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Home >> Kia >> 2023 >> K5 EX >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Crash Pad >> 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. Remove the main crash pad assembly.

    (Refer to " Replacement  ") 

  3. Disconnect the steering column connectors.

    (Refer to " Removal  " ) 

  4. Press the lock pin and separate the airbag system control module connector (A).
    G13835581Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the mounting clips from the front pillar area and disconnect the various connectors (A).

    [Driver] 

    G13835582Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger] 

    G13835583Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the passenger compartment junction box connectors (A).
    G13835584Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the multi box connectors (A).

    [Driver] 

    G13835585Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger] 

    G13835586Courtesy of KIA MOTORS AMERICA, INC.
  8. Separate the heater and blower unit connector.

    [Driver] 

    1. Separate the temperature control actuator (A) and mode control actuator (B) connectors.
    G13835587Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger] 

    1. Separate the auto defogging actuator connector (A).
      G13835588Courtesy of KIA MOTORS AMERICA, INC.
    2. Separate the intake actuator (A), cluster ionizer (B), temperature control actuator (C) connectors.
      G13835589Courtesy of KIA MOTORS AMERICA, INC.
    3. Separate the evaporator sensor (A) and power mosfet (B) connectors.
      G13835590Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the plug hole (A) and loosen the cowl cross bar side mounting bolts.

    [LH] 

    G13835591Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    G13835592Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the battery.

    (Refer to  Removal  ) 

  11. Loosen the engine room cowl cross bar assembly mounting bolts.
    G13835593Courtesy of KIA MOTORS AMERICA, INC.
  12. Loosen the mounting bolts remove the cowl cross bar assembly (A).

    Tightening torque: 

    16.7 - 22.6 N.m(1.7 - 2.3 kgf.m, 12.3 - 16.6 lb-ft)

    G13835594Courtesy of KIA MOTORS AMERICA, INC.
  13. Separate the main wiring (A) from cowl cross bar assembly.
    G13835595Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Refit the main wiring exactly as it was originally intended.
  14. 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.
    • Make sure that each of the assembly components operates properly.
    • Replace any damaged clips (or pin-type retainers).
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