Windshield Glass: Installation

Using a knife or the special tool (09861-31200), cut 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 paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-up-paint.

Fig 1: Cutting Old Sealant
Courtesy of HYUNDAI MOTOR CO.
Clean the body bonding surface with a sponge dampened in alcohol, or wax and grease remover.
Center the 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. See Fig 2.

Fig 2: Identifying Marking Lines Across Glass And Body
Courtesy of HYUNDAI MOTOR CO.

Glue the rubber dam to the inside surface of the windshield glass around the entire edge as shown, to contain the sealant during installation. See Fig 3.

PART REFERENCE CHART

Part	"A"	Remarks
Upper	13.5mm constant	Glass molding sub
Side	13.5mm constant	Glass molding sub

Fig 3: Identifying Dam Position

Courtesy of HYUNDAI MOTOR CO.

Install the windshield glass molding. Do not allow any gaps.

Fig 4: Installing Windshield Glass Molding
Courtesy of HYUNDAI MOTOR CO.
Clean the surface applying primer with alcohol.

Fig 5: Identifying Cleaning Surface
Courtesy of HYUNDAI MOTOR CO.
Apply a light coat of glass primer to the outside of the dam.
NOTE:
1. Never touch the surface with your hand after you have applied primer.
  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 primer.
Fig 6: Applying Light Coat Of Glass Primer To Outside Of Dam
Courtesy of HYUNDAI MOTOR CO.

Fig 7: Identifying Primer Application Areas
Courtesy of HYUNDAI MOTOR CO.
Apply sealant around the edge of the glass.

Fig 8: Applying Sealant Around Edge Of Glass (Upper And Side)
Courtesy of HYUNDAI MOTOR CO.

Fig 9: Applying Sealant Around Edge Of Glass (Lower)
Courtesy of HYUNDAI MOTOR CO.

NOTE: Apply the adhesive within 5 minutes after applying the primer.
Apply a light coat of body primer to the original sealant remaining around the window opening flange. The glass should be installed within 10 minutes after you apply the primer.

Fig 10: Identifying Windshield Glass
Courtesy of HYUNDAI MOTOR CO.
Using suction cups or the special tool (09861-31400), lower the glass over the opening, align it with the marks made in step 3 and set it down on the sealant.

Fig 11: Lowering Glass
Courtesy of HYUNDAI MOTOR CO.
Remove excess adhesive with a putty knife or gauze. Fill any cavities around the windshield glass.
After one hour, 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.
If there are leaks, dry the affected area, then apply sealant.

Fig 12: Applying Sealant
Courtesy of HYUNDAI MOTOR CO.
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. Take care not to slam the doors with all the windows rolled up.
4. Take care not to stress the body (such as when going in and out of driveways at an angle or driving over rough, uneven roads).