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2009 Hyundai Sonata

Windshield removal and replacement instructions.

2009 Hyundai Sonata.

Vehicle type: Four-door sedan.

NAGS® numbers*: Windshield part numbers FW2560; FW2561 heated wiper park; FW2562 heated wiper park, solar; FW2563 electrochromic mirror; FW2564 electrochromic mirror, solar; FW2565 electrochromic mirror, heated wiper park; FW2566 electrochromic mirror, heated wiper park, solar; FW2577 solar.

A. Windshield.

1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings and that the urethane systems you are about to use are current. Windshield part numbers are FW2560, FW2561, FW2562, FW2563, FW2564, FW2565, FW2566, and FW2577.

2. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

3. To remove the rearview mirror, tap it down off the mirror pad using a padded tool or your hand.

4. Remove the windshield-wiper nut covers.

5. Remove the windshield-wiper nuts using a 15-millimeter wrench or socket. Move the wiper arm in an up-and-down motion to break it loose from the post, or use a wiper-puller. Caution: Wipers can sometimes be hard to remove. To avoid stressing the post, use a wiper-puller.

6. To remove the cowl panel, first remove the two push-in-the-center-type retainers in the two corners.

7. Remove the hood bulb seal from the front leading edge of the panel using a tack puller or door-pad tool.  Slide the panel toward the engine compartment and remove. Note, there are several hooks that slide under the lower glass edge. Put the panel in a safe place.

8. The side moldings run the entire length of the vehicle roof and are held in place with clips that you can easily release using your fingers.  To remove the side molding, pull it toward the A pillar and lift up on the backside with your fingers.  To release the last clip near the back glass, push the molding toward the back glass. The clip will release without damage. 

9. The top molding is an underside molding that does not come with the glass. You can use a universal underside molding as a replacement. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.

10. Make sure cutting blades are sufficiently sharp.

11. Before cutting out the windshield, remove contaminants from the glass and pinchweld to prevent contact with the urethane.

12. Use the cutting tools of your choice to remove the glass from the adhesive bead. If you use a power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. There are two guide pins/gravity stops on the underside of the glass that may pose a problem if your goal is to salvage the part. Be careful not to hit or cut the gravity stops; mark their location with a marking pencil or retention tape.

13. Take the windshield out of the opening using vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

14. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

15. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

16. Place your vacuum cups on the new windshield in the appropriate location.

17. Set the windshield onto the old urethane.

18. With the windshield resting in the opening, make sure it is in the right spot.

19. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

20. Follow the urethane manufacturer’s recommendations for installation.

21. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

22. Wear powder-free Nitrile gloves to protect against harsh chemicals.

23. Attach the underside moldings to the top underside of the glass edge.  There are usually marks in the frit to guide the molding application.

24. Apply the glass prep and primer following the urethane manufacturer’s recommendations.

25. Using the tool of your choice, remove the original urethane bead, leaving 1 millimeter to 2 mm of urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after you have prepped the area.

26. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

27. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

28. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver’s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

29. The windshield is now ready to be decked. Press firmly to ensure a good seal.

30. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

31. Re-install the removed parts in reverse order.

32. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

33. You have completed the removal and replacement of the windshield.
By Bob Beranek.
© 2009 National Glass Association

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