Hyundai i20 Quiz
Body Work (Interior and Exterior)

Repair Procedures

In this manual: Body Work (Interior and Exterior)
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
21steps
~126min
5/5difficulty
Done 0 of 21

REPLACEMENT

[Disassembly]
  1. Remove the front pillar garnish. (Refer to Interior Trim - "Front Pillar Trim")
  2. Remove the headliner cover. (Refer to Headliner group - "Headliner Cover")
  3. Remove the inside rearview mirror. (Refer to Rear View Mirror - "Inside Rear View Mirror")
  4. Cut the adhesive with a cutter (A).
  5. Cut the seal at the edge (B) by pulling the piano wire (A) to the left and right.
  6. If you see the piano wire in the body, place the piano wire inside (A).
  7. Cut the seal at (A-A), (B-B), (C-C) by pulling the piano wire (A) to the left and right.
  8. Carefully remove the windshield (B) using suction cups (A).
  9. Scrape off the old adhesive with a knife to a thickness of approximately 2 mm (0.08 in.) on the windshield opening flange bonding surface.
  10. Clean the adhesive surface with a sponge moistened with alcohol. Once cleaned, do not allow oil, grease or water to contact the cleaned surface.
  11. Install the spacer (A), temporarily install the windshield (B) centered, then apply the locating marks (C).
  12. Remove the windshield molding strip (A) and install the molding on the windshield (B).
  13. Using a sponge, apply a thin coat of body primer up to the original sealant remaining on the edge of the windshield opening. Allow the body primer to dry for at least 10 minutes.
  14. Apply a thin coat of glass primer to the outer part of the locating devices.
  15. Load the adhesive into the cartridge without air pockets to ensure a constant flow. Place the cartridge in the sealant gun and extrude adhesive (B) along the edge of the windshield (A) between the fasteners and the molding, as shown. Apply the adhesive within 30 minutes after applying primer. Apply a slightly thicker layer at each corner.

    Butt joint bead: Height: 12 mm (0.4724 in.) Width: 8 mm (0.3150 in.)

  16. Use suction cups (A) to hold the windshield (B) over the opening, align it with the locating marks (C) made at step 15, and set it onto the adhesive. Gently press the windshield glass until its edges are properly seated in the adhesive all around. Do not open or close the doors until the adhesive is dry.
  17. Scrape or wipe off excess adhesive with a spatula or sandpaper. To remove adhesive from the painted surface or windshield, wipe with a soft cloth moistened with alcohol.
  18. Allow the adhesive to dry for at least 1 hour, then spray water on the roof and check for leaks. If there is a leak, allow it to dry, then apply sealant:
  19. Install the inside rear view mirror.
  20. Install the windshield garnish molding.
  21. Install the front pillar garnish.
[Tool]

Test yourself

A quick Hyundai i20 quiz: every answer comes with an explanation and a link to the manual page.