Hyundai Tucson LM Quiz
Body (Interior and Exterior)

Windshield Repair Procedures

In this manual: Body (Interior and Exterior)
General Information — 1Engine Mechanical System — 44Engine Electrical System — 45Emission Control System — 24Engine Control System/Fuel System — 93Clutch System — 13Manual Transmission — 18Automatic Transmission — 87Four-Wheel Drive (4WD) System — 26Drive Shaft and Axle — 29Suspension System — 35Steering — 20Restraints — 47Brake System — 36Body (Interior and Exterior) — 53Body Electrical System — 202Heating, Ventilation, and Air Conditioning — 58
22steps
~132min
4/5difficulty
Done 0 of 22

Removal
  • Wear gloves to protect your hands.
  • Use seat covers to avoid damaging the surfaces.
  1. Remove the following items.
    A. Front Pillar Trim (Refer to Body Interior - "Interior Trim")
    B. Inside Rear View Mirror (Refer to Body Exterior - "Mirror")
    C. Rain Sensor (Refer to Body Interior - "Roof Trim")
    D. Wiper Arm (Refer to Body Exterior - "Hood Top Cover")
    E. Hood Top Cover (Refer to Body Exterior - "Hood Top Cover")
    F. Windshield Antifreezer Connector (Refer to Body Electrical System - "Windshield Wiper")
  2. Using a screwdriver or puller, remove the windshield molding (A).
    • Always replace the windshield molding with a new one.
  3. Cut the adhesive using the cutter (A).
    • Use a cutter with a blade length of 8 to 12 inches.
  4. Cut the sealant at the edge (B) by pulling the piano wire (A) left and right.
    • Wear gloves to protect your hands.
    • Heat may be generated when working with the wires. Be careful not to burn your hands.
    • Be careful not to disconnect the piano wire.
  5. If the piano wire is visible inside the body, pull the piano wire (A) into the vehicle.
  6. Cut the sealant at (A-A), (B-B), and (C-C) by pulling the piano wire (A) left and right.
    • Wear gloves to protect your hands.
    • Heat may be generated when working with the wires. Be careful not to burn your hands.
    • Be careful not to disconnect the piano wire.
  7. Carefully remove the windshield (B) using the glass holder (A).

Installation

  1. Using a knife, scrape off the old adhesive to a thickness of approx. 2 mm (0.08 in.) on the bonding surface around the entire windshield opening flange:
    A. Do not scrape down to the painted body surface; damaged paint will interfere with proper bonding.
    • Remove the grommet and clips from the body.
    • Mask the surrounding surfaces before painting.
  2. Clean the bonding surface with a sponge moistened with alcohol. After cleaning, make sure that oil, grease and water do not contact the cleaned surface.
  3. Install the spacer (A) and temporarily install the windshield glass (B) with the alignment marks. Be sure to center them, then mark the alignment position (C).
  4. Remove the tape from the windshield molding (A) and install the molding on the windshield glass (B).
  5. Using a sponge, apply a thin coat of body primer to the original adhesive remaining around the windshield opening flange. Allow the body primer to dry for at least 10 minutes.
    • Do not apply glass primer to the body. Be careful not to mix up the glass primer and body primer sponges.
    • Never touch primed surfaces with your hands.
    • Mask the instrument panel before painting the flange.
  6. Apply a thin layer of glass primer to the outer side of the fasteners.
    • Never touch the primed surface with your hands. If you do, the adhesive may not bond properly to the glass, causing a leak after the windshield is installed.
    • Do not apply body primer to the glass.
    • Keep water, dust, and abrasive materials off the primer.
  7. Pack the adhesive into a cartridge without air pockets to ensure continuous delivery. Place the cartridge in a sealant gun and apply an adhesive bead (B) along the edge of the windshield glass (A) between the clip and the molding, as shown in the illustration. Apply the adhesive within 30 minutes after applying the glass primer. Make the bead slightly thicker at each corner. Sealant bead dimensions: Height: 12 mm (0.4724 in.) Width: 8 mm (0.3150 in.)
  8. Use suction cups (A) to hold the windshield glass (B) over the opening, align it with the installation marks (C) made in step 15, and set it onto the adhesive. Lightly press the windshield glass until all edges are fully seated on the adhesive around the entire perimeter. Do not open or close the doors until the adhesive has cured.
  9. Scrape or wipe off excess adhesive with a spatula or a clean towel. To remove adhesive from painted surfaces or the windshield, wipe with a soft cloth moistened with alcohol.
  10. Allow the adhesive to dry for at least one hour, then spray water over the roof and check for leaks. If a leak occurs, allow it to dry, then seal with sealant:
    A. Allow the vehicle to stand for at least four hours after windshield installation. If the vehicle must be driven within 4 hours, drive it slowly.
    B. Keep the windshield dry for the first hour after installation.
  11. Install the automatic anti-fog sensor.
  12. Install the rain sensor.
  13. Install the inside rear view mirror assembly.
  14. Install the hood upper cover.
  15. Install the front pillar garnish.

Test yourself

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