate dam lower is complete.

  1. To the 67º-end of the liftgate dam lower center and the 67º-end of the liftgate dam lower side, apply the adhesive.

NOTE: When applying the adhesive to the adhesion surfaces of the liftgate dam lower center and the liftgate dam lower side (LH, RH), the task becomes easier if a tooth pick is used.

Mitsubishi Outlander. Body

  1. Attach the 67º-end of the liftgate dam lower center with the 67º-end of the liftgate dam lower side.

CAUTION

Mitsubishi Outlander. Body

9. To both ends of the liftgate dam lower, adhere the liftgate dam side (LH, RH) according to the procedure below.

  1. Apply the adhesive only to the lip of the liftgate dam lower 30º-end.

    NOTE: When applying the adhesive to the adhesion surfaces of the liftgate dam lower and the liftgate dam side (LH, RH), the task becomes easier if a tooth pick is used.

Mitsubishi Outlander. Body

  1. Attach together the lip of liftgate dam lower 30º-end with the lip of liftgate dam side 62º-end (ensure that there is no level difference at the lip adhesion area).

Mitsubishi Outlander. Body

  1. After adhering the lip of the liftgate dam lower 30º-end with the lip of the liftgate dam side 62º-end, apply the adhesive to the remaining area.

Mitsubishi Outlander. Body

  1. Adhere the remaining area (ensure that there is no level difference at the tape part).

Mitsubishi Outlander. Body

CAUTION Before the next operation, leave the degreased parts for 3 minutes or more to dry. Do not touch the degreased parts.

10.Use 3M AAD Part number 8906 or equivalent to degrease the inside circumference of the liftgate window glass and the liftgate flanges.

Mitsubishi Outlander. Body

11.Install the liftgate dam lower, liftgate dam side, and liftgate dam upper according to the procedures below.

  1. Peel the backing paper of the liftgate dam lower.
  2. Adhere the liftgate dam lower to the liftgate window glass.

    NOTE: The liftgate dam lower can be attached cleanly if the liftgate dam lower is attached to the liftgate window glass starting from the adhesion areas of the liftgate dam lower center and the liftgate dam lower side (LH, RH) located at the liftgate dam lower.

  3. Peel the backing paper of the liftgate dam side.
  4. Adhere the liftgate dam side to the liftgate window glass.

    NOTE: The liftgate dam side can be attached cleanly if the liftgate dam side is attached to the liftgate window glass starting from the adhesion areas of the liftgate dam lower and the liftgate dam side (LH, RH) located at the liftgate dam lower.

  5. Peel the backing paper of the liftgate dam upper.
  6. Adhere the liftgate dam upper to the liftgate window glass.
  7. When the liftgate dam side's upper end section is protruding from the liftgate dam upper's upper end section, cut off the upper end section of the liftgate dam side so that the liftgate dam side's upper end section becomes leveled with the liftgate dam upper's upper end section.

12.Install the glass stopper and fastener to the specified positions.

13.Correctly install the fasteners to the specified positions on the liftgate flange.

LIFTGATE WINDOW GLASS ASSEMBLY INSTALLATION

1. Apply the primer and adhesive.

2. Install the liftgate window glass by the same procedures as for the windshield glass.

Mitsubishi Outlander. Body

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