Kia Soul: Cowl Cross Bar Assembly Replacement - Crash Pad - Body (Interior and Exterior)Kia Soul: Cowl Cross Bar Assembly Replacement

Kia Soul 2014-2019 PS Service Manual / Body (Interior and Exterior) / Crash Pad / Cowl Cross Bar Assembly Replacement

  
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Put on gloves to protect your hands.
  
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When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
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Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
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Take care not to bend or scratch the trim and panels.
1.
Disconnect the negative (-) battery terminal.
2.
Recover the refrigerant with a recovery/recycling/charging station.
3.
When the engine is cool, drain the engine coolant from the radiator.
(Refer to Engine Mechanical System - “Coolant”)
4.
Remove the cowl top cover.
(Refer to "Cowl Top Cover")
5.
Remove the bolts and the expansion valve (A) from the evaporator core.
Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)

6.
Remove the expansion valve flange (A) after loosening the screws.

  
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Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
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When installing, replace with a new O-ring (B).
7.
Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.

  
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When disconnecting the hoses, engine coolant will pour out of the hose. So drain the coolant into a clean drip pan.
8.
Remove the inlet and outlet heater hoses flange (A) after loosening the nuts (B).
9.
Loosen the cowl cross member mounting bolts (A).
10.
Remove both sides of front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
11.
Remove the main crash pad assembly.
(Refer to Crash Pad - "Main Crash Pad Assembly")
12.
Disconnect the steering column connectors.
(Refer to Steering System - "Steering Column and Shaft")
13.
Down the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
14.
Remove the rear airduct assembly (A).
15.
Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift lever")
16.
Disconnect the airbag control module (SRSCM) connector (A).
17.
After loosening the mounting bolts and nuts, then remove the cowl cross bar center bracket (A).
18.
Disconnect the passenger compartment junction box connectors (A).
19.
Remove the passenger compartment junction box mounting clips (A).
20.
Disconnect the multi box connectors (A).
[Driver's]

[Passenger's]
21.
Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]

[Passenger's]
22.
Remove the drain hose (A).
23.
After loosening the nuts and bolts remove the cowl cross bar and heater & blower unit (A) together.
24.
Disconnect the heater & blower unit connectors.
(1)
Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
(2)
Disconnect the blower motor (A), temperature control actuator (B), mode control actuator (C) connectors and then remove the wiring mounting clips.
(3)
Disconnect the evaporator temperature sensor (A) field effect transistor air conditioning resistor (B) connectors and then remove the wiring mounting clips.
(4)
Disconnect the cluster ionizer connector (A) and then remove the wiring mounting clips.
(5)
Remove the heater & blower unit wiring mounting clips (A).
25.
Loosen the heater and blower unit mounting bolts (A) and then remove the mounting clips (B).

26.
Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.
27.
Install in the reverse order of removal.
  
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Make sure the crash pad fits onto the guide pins correctly.
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Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
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Make sure the connectors are plugged in properly, and the antenna lead is connected properly.
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Enter the anti- theft code for the radio, then enter the customer`s radio station presets.
    Cowl Cross Bar Assembly Component Location
    1. Cowl cross bar assembly ...

    Fender
    ...

    See also:

    Intake Actuator Replacement
    1. Disconnect the negative (-) battery terminal. 2. Remove the glove box housing. (Refer to Body - "Glove Box Housing") ...

    Radial-ply tires
    Radial-ply tires provide improved tread life, road hazard resistance and smoother high speed ride. The radial- ply tires used on this vehicle are of belted construction, and are selected to comple ...

    Multi box
    To open the box, pull the lever and the cover will open. Push down the cover to close. ...