Repair Procedures: Replacement

Information 

• 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 without marring the surface.
• Take care not to bend or scratch the trim and panels.

1. Remove the cowl top cover.

   (Refer to COWL TOP COVER - OPTIMA (EXCEPT HEV) )

2. Remove the main crash pad assembly.

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

3. Remove the cowl side trim.

   (Refer to Interior Trim - "COWL SIDE TRIM ")

4. Remove the front door scuff trim.

   (Refer to Interior Trim - "COWL SIDE TRIM ")

5. Disconnect the steering column connectors.

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

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

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

7. Remove the accel pedal.

   (Refer to Engine Control/Fuel System - "ACCELERATOR POSITION SENSOR (APS) ")

8. Separate the floor carpet (A) to obtain space for removing the rear heating duct.

   [Driver's] 

   Fig 1: Separating Floor Carpet (Driver Side)

   Courtesy of KIA MOTORS AMERICA, INC.

   [Passenger's] 

   Fig 2: Separating Floor Carpet (Passenger Side)

   Courtesy of KIA MOTORS AMERICA, INC.
9. Detach the mounting clip and then remove the rear heating duct (A).

   [Driver's] 

   Fig 3: Locating Rear Heating Duct And Mounting Clip (Driver Side)

   Courtesy of KIA MOTORS AMERICA, INC.

   [Passenger's] 

   Fig 4: Locating Rear Heating Duct And Mounting Clip (Passenger Side)

   Courtesy of KIA MOTORS AMERICA, INC.
10. Disconnect the connector (A) and the mounting clips in the front pillar.

    [Driver's] 

    Fig 5: Disconnecting Front Pillar Connector And Mounting Clips (Driver Side)

    Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 6: Disconnecting Front Pillar Connector And Mounting Clips (Passenger Side)

    Courtesy of KIA MOTORS AMERICA, INC.
11. Disconnect the multi box connectors (A).

    [Driver's] 

    Fig 7: Locating Multi Box Connectors (Driver Side)

    Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 8: Locating Multi Box Connectors (Passenger Side)

    Courtesy of KIA MOTORS AMERICA, INC.
12. Disconnect the passenger compartment junction box connectors (A).
    Fig 9: Removing Passenger Compartment Junction Box Connectors

    Courtesy of KIA MOTORS AMERICA, INC.
13. Disconnect the airbag control module connector (A).
    Fig 10: Removing Airbag Control Module Connector

    Courtesy of KIA MOTORS AMERICA, INC.
14. Disconnect the mode actuator (A), AFLS unit (B), temperature actuator (C) connectors.

    [Driver's] 

    Fig 11: Disconnecting Mode Actuator, AFLS Unit, Temperature Actuator Connectors (Driver)

    Courtesy of KIA MOTORS AMERICA, INC.
15. Disconnect the auto defogging connector (A).
    Fig 12: Removing Auto Defogging Connector

    Courtesy of KIA MOTORS AMERICA, INC.
16. Disconnect the temperature actuator (A), FET (B), evaporator temperature sensor (C) connectors.

    [Passenger's] 

    Fig 13: Disconnecting Temperature Actuator, FET, Evaporator Temperature Sensor Connectors (Passenger)

    Courtesy of KIA MOTORS AMERICA, INC.
17. Disconnect the intake actuator connector (A).
    Fig 14: Disconnecting Intake Actuator Connector

    Courtesy of KIA MOTORS AMERICA, INC.
18. Disconnect the blower motor connector (A).
    Fig 15: Disconnecting Blower Motor Connector

    Courtesy of KIA MOTORS AMERICA, INC.
19. Loosen the cowl cross bar mounting bolts (A).
    Fig 16: Loosening Cowl Cross Bar Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
20. Remove the cowl cross bar mounting bolt cap (A).
    Fig 17: Removing Cowl Cross Bar Mounting Bolt Cap

    Courtesy of KIA MOTORS AMERICA, INC.
21. Remove the cowl cross bar assembly (A) after loosening the mounting bolts & nuts.

    [Driver's] 

    Fig 18: Removing Cowl Cross Bar Assembly Mounting Bolts And Nuts (Driver Side)

    Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 19: Removing Cowl Cross Bar Assembly Mounting Bolts And Nuts (Passenger Side)

    Courtesy of KIA MOTORS AMERICA, INC.
22. Install in the reverse order of removal.

    Information 

    • Make sure the connector are connected in properly.
    • Replace any damaged clips.