Hyundai Sonata: Cowl Cross Bar Assembly Repair procedures - Crash Pad - Body (Interior and Exterior)Hyundai Sonata: Cowl Cross Bar Assembly Repair procedures

Replacement
   
Put on gloves to protect your hands.
   
When prying with a flat-tip screwdriver or use a prying trim tool, 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.
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.
Loosen the cowl cross member mounting bolts.

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.
Down the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
12.
Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift lever")
13.
Disconnect the airbag control module (SRSCM) connector (A).

14.
Disconnect the connector (A) and the mounting clips in the front pillar.
[Driver's]

[Passenger's]

15.
Disconnect the passenger compartment junction box connectors (A).

16.
Disconnect the multi box connectors (A).
[Driver's]

[Passenger's]

17.
Remove the drain hose (A).

18.
After loosening the nuts and bolts remove the cowl cross bar and heater & blower unit (A) together.

19.
Disconnect the heater & blower unit connectors.
(1)
Disconnect the blower motor connector (A) and then remove the wiring mounting clips.

(2)
Disconnect the temperature control actuator (A), mode control actuator (B) connectors and then remove the wiring mounting clips.

(3)
Disconnect the auto defogging sensor connector (A) and then remove the wiring mounting clips.

(4)
Disconnect the intake actuator (A), cluster ionizer connector (B), power mosfet (C) connectors and then remove the wiring mounting clips.

20.
Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.

21.
Install in the reverse order of removal.
   
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.
    Cowl Cross Bar Assembly Components and Components Location
    Component Location 1. Cowl cross bar assembly ...

    Roof Trim
    ...

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