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Windshield Glass: Installation

  1. Using a cutter knife or the special tool (09861-31200), scrape the old sealant smoothly to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield flange.
    CAUTION: Be careful not to remove more adhesive than necessary, and also not to damage the paint work on the body surface with the knife. If the paint work is damaged, repair the damaged area with touch-up paint.
    Fig 1: Removing Old Sealant Using Cutter Knife Or Special Tool
    G03853170Courtesy of HYUNDAI MOTOR CO.
  2. Clean the body bonding surface with a sponge dampened in alcohol or wax and grease remover.
  3. Install the spacer in the windshield aperture.
    Fig 2: Installing Spacer In Windshield Aperture
    G03853171Courtesy of HYUNDAI MOTOR CO.
  4. Center a new windshield glass in the opening. Mark the location by marking lines across the glass and body with a grease pencil at the four points as shown.
    Fig 3: Identifying Four Marking Points
    G03853172Courtesy of HYUNDAI MOTOR CO.
  5. Install the windshield glass molding without any gaps.
    Fig 4: Installing Windshield Glass Molding Without Any Gaps
    G03853173Courtesy of HYUNDAI MOTOR CO.
  6. Glue the rubber dam to the inside surface of the windshield glass around the entire edge as shown, to contain the sealant during installation.
    PARTS REMARKS CHART

    G03853174
    Part "A" Remarks
    Upper 13.5 mm Glass molding sub
    Side 13.5 mm
    Lower 27 mm
  7. Apply a light coat of glass primer to the outside of the dam.
    NOTE:
    1. Never touch the surface applied primer with your hand.

      If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.

    2. Do not apply body primer to the glass.
    3. Keep water, dust, and abrasive materials away from the surface applied primer.
    8. Fig 5: Applying A Light Coat Of Glass Primer To Outside Of Dam
    G03853175Courtesy of HYUNDAI MOTOR CO.
  8. Apply a primer to the lower glass as shown.
    Fig 6: Applying A Primer To Lower Glass
    G03853176Courtesy of HYUNDAI MOTOR CO.
  9. Apply a sealant around the edge of the glass.
    Fig 7: Applying A Sealant Around Edge Of Glass (Upper And Side)
    G03853177Courtesy of HYUNDAI MOTOR CO.
    Fig 8: Applying A Sealant Around Edge Of Glass (Lower)
    G03853178Courtesy of HYUNDAI MOTOR CO.
    NOTE: Apply the adhesive within 5 minutes after applying the primer to the glass.
  10. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The glass should be installed within 5 minutes after you apply the primer.
    Fig 9: Applying A Light Coat Of Body Primer To Original Sealant Remaining Around Window Opening Flange
    G03853179Courtesy of HYUNDAI MOTOR CO.
  11. Using suction cups or the special tool (09861-31400), lower the glass over the opening, align it with the marks made in step  4 and set it down on the sealant.
    Fig 10: Using Suction Cups Or Special Tool To Lower Glass Over Opening
    G03853180Courtesy of HYUNDAI MOTOR CO.
  12. Scrape or wipe excess adhesive off with a putty knife or gauze. Fill all cavities around the windshield glass.
    13. Fig 11: Scraping Or Wiping Excess Adhesive Off With A Putty Knife Or Gauze
    G03853181Courtesy of HYUNDAI MOTOR CO.
  13. Perform a water-leak test for the windshield. Use a cold water spray, being careful not to direct a powerful stream of water on the new adhesive material. Allow water to spill over the edges of the glass.
  14. If there are leaks, dry the affected area, then apply sealant.
  15. Install the removed parts.
CAUTION:
  1. Keep the windshield dry for the first hour after installation.
  2. Let the car stand for at least four hours after windshield installation. If the car has to be used within the first 8 hours, it must be driven slowly.
  3. Be careful not to slam the doors with all the windows rolled up.
  4. Be careful not to twist the vehicle excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
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