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Home >> Kia >> 2019 >> Niro Plug-In Hybrid EX >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Crash Pad (PHEV) >> Cowl Cross Bar Assembly >> Repair Procedures >> Replacement

Repair Procedures: Replacement

CAUTION: Put on gloves to protect your hands.

Information 

CAUTION:
  • Use a plastic panel removal tool to remove interior trim pieces without marring the surface.
  • Be careful not to bend or scratch the trim and panels.
  1. Remove the cowl top cover.

    (Refer to " COWL TOP COVER  ") 

  2. Remove the front wiper motor.

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

  3. Remove the main crash pad assembly.

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

  4. Remove the cowl side 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 accelerator pedal.

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

  8. Disconnect the connector (A) and the mounting clips in the front pillar.

    [Driver side] 

    G12697428Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger side] 

    G12697429Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the multi box connectors (A).

    [Driver side] 

    G12697430Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger side] 

    G12697431Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the passenger compartment junction box connectors (A).
    G12697432Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the rear air duct (A) after loosening the nut.
    G12697433Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the connector (A) and wiring mounting clip.
    G12697434Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the airbag control module (SRSCM) connector (A) and wiring mounting clip.
    G12697435Courtesy of KIA MOTORS AMERICA, INC.
  14. Loosen the external amplifier mounting bolts (A).
    G12697436Courtesy of KIA MOTORS AMERICA, INC.
  15. Separate the shower duct (A).
    G12697437Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the shower duct (B) after disconnecting the connector (A).
    G12697438Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the temperature actuator connector (A).
    G12697439Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the mode actuator connector (A), duct sensor (B) and wiring mounting clip.
    G12697440Courtesy of KIA MOTORS AMERICA, INC.
  19. Disconnect the blower motor connector (A).
    G12697441Courtesy of KIA MOTORS AMERICA, INC.
  20. Disconnect the BCM unit connectors (A).
    G12697442Courtesy of KIA MOTORS AMERICA, INC.
  21. Separate the BCM unit (A) after loosening the bolts and nuts.
    G12697443Courtesy of KIA MOTORS AMERICA, INC.
    G12697444Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the BCM unit after disconnecting the connectors (A).
    G12697445Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the wiring mounting clip (A).
    G12697446Courtesy of KIA MOTORS AMERICA, INC.
  24. Separate the smart key unit (A) after loosening the bolt.
    G12697447Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the smart key unit after disconnecting the connectors (A).
    G12697448Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the intake actuator (A).
    G12697449Courtesy of KIA MOTORS AMERICA, INC.
  27. Disconnect the passenger side temperature actuator (A) & evaporator temperature sensor connectors (B) and then disconnect the wiring mounting clip.
    G12697450Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the auto defogging connector (A) & passenger side mode actuator connectors (B) and then disconnect the wiring mounting clip.
    G12697451Courtesy of KIA MOTORS AMERICA, INC.
  29. Loosen the cowl cross bar mounting bolts (A).
    G12697452Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the cowl cross bar mounting bolt cap (A).
    G12697453Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the cowl cross bar assembly (A) after loosening the mounting bolts & nuts.

    [Driver Side] 

    G12697454Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger Side] 

    G12697455Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the smart junction block (SJB) (A) after loosening the mounting nuts.
    G12697456Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the smart junction block (SJB) after disconnecting the connectors (A).
    G12697457Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the smart key antenna (A) after removing the connectors & nuts.
    G12697458Courtesy of KIA MOTORS AMERICA, INC.
  35. Remove the external amplifier (A) after removing the connectors & nuts.
    G12697459Courtesy of KIA MOTORS AMERICA, INC.
    G12697460Courtesy of KIA MOTORS AMERICA, INC.
  36. Remove the cluster speaker (A) after removing the connectors (B) & nuts.
    G12697461Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the main wiring from the cowl cross bar.
    G12697462Courtesy of KIA MOTORS AMERICA, INC.
  38. Install in the reverse order of removal.

    Information 

    CAUTION:
    • 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.
    • Enter the anti-theft code for the radio, then enter the customer's radio station presets.
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