Hyundai Kona: Crash Pad / Cowl Cross Bar Assembly Repair procedures

Hyundai Kona (OS) 2018-2025 Service Manual / Body (Interior and Exterior) / Crash Pad / Cowl Cross Bar Assembly Repair procedures

Replacement

•	Put on gloves to prevent hand injuries.

•	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.

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.	Disconnect the expansion valve from the evaporator core. (Refer to Heating,Ventilation And Air Conditioning - "Heater Unit")

6.	Disconnect the inlet and outlet heater hoses from the heater unit. (Refer to Heating,Ventilation And Air Conditioning - "Heater Unit")

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

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

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

10.	Loosen the mounting nuts and through bolts in the frontal area and lower the steering column. (Refer to Steering System - "Steering Column and Shaft")

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

12.

Loosen the engine room cowl cross bar assembly mounting bolts.

Tightening torque :

16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

13.	Separate the floor carpet (A) to obtain space for removing the rear heating duct.

14.	Loosen the nut and then separate the rear air duct (A).

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

16.	Disconnect the connector (A) and the mounting wiring fasteners in the front pillar. [Driver's] [Passenger's]

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

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

19.

Disconnect the heater and blower unit connector.

[Driver's]

(1)	Disconnect the mode actuator connector (A).

[Passenger's]

(2)	Disconnect the temperature actuator connector (A) and power mosfet connector (B).

(3)	Disconnect the auto defogging actuator connector (A) and intake actuator connector (B).

(4)	Disconnect the blower motor connector (A).

(5)	Disconnect the cluster ionizer connector (A).

20.

After loosening the bolts and nuts, then remove the cowl cross bar assembly (A).

Tightening torque :

16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

21.

To install, reverse removal procedure.

•	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.

•	Make sure that each of the assembly components operates properly.

•	Replace any damaged clips (or pin-type retainers).

Cowl Cross Bar Assembly Components and components location

Component Location 1. Cowl cross bar assembly ...

Roof Trim

...

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