2009-2010 Kia Soul

Sponsored by Extractor

© 2009 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 400 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org. 

Vehicle type: Four-door sport utility vehicle

NAGS® numbers*: Windshield part number FW3051 and back glass FB24165 

Helpful tools or supplies: Cutout wire

Watch for: The back glass on this vehicle fits extremely tight to the vehicle body and is exposed on all sides, making an outside cutout impossible. You may need to break the glass to remove it cleanly from the vehicle and avoid damage to the body. To salvage the glass, have the rear deck painted to correct any damage incurred during cutout.

*With permission from National Auto Glass Specifications. Call NAGS at 800/551-4012 or visit http://glass.mitchell.com/.

A. Windshield
Preparation
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 number is FW3051.

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, pry up the underside clip and wiggle the mirror off the pad.

4. Remove the windshield-wiper nut covers.

5. Remove the windshield-wiper nuts using a 14-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. The cowl has five faux Phillips-head retainers in the front leading edge of the panel. Remove these retainers by lifting up on the center stud with a tack puller or door-pad tool, or backing off the center stud with a small slot screwdriver and then prying up on the base. There are several underside retainers beneath the fascia of the panel. Release and remove by lifting up with your fingers. Remove the cowl panel and set it in a safe place.

7. The A-pillar moldings are held in place with underside retainers that snap into holes in the pillar. Use a door-pad tool to pry them out, carefully starting at the bottom of the pillar.

8. The new glass will come bonded with top and side moldings already attached. 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.

Removal
9. Make sure cutting blades are sufficiently sharp.

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

11. 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. Do not hit or cut the gravity stops; mark their location with a marking pencil or retention tape.

12. 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.

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

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

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

16. Set the windshield onto the old urethane.

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

18. 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.

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

20. 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.

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

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

23. Using the tool of your choice, remove the original urethane bead, leaving 1 millimeter to 2 mm of existing urethane on the pinchweld. This vehicle is constructed of aluminum and strip-out must be completed with no scratches to the paint. If the paint is damaged, follow the adhesive manufacturer’s recommendations for repair. Make sure there are no contaminants and do not touch the pinchweld after prepping the area.

24. 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.

25. 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.

26. 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.

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

28. 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.

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

30. 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.

31. You have completed the removal and replacement of the windshield.

B. Back glass
Removal
1. Make sure you have the right glass. Back glass part number is FB24165.

2. Remove the rear wiper by lifting the cap and removing the 14-mm nut. The wiper points to the passenger side of the vehicle.

3. Remove the interior rear-hatch panel by removing two Phillips screws at the top of the panel and then releasing the perimeter retainers with a door-pad tool. Disconnect the defroster wiring harnesses.

4. Cut out the glass using the tool of your choice. Note, the back glass on this vehicle fits extremely tight to the vehicle body and is exposed on all sides, making an outside cutout impossible. You may need to break the glass to remove it cleanly from the vehicle and avoid damage to the body. To salvage the glass, use 20a cutout wire or an inside cutout tool, such as the Fein knife or BTB tool. Have the rear deck painted to correct any damage incurred during cutout.

Installation
5. After cutting the back glass out, remove contaminants such as dirt, moisture and debris from the pinchweld.

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

7. Place your vacuum cups on the new back glass in the appropriate location.

8. Set the back glass onto the old urethane.

9. With the back glass resting in the opening, make sure it is in the right spot.

10. 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.

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

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

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

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

15. Using a pinchweld scraper, remove as much of the original urethane as the urethane manufacturer recommends. Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after prepping the area.

16. 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.

17. 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.

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

19. The back glass is now ready to be decked. Press firmly to ensure a good seal.

20. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the back glass. 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.

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

22. Re-connect the defroster connectors.

23. Re-install the removed parts in reverse manner.

24. Check the operation of the back glass electrical systems.

25. 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.

26. You have completed the removal and replacement of the back glass.

© 2009 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 400 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org.