Mitsubishi Montero (2002-2004). Manual — part 3
FUEL FILLER LID
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REMOVAL SERVICE POINT
.
<<A>> RIVET REMOVAL
Use a drill [
φ6.5 − 7.5 mm (φ0.25 − 0.29 inch)] to break the rivet
by drilling a hole, and remove the rivet.
INSTALLATION SERVICE POINT
.
>>A<< RIVET INSTALLATION
1. Insert the rivet [
φ6.4mm (φ0.25 inch)] into the body panel
and wide fender.
2. Insert the "A" side of the rivet into the riveter.
3. Pressing the flange surface of the rivet, move the handle of
the riveter.
4. The thinnest point of "A" is cut and the rivet is held in the
position.
DRILL
RIVET
FUEL FILLER
DOOR PANEL
AB
ACX00468
RIVETER
BODY
PANEL
FUEL FILLER DOOR
PANEL ASSEMBLY
RIVETER
RIVET
FLANGE SURFACE
RIVET
A
1
2
3
4
AB
WINDOW GLASS
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WINDOW GLASS
GENERAL DESCRIPTION
M1422000100287
The windshield, quarter window and liftgate glass are
attached by urethane-base adhesive to the window
frame. This adhesive provides improved glass hold-
ing and sealing, and also permits use of body open-
ings 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
ä AAD Part No. 8880 or
equivalent
For cleaning
As required
Glass holder MB990480
For holding window glass
Two
Window molding remover
MB990449
For roof drip molding removal
One
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.
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 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 THE PRIMER 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 ADHESIVE, LIGHTLY 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 WATER LEAKS
CARRY OUT A SHOWER TEST TO CHECK THAT NO WATER WILL
LEAKS THROUGH.
REPLACE THE GLASS
REUSING THE GLASS
WINDOW GLASS INSTALLATION
PROCEDURE
BODY SIDE
WINDOW GLASS SIDE
AC204055
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
M1422006900258
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Water Leak through Windshield/Water Leak through Quarter Window
Glass/Water Leak through Back Door 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 TOOLS
M1422000600033
SYMPTOM
INSPECTION
PROCEDURE
REFERENCE PAGE
Water leak through windshield
1
Water leak through quarter window glass
Water leak through back door glass
TOOL
TOOL NUMBER AND
NAME
SUPERSESSION
APPLICATION
MB990480
Glass holder
General service tool
Removal and installation of
window glass
MB990449
Window molding remover
General service tool
Removal of drip molding
MB990480
MB990449
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