Kia Soul EV: Crash Pad / Cowl Cross Bar Assembly Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Body (Interior and Exterior) / Crash Pad / Cowl Cross Bar Assembly Repair procedures

Replacement

•	Put on gloves to protect your hands.

•	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 to protect from marring the surface.

•	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 then pipe (A) from the evaporator core.

Remove the bolts, and then 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)

•	Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

•	When installing, replace with a new O-ring (B).

7.	Loosen the cowl cross member mounting bolts (A).

8.	Remove both sides of front seat assembly. (Refer to Front Seat - "Front Seat Assembly")

9.	Remove the main crash pad assembly. (Refer to Crash Pad - "Main Crash Pad Assembly")

10.	Disconnect the steering column connectors. (Refer to Steering System - "Steering Column and Shaft")

11.	Lower the steering column after loosening the mounting bolts. (Refer to Steering System - "Steering Column and Shaft")

12.

Remove the rear airduct assembly (A).

[LH]

(1)	Remove the accelerator pedal fixed cap (A).

(2)	Remove the mounting bolt (A), and then remove the accelerator pedal module.

(3)	Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).

(4)	Remove the carpet floor.

(5)	Loosen the nut and then remove the rear air duct assembly (A).

[RH]

(1)	Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).

(2)	Remove the carpet floor (A).

(3)	Loosen the nut and then remove the rear air duct assembly (A).

13.	Remove the shift lever assembly. (Refer to Automatic Transaxle System - "Shift lever")

14.	Disconnect the airbag control module (SRSCM) connector (A).

15.	After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).

16.	Disconnect the passenger compartment junction box connectors (A).

17.	Remove the passenger compartment junction box mounting clips (A).

18.	Disconnect the multi box connectors (A). [Driver''s] [Passenger''s]

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

20.	Remove the drain hose (A).

21.

Untie locking pin and then remove the high voltage PTC heater cable (A).

(1)	Pull the pin (A) in the direction of the arrow.

(2)	Press the fixed pin (-) and then pull it while inserting the driver (A) into the hole (B).

22.	After loosening the nuts and bolts, remove the cowl cross bar and heater & blower unit (A) altogether.

23.

Disconnect the heater & blower unit connectors.

(1)	Remove the bolt (A) and clip (B), and then remove the high voltage PTC heater Ground.

(2)	Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.

(3)	Disconnect the blower unit (A) and then remove the wiring mounting clips.

(4)	Disconnect PWM unit (A) and then remove the wiring mounting clips.

(5)	Disconnect the blower motor (A) and then remove the wiring mounting clips.

(6)	Disconnect the temperature control actuator (A) and duct sensor (B) connectors.

(7)	Disconnect the mode control actuator (A) connectors and then remove the wiring mounting clips.

(8)	Remove the screw (A) and fastener (B) and then remove the virtual engine sound control unit.

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.

•	Make sure that the crash pad fits onto the guide pins correctly.

•	Before tightening the bolts, make sure that the crash pad wire harnesses are not pinched.

•	Make sure that the connectors are plugged in properly, and the antenna lead is connected properly.

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

Cowl Cross Bar Assembly Components and Components Location

Component Location 1. Cowl cross bar assembly ...

Fender

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