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# 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.

6. | 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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##### Other information:

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### Kia Soul EV (PS EV) 2015-2020 Service Manual: Power Electric Frame Repair procedures

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