Repair Procedures: Replacement

WARNING: This page is about a different car, the 2015 Kia Soul EV. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Put on gloves to protect your hands.

NOTE:

When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
Take care not to bend or scratch the trim and panels.

Disconnect the negative (-) battery terminal.
Recover the refrigerant with a recovery/recycling/charging station.
When the engine is cool, drain the engine coolant from the radiator.
(Refer to COOLING SYSTEM Engine Mechanical System - "Coolant")
Remove the cowl top cover.
(Refer to COWL TOP COVER "Cowl Top Cover")
Remove the bolts and then pipe (A) from the evaporator core.

Fig 1: Evaporator Core Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the bolts, and then expansion valve (A) from the evaporator core.
Tightening torque:

7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)

Fig 2: Expansion Valve Bolts From Evaporator Core
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
- When installing, replace with a new O-ring (B).
Loosen the cowl cross member mounting bolts (A).

Fig 3: Cowl Cross Member Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove both sides of front seat assembly.
(Refer to Front Seat - "FRONT SEAT ASSEMBLY ")
Remove the main crash pad assembly.
(Refer to Crash Pad - "MAIN CRASH PAD ASSEMBLY ")
Disconnect the steering column connectors.
(Refer to Steering System - "STEERING COLUMN AND SHAFT ")
Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "STEERING COLUMN AND SHAFT ")
Remove the rear airduct assembly (A).
[LH]
1. Remove the accelerator pedal fixed cap (A).
  
  Fig 4: Accelerator Pedal Fixed Cap
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the mounting bolt (A), and then remove the accelerator pedal module.
  
  Fig 5: Accelerator Pedal Module Mounting Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).
  
  Fig 6: Floor Carpet Fixing Clip, Floor Stripping And Wire Clips
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the carpet floor.
5. Loosen the nut and then remove the rear air duct assembly (A).
  
  Fig 7: Rear Air Duct Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
[RH]
1. Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).
  
  Fig 8: Floor Carpet Fixing Clip, Floor Stripping And Wire Clips
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the carpet floor (A).
  
  Fig 9: Carpet Floor
  Courtesy of KIA MOTORS AMERICA, INC.
3. Loosen the nut and then remove the rear air duct assembly (A).
  
  Fig 10: Rear Air Duct Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift lever")
Disconnect the airbag control module (SRSCM) connector (A).

Fig 11: Airbag Control Module Connector
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).

Fig 12: Cowl Cross Bar Center Bracket Mounting Bolts And Nuts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the passenger compartment junction box connectors (A).

Fig 13: Passenger Compartment Junction Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Remove the passenger compartment junction box mounting clips (A).

Fig 14: Passenger Compartment Junction Box Mounting Clips
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the multi box connectors (A).
[Driver's]

Fig 15: Drivers Multi Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 16: Passengers Multi Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]

Fig 17: Front Pillar Connector And Mounting Clips (Drivers)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 18: Front Pillar Connector And Mounting Clips (Passengers)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drain hose (A).

Fig 19: Drain Hose
Courtesy of KIA MOTORS AMERICA, INC.
Untie locking pin and then remove the high voltage PTC heater cable (A).

Fig 20: High Voltage PTC Heater Cable
Courtesy of KIA MOTORS AMERICA, INC.

Information
1. Pull the pin (A) in the direction of the arrow.
  
  Fig 21: Pulling Pin
  Courtesy of KIA MOTORS AMERICA, INC.
2. Press the fixed pin (-) and then pull it while inserting the driver (A) into the hole (B).
Fig 22: Driver Into Hole
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the nuts and bolts, remove the cowl cross bar and heater & blower unit (A) altogether.

Fig 23: Cowl Cross Bar And Heater/Blower Unit Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater & blower unit connectors.
1. Remove the bolt (A) and clip (B), and then remove the high voltage PTC heater Ground.
  
  Fig 24: High Voltage PTC Heater Ground Bolt And Clip
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
  
  Fig 25: Intake Actuator Connector And Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the blower unit (A) and then remove the wiring mounting clips.
  
  Fig 26: Blower Unit And Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect PWM unit (A) and then remove the wiring mounting clips.
  
  Fig 27: PWM Unit
  Courtesy of KIA MOTORS AMERICA, INC.
5. Disconnect the blower motor (A) and then remove the wiring mounting clips.
  
  Fig 28: Blower Motor And Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
6. Disconnect the temperature control actuator (A) and duct sensor (B) connectors.
  
  Fig 29: Temperature Control Actuator And Duct Sensor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the mode control actuator (A) connectors and then remove the wiring mounting clips.
  
  Fig 30: Mode Control Actuator Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
8. Remove the screw (A) and fastener (B) and then remove the virtual engine sound control unit.
Fig 31: Virtual Engine Sound Control Unit Screw And Fastener
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater & blower unit connectors.
1. Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
  
  Fig 32: Intake Actuator Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the blower motor (A), temperature control actuator (B), mode control actuator (C) connectors and then remove the wiring mounting clips.
  
  Fig 33: Blower Motor, Temperature Control Actuator, Mode Control Actuator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the evaporator temperature sensor (A), field effect transistor air conditioning resistor (B) connectors and then remove the wiring mounting clips.
  
  Fig 34: Evaporator Temperature Sensor And Field Effect Transistor Air Conditioning Resistor
  Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the cluster ionizer connector (A) and then remove the wiring mounting clips.
  
  Fig 35: Cluster Ionizer Connector
  Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the heater & blower unit wiring mounting clips (A).
  
  Fig 36: Heater And Blower Unit Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
Loosen the heater and blower unit mounting bolts (A) and then remove the mounting clips (B).

Fig 37: Heater And Blower Unit Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.

Fig 38: Heater And Blower Unit
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.
Information
- Make sure that the crash pad fits onto the guide pins correctly.
- Before tightening the bolts, make sure that the crash pad wire harnesses are not pinched.
- Make sure that the connectors are plugged in properly, and the antenna lead is connected properly.
- Enter the anti-theft code for the radio, and then enter the customer's radio station presets.