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Home › Kia › 2019 › Forte EX › Repair and Diagnosis › External Pages › Different car › Section 13 (Crash Pad) › Cowl Cross Bar Assembly › Repair Procedures › Replacement

Repair Procedures: Replacement

WARNING: This page is about a different car, the 2019 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.
  1. Disconnect the negative (-) battery terminal.
  2. Recover the refrigerant with a recovery/recycling/charging station.
  3. When the engine is cool, drain the engine coolant from the radiator.

    (Refer to Engine Mechanical System - "COOLANT ")

  4. Remove the cowl top cover.

    (Refer to "COWL TOP COVER ")

  5. Remove the bolts and then pipe (A) from the evaporator core.
    G11934031Courtesy of KIA MOTORS AMERICA, INC.
  6. 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 Ib-ft)

    G11934032Courtesy 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).
  7. Loosen the cowl cross member mounting bolts (A).
    G12820145Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove both sides of front seat assembly.

    (Refer to Front Seat - "FRONT SEAT ASSEMBLY ")

  9. Remove the main crash pad assembly.

    (Refer to Crash Pad - "MAIN CRASH PAD ASSEMBLY ")

  10. Disconnect the steering column connectors.

    (Refer to Steering System - "STEERING COLUMN AND SHAFT ")

  11. Lower the steering column after loosening the mounting bolts.

    (Refer to Steering System - "STEERING COLUMN AND SHAFT ")

  12. Remove the rear airduct assembly (A).

    [LH] 

    1. Remove the accelerator pedal fixed cap (A).
      G11934034Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the mounting bolt (A), and then remove the accelerator pedal module.
      G12820147Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).
      G11934036Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the carpet floor.
    5. Loosen the nut and then remove the rear air duct assembly (A).
      G11934037Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    1. Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).
      G11934038Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the carpet floor (A).
      G11934039Courtesy of KIA MOTORS AMERICA, INC.
    3. Loosen the nut and then remove the rear air duct assembly (A).
      G11934040Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the shift lever assembly.

    (Refer to Automatic Transaxle System - "SHIFT LEVER ")

  14. Disconnect the airbag control module (SRSCM) connector (A).
    G11934041Courtesy of KIA MOTORS AMERICA, INC.
  15. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    G11934042Courtesy of KIA MOTORS AMERICA, INC.
  16. Disconnect the passenger compartment junction box connectors (A).
    G11934043Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the passenger compartment junction box mounting clips (A).
    G11934044Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the multi box connectors (A).

    [Driver's] 

    G11934045Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    G11934046Courtesy of KIA MOTORS AMERICA, INC.
  19. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    G11934047Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    G11934048Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the drain hose (A).
    G11934049Courtesy of KIA MOTORS AMERICA, INC.
  21. Untie locking pin and then remove the high voltage PTC heater cable (A).
    G11934050Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    1. Pull the pin (A) in the direction of the arrow.
      G11934051Courtesy of KIA MOTORS AMERICA, INC.
    2. Press the fixed pin (-) and then pull it while inserting the driver (A) into the hole (B).
    G11934052Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the nuts and bolts, remove the cowl cross bar and heater & blower unit (A) altogether.
    G11934053Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the heater & blower unit connectors.
    1. Remove the bolt (A) and clip (B), and then remove the high voltage PTC heater Ground.
      G11934054Courtesy of KIA MOTORS AMERICA, INC.
    2. Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
      G11934055Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the blower unit (A) and then remove the wiring mounting clips.
      G11934056Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect PWM unit (A) and then remove the wiring mounting clips.
      G11934057Courtesy of KIA MOTORS AMERICA, INC.
    5. Disconnect the blower motor (A) and then remove the wiring mounting clips.
      G11934058Courtesy of KIA MOTORS AMERICA, INC.
    6. Disconnect the temperature control actuator (A) and duct sensor (B) connectors.
      G11934059Courtesy of KIA MOTORS AMERICA, INC.
    7. Disconnect the mode control actuator (A) connectors and then remove the wiring mounting clips.
      G11934060Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the screw (A) and fastener (B) and then remove the virtual engine sound control unit.
      G11934061Courtesy of KIA MOTORS AMERICA, INC.
  24. Disconnect the heater & blower unit connectors.
    1. Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
      G11934062Courtesy 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.
      G11934063Courtesy 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.
      G12820176Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the cluster ionizer connector (A) and then remove the wiring mounting clips.
      G11934065Courtesy of KIA MOTORS AMERICA, INC.
    5. Remove the heater & blower unit wiring mounting clips (A).
      G12820178Courtesy of KIA MOTORS AMERICA, INC.
  25. Loosen the heater and blower unit mounting bolts (A) and then remove the mounting clips (B).
    G11934067Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.
    G11934068Courtesy of KIA MOTORS AMERICA, INC.
  27. 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.
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