Kia Sportage: Windshield Glass / Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Body (Interior and Exterior) / Windshield Glass / Repair procedures

Removal
  
Put on gloves to prevent hand injuries.
  
Use seat covers to avoid damaging any surfaces.
1.
Remove the roof side molding.
(Refer to Body Side Moldings - "Roof Side Molding")
2.
Remove the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
3.
Remove the LDWS (Lane Departure Warning System) unit.
(Refer to Body Electrical System - "Lane Departure Warning System (LDWS) unit")
4.
Remove the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
5.
Remove the cowl top cover.
(Refer to "Cowl Top Cover")
6.
Using a remover, remove the windshield glass side molding assembly (A).

7.
Cut out the adhesive using a cutter (A).
  
Use a cutter with a blade length between 8-12 inches.

8.
Cut off the sealant on the edge (B) while pulling the piano wire (A) left and right.
  
Put on gloves to protect your hands.
Be careful not to burn your hands as excessive heat may be generated when working on wires.
Be careful not to break the piano wire.

9.
If the piano wire (A) is visible outside the chassis, push it back into the chassis.

10.
Cut off the sealant on (A-A), (B-B), (C-C), while pulling a piano wire (A) left and right.
  
Put on gloves to protect your hands.
Be careful not to burn your hands as excessive heat may be generated when working on wires.
Be careful not to break the piano wire.

11.
Carefully lift up the windshield glass (B) by using a glass holder (A).

Installtion
1.
With a knife, smoothly scrape off the old adhesive to a thickness of about 2 mm (0.0079 in.) on the bonding surface around the entire windshield opening flange:
  
Do not scrape down to the painted surface of the body as damaged paint may degrade the bonding strength.
  
Remove the rubber dam and fasteners from the body.
Mask off surrounding surfaces before painting.
2.
Clean the bonding surface with a sponge dampened in alcohol. After cleaning, keep the surface clean from oil, grease and water.
3.
With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes.
  
Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
Do not touch the primed surfaces by hand.
Mask off the dashboard before painting the flange.

4.
Apply a light coat of glass primer to the outside of the fasteners.
  
Do not touch the primed surface by hand as the adhesive may not bond to the glass properly, causing leakage after installing the windshield glass.
Do not apply body primer to the glass.
Keep water, dust, and abrasive materials away from the primer.

5.
Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Load the cartridge in a caulking gun, and run a bead of adhesive (B) around the edge of the windshield glass (A) between the fastener and molding as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead in each corner.

6.
Install the windshield glass side molding assembly (A).

7.
Use suction cups (A) to hold the windshield glass (B) over the opening, align it with the alignment marks (C) made in step 15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.

8.
Install the cowl top cover.
(Refer to "Cowl Top Cover")
9.
Let the adhesive dry for at least one hour, then spray water over the roof and check for leaks. If a leak occurs, let it dry, then seal with sealant :
  
Let the vehicle stand for at least four hours after windshield installation. If the vehicle must be driven within 4 hours, it must be driven slowly.
Keep the windshield dry for the first hour after installation.
10.
Install the LDWS (Lane Departure Warning System) unit.
(Refer to Body Electrical System - "Lane Departure Warning System (LDWS) unit")
11.
Install the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
12.
Install the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
13.
Install the roof side molding.
(Refer to Body Side Moldings - "Roof Side Molding")
14.
Perform SPATC (Service Point Target Auto Calibration) calibration of the LDWS unit.
(Refer to Body Electrical System - "Lane Departure Warning System (LDWS) - Repair procedure")
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