Hyundai Kona: Windshield Glass / Repair procedures

Replacement
[Removal]
  
Put on gloves to prevent hand injuries.
  
Use seat covers to avoid damaging any surfaces.
1.
Remove the roof side molding.
(Refer to Interior Trim - "Roof Side Molding")
2.
Remove the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
3.
Remove the front pillar trim.
(Refer to Interior Trim - "Front Fillar Trim")
4.
Remove the cowl top cover.
(Refer to "Cowl Top Cover")
5.
Remove the windshield glass weatherstrip (A).

6.
Using a cutter (A) knife, carefully remove the windshield glass molding.
  
Use the cutter with a 20 to 30 cm-long blade.

7.
Cut off the sealant on the edge (B) while pulling the piano wire (A) to the 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.
Put in a piano wire (A) through the corner of the windshield glass and insert wire grips into both ends of the wire.

9.
Cut off the sealant on (A-A), (B-B), (C-C), while pulling a piano wire (A) to the 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).

[Installtion]
1.
Using a knife, scrape the remaining sealant around the body panel leaving about 2mm-thick sealant (0.0079 in.) on the bonding surface. If installing a new windshield glass, make alignment marks on the windshield glass and the body.
  
Be careful not to damage the painted surface of the body.
  
If the surface is damaged, apply paint or rust inhibitor for maintenance.
2.
Clean the edges of body panel and windshield glass with alcohol. Apply glass primer to the edges of windshield glass and attach the molding onto the edges.
3.
Apply the body primer to the bonding surface of body panel.
  
Be careful not to touch the surface covered with the primer because touching it may lead to water leaks after installing the windshield glass.
Do not apply the body primer to the glass.
Remove any foreign materials from the primer-covered surface.

4.
Apply the glass primer to the outer edge of windshield glass.
  
Be careful not to touch the surface covered with the primer because touching it may lead to water leaks after installing the windshield glass.
Do not apply the body primer to the glass.
Remove any foreign materials from the primer-covered surface.
Apply the sealant within 5 minutes of applying the primer.

5.
Apply a bead of sealant (B) around the windshield glass (A).

6.
Using the glass holder (A), adjust the windshield glass (B) to fit the alignment marks (C) on the body and lightly push the windshield glass to make the edges fully seated on the bonding surface of body.

7.
Install the windshield glass weatherstrip (A).

8.
To make sure that the applied sealant is completely hardened, leave the car on a flat surface for at least 4 hours after installing the windshield glass.
  
If driving the car is inevitable, drive at a low speed for at least 8 hours.
Advise the driver to avoid aggressive driving or driving on rough roads for 2-3 days after installing the windshield glass.
9.
Conduct a leak testing.
The leak testing shall be conducted at least 4 hours after the windshield glass installation is completed.
Do not directly spray the high-pressure water to the joint area.
10.
Install the cowl top cover.
(Refer to "Cowl Top Cover")
11.
Install the roof side molding.
(Refer to Interior Trim - "Roof Side Molding")
12.
Install the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
13.
Install the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
Components and components location
Components 1. Windshield glass 2. Windshield glass weather strip ...

Tail Gate Window Glass
...

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