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Home >> Hyundai >> 2020 >> Sonata SEL >> Repair and Diagnosis >> Accessories & Equipment >> Interior/Exterior Trim >> Crash Pad (Except HEV) >> Cowl Cross Bar Assembly >> Repair Procedures >> Replacement

Repair Procedures: Replacement

CAUTION:
  • When removing with a flat-tip screwdriver or remover, wrap protective tape around the tools to prevent damage to components.
  • Use a plastic panel removal tool to remove interior trim pieces without marring the surface.
  • Take care not to bend or scratch the trim and panels.
  • Put on gloves to prevent hand injuries.
  1. Disconnect the negative (-) battery terminal.
  2. Recover the refrigerant with a recovery/recycling/charging station.

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

  3. Remove the knee airbag (KAB).

    (Refer to Restraint (AUTOLIV (Depowered) - "KNEE AIRBAG (KAB) ")

  4. Disconnect the steering column connectors.

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

  5. Loosen the mounting nuts and through bolts in the frontal area and lower the steering column.

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

  6. Disconnect the expansion valve from the evaporator core.

    (Refer to Heating, Ventilation And Air Conditioning - "HEATER UNIT ")

  7. Disconnect the inlet and outlet heater hoses from the heater unit.

    (Refer to Heating, Ventilation And Air Conditioning - "HEATER UNIT ")

  8. Press the lock pin and separate the airbag system control module connector (A).
    G14526401Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the mounting clips from the front pillar area and disconnect the various connectors (A).

    [Driver] 

    G14526402Courtesy of HYUNDAI MOTOR AMERICA

    [Passenger] 

    G14526403Courtesy of HYUNDAI MOTOR AMERICA
  10. Disconnect the passenger compartment junction box connectors (A).
    G14526404Courtesy of HYUNDAI MOTOR AMERICA
  11. Disconnect the multi box connectors (A).

    [Driver] 

    G14526405Courtesy of HYUNDAI MOTOR AMERICA

    [Passenger] 

    G14526406Courtesy of HYUNDAI MOTOR AMERICA
  12. Separate the heater and blower unit connector.

    [Driver] 

    1. Separate the temperature control actuator [LH] (A) and mode control actuator (B) connectors.
    G14526407Courtesy of HYUNDAI MOTOR AMERICA

    [Passenger] 

    1. Separate the auto defogging actuator connector (A).
      G14526408Courtesy of HYUNDAI MOTOR AMERICA
    2. Separate the intake actuator (A), cluster ionizer (B), temperature control actuator [LH] (C) connectors.
      G14526409Courtesy of HYUNDAI MOTOR AMERICA
    3. Separate the evaporator sensor (A) and power mosfet (B) connectors.
      G14526410Courtesy of HYUNDAI MOTOR AMERICA
  13. Remove the plug hole (a) and loosen the cowl cross bar side mounting bolts.

    [LH] 

    G14526411Courtesy of HYUNDAI MOTOR AMERICA

    [RH] 

    G14526412Courtesy of HYUNDAI MOTOR AMERICA
  14. Remove the front wiper motor.

    (Refer to Body Electrical System - "FRONT WIPER MOTOR ")

  15. Remove the battery.

    (Refer to Engine Electrical System - "BATTERY ")

  16. Loosen the mounting bolts, nuts and remove the cowl cross bar assembly (A).

    Tightening torque: 

    16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

    G14526413Courtesy of HYUNDAI MOTOR AMERICA
  17. Separate the main wiring (A) from cowl cross bar assembly.
    G14526414Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Refit the main wiring exactly as it was originally intended.
  18. To install, reverse the removal procedure.

    Information 

    • Make sure the crash pad fits onto the guide pins correctly.
    • Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
    • Make sure the connectors are plugged in properly, and the antenna lead is connected properly.
    • Make sure that each of the assembly components operates properly.
    • Replace any damaged clips (or pin-type retainers).
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