Windshield Glass: Installation

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
Courtesy of HYUNDAI MOTOR CO.
Clean the body bonding surface with a sponge dampened in alcohol or wax and grease remover.
Install the spacer in the windshield aperture.

Fig 2: Installing Spacer In Windshield Aperture
Courtesy of HYUNDAI MOTOR CO.
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: Centering & Referencing New Windshield
Courtesy of HYUNDAI MOTOR CO.
Install the windshield glass molding without any gaps.

Fig 4: Installing Windshield Glass Molding
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.

Sealant Application Specification

Part	"A"	Remarks
Upper	13.5 mm	Glass molding sub
Side	13.5 mm	.....
Lower	27 mm	.....

Fig 5: Identifying Glass Molding

Courtesy of HYUNDAI MOTOR CO.

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.
Fig 6: Applying Glass Primer
Courtesy of HYUNDAI MOTOR CO.
Apply a primer to the lower glass as shown.

Fig 7: Applying Primer To Lower Glass
Courtesy of HYUNDAI MOTOR CO.
Apply a sealant around the edge of the glass.

Fig 8: Applying Sealant (Upper Side)
Courtesy of HYUNDAI MOTOR CO.

Fig 9: Applying Sealant (Lower Side)
Courtesy of HYUNDAI MOTOR CO.

NOTE: Apply the adhesive within 5 minutes after applying the primer to the glass.
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 10: Applying Primer To Body
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 4 and set it down on the sealant.

Fig 11: Installing Windshield
Courtesy of HYUNDAI MOTOR CO.
Scrape or wipe excess adhesive off with a putty knife or gauze. Fill all cavities around the windshield glass.
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 To Leaking Area
Courtesy of HYUNDAI MOTOR CO.
Install the removed parts.

CAUTION:

Keep the windshield dry for the first hour after installation.
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.
Take care not to slam the doors with all the windows rolled up.
Take care not to twist the vehicle excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).