Hyundai Sonata: Repair procedures - Windshield Glass - Body (Interior and Exterior)Hyundai Sonata: Repair procedures

Removal
   
Put on gloves to protect your hands.
   
Use seat covers to avoid damaging any surfaces.
1.
Remove the roof side molding.
(Refer to Body Side Moldings - "Roof Side Molding")
2.
Remove the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
3.
Remove the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
4.
Remove the cowl top cover.
(Refer to "Cowl Top Cover")
5.
Using a screwdriver or remover, remove the windshield glass side molding assembly (A).

6.
Cut out the adhesive using a cutter (A).
   
Please use a cutter with a blade length between 8-12 inches.

7.
Cut off the sealant on the edge (B) while pulling the piano wire (A) left and right.
   
Put on gloves to protect your hands.
Heat may occur when working on the wires. Be careful not to burn your hands.
Be careful not to disconnect the piano wire.

8.
If a piano wire is visible inside the chassis, pull the piano wire (A) line inside.

9.
Cut off the sealant on (A-A), (B-B), (C-C), while pulling a piano wire (A) left and right.
   
Put on gloves to protect your hands.
Heat may occur when working on the wires. Be careful not to burn your hands.
Be careful not to disconnect the piano wire.

10.
Remove the windshield glass (B) carefully using the glass holder (A).

Installation
1.
With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.0079 in.) on the bonding surface around the entire windshield opening flange:
   
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
   
Remove the rubber dam and fastereners from the body.
Mask off surrounding surfaces before painting.
2.
Clean the bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
3.
Peel off the tape from the windshield glass moulding (A) and install the moulding on the windshield glass (B).

4.
With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes.
   
Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the flange.

5.
Apply a light coat of glass primer to the outside of the fasteners.
   
Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.
Do not apply body primer to the glass.
Keep water, dust, and abrasive materials away from the primer.

6.
Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (B) around the edge of the windshield glass (A) between the fastener and molding as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.

7.
Use suction cups (A) to hold the windshield glass (B) over the opening, align it with the alignment marks (C) made in step 15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.

8.
Install the windshield glass side monlding assembly (A).

9.
Install the cowl top cover.
(Refer to "Cowl Top Cover")
10.
Let the adhesive dry for at least one hour, then spray water over the roof and check for leaks. If a leak occurs, let it dry, then seal with sealant :
   
Let the vehicle stand for at least four hours after windshield installation. If the vehicle must be driven within 4 hours, it must be driven slowly.
Keep the windshield dry for the first hour after installation.
11.
Install the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
12.
Install the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
    Components and Components Location
    Components 1. Windshield glass 2. Windshield moulding mounting bracket3. Windshield glass side moulding4. Windshield glass upper moulding ...

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