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Home >> Kia >> 2020 >> 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 

  1. Remove the cowl top cover.

    (Refer to Cowl Top Cover - "REPAIR PROCEDURES ")

  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. Disconnect the steering column connectors.

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

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

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

  6. Remove the accelerator pedal.

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

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

    [Driver side] 

    G13350370Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger side] 

    G13350371Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the multi box connectors (A).

    [Driver side] 

    G13350372Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger side] 

    G13350373Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the passenger compartment junction box connectors (A).
    G13350374Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the rear air duct (A) after loosening the nut.
    G13350375Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the connector (A) and wiring mounting clip.
    G13350376Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the airbag control module (SRSCM) connector (A) and wiring mounting clip.
    G13350377Courtesy of KIA MOTORS AMERICA, INC.
  13. Loosen the external amplifier mounting bolts (A).
    G13350378Courtesy of KIA MOTORS AMERICA, INC.
  14. Separate the shower duct (A).
    G13350379Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the shower duct (B) after disconnecting the connector (A).
    G13350380Courtesy of KIA MOTORS AMERICA, INC.
  16. Disconnect the temperature actuator connector (A).
    G13350381Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the mode actuator connector (A), duct sensor (B) and wiring mounting clip.
    G13350382Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the blower motor connector (A).
    G13350383Courtesy of KIA MOTORS AMERICA, INC.
  19. Disconnect the BCM unit connectors (A).
    G13350384Courtesy of KIA MOTORS AMERICA, INC.
  20. Separate the BCM unit (A) after loosening the bolts and nuts.
    G13350385Courtesy of KIA MOTORS AMERICA, INC.
    G13350386Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the BCM unit after disconnecting the connectors (A).
    G13350387Courtesy of KIA MOTORS AMERICA, INC.
  22. Disconnect the wiring mounting clip (A).
    G13350388Courtesy of KIA MOTORS AMERICA, INC.
  23. Separate the smart key unit (A) after loosening the bolt.
    G13350389Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the smart key unit after disconnecting the connectors (A).
    G13350390Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the intake actuator (A).
    G13350391Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the passenger side temperature actuator (A) & evaporator temperature sensor connectors (B) and then disconnect the wiring mounting clip.
    G13350392Courtesy of KIA MOTORS AMERICA, INC.
  27. Disconnect the auto defogging connector (A) & passenger side mode actuator connectors (B) and then disconnect the wiring mounting clip.
    G13350393Courtesy of KIA MOTORS AMERICA, INC.
  28. Loosen the cowl cross bar mounting bolts (A).
    G13350394Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the cowl cross bar mounting bolt cap (A).
    G13350395Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the cowl cross bar assembly (A) after loosening the mounting bolts & nuts.

    [Driver Side] 

    G13350396Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger Side] 

    G13350397Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the smart junction block (SJB) (A) after loosening the mounting nuts.
    G13350398Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the smart junction block (SJB) after disconnecting the connectors (A).
    G13350399Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the smart key antenna (A) after removing the connectors & nuts.
    G13350400Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the external amplifier (A) after removing the connectors & nuts.
    G13350401Courtesy of KIA MOTORS AMERICA, INC.
    G13350402Courtesy of KIA MOTORS AMERICA, INC.
  35. Remove the cluster speaker (A) after removing the connectors (B) & nuts.
    G13350403Courtesy of KIA MOTORS AMERICA, INC.
  36. Remove the main wiring from the cowl cross bar.
    G13350404Courtesy of KIA MOTORS AMERICA, INC.
  37. Install in the reverse order of removal.

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