SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Body (Interior & Exterior) Windshield & Rear Window
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COMPONENTS 
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REMOVAL 
  1. Remove the hood hinge mounting bolts take out the hood panel.

    TORQUE SPECIFICATION
    Hood hinge mounting bolts 22-27 Nm ( 220-270 kg·cm, 16-19.5 lb·ft )
  1. Remove the front windshield wiper arm.

  1. Remove the front filler trim.

  1. Remove the crash pad main complete assembly.

  1. Remove the sunvisor and roof assist handle.

  1. Remove the map lamp.

  1. Loosen the headlining (Front side).

  1. Loosen the wiper arm link pivot shaft.

    TORQUE SPECIFICATION
    Wiper arm link pivot shaft 4-6 Nm ( 40-60 kg·cm, 2.9-4.3 lb·ft )
  1. Use the special tool (09861-31100) to cut through the wind shield sealant.

  1. Make mating marks on the glass and body if the glass is to be reinstalled.

    NOTE
    Use chalk or equivalent to make mating marks on the glass and body.
  1. Take out the windshield glass with special tool, Glass Holder.

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INSTALLATION 
  1. Using a cutter knife or the special tool, scrape the old sealant smoothly to a thickness of about 2 mm on the bonding surface around the entire windshield flange.

    CAUTION
    Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-up paint.
  1. Clean the body flange surface of front windshield aperture with a sponge damped in solvent.

    • Clean (wipe out) completely the contaminants such as oil and dust in the primer applied part of body aperture.
    • After cleaning body aperture flange surface, pass a minute or more then, apply the primer to body.
  1. Center a new windshield in the opening.

    Mark the location by scribing lines across the glass and body with a grease pencil at the four points as shown.

  1. Apply the primer to body aperture flange surface of windshield glass.

    • To use the primer, shake the vessel in ten minutes or more.
    • After application, It takes a day to dry the windshield glass. After passing a day, re-apply.
  1. Clean the primer-applied parts of windshield glass.

    • Clean completely contaminants such as oil and dust in the primer-applied parts of windshield glass.
    • After cleaning the windshield glass, pass a minute or more and apply the primer to windshield glass.
  1. Install the spacer in windshield glass with the body panel closed.

  1. Adhere dam to windshield glass.

    • Adhere the dam at regular intervals in the edge of windshield glass.
    • Adhere the dam at 10 mm intervals from the lower edge of windshield glass.
  1. Moulding installation in front windshield glass.

    • When working the moulding installation in front windshield glass, install the "A" part of moulding on the standard of "B" part of front windshield glass.
    • When inserting the moulding, be careful not to change the directions.
  1. Primer application to windshield glass.

    • To use the primer, shake the primer vessel ten minutes or more.
    • After application, It takes a day to dry the windshield glass. After passing a day re-apply.
  1. Apply sealant to windshield glass.

    • When the application shape, quantity and height of sealant are not regular.
      If the sealant is sufficient: Appearance is inferior because that the sealants are flooded with inner surface.
      If the sealant is deficient: Glass comes to separate and waterproof is inferior because of weak adhesion.
  1. Install the glass to the body aperture of windshield glass.

  1. After installing the windshield glass, adjust position.

  1. After installing the windshield glass, wipe out foreign material on the windshield glass and body.

  1. Perform the water-test for the windshield.

    Use a cold water spray, being careful not to direct a powerful stream of water on the new adhesive material. Allow water to spill over the edges of the glass.

  1. If there are leaks, apply sealant at the leak points.

  1. Installation of the each trim parts is the reverse of the removal procedure.

    CAUTION
    Before operating wiper arm, solidify completely sealant.