Hyundai Santa Fe: Crash Pad / Cowl Cross Bar Assembly. Repair procedures

Hyundai Santa Fe (TM) 2019-2024 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 inlet and outlet heater hoses from the heater unit.
(Refer to Heating,Ventilation And Air Conditioning - "Heater Unit")
6.
Remove both sides of front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
7.
Remove the main crash pad assembly.
(Refer to Crash Pad - "Main Crash Pad Assembly")
8.
Disconnect the steering column connectors.
(Refer to Steering System - "Steering Column and Shaft")
9.
Loosen the mounting nuts and through bolts in the frontal area and lower the steering column.
(Refer to Steering System - "Steering Column and Shaft")
10.
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)

11.
Loosen the mounting nuts and remove the floor air duct (A).
12.
Loosen the mounting bolt and nut, remove the accelerator pedal module (A).
13.
Press the lock pin, separate the accelator pedal connector (A).
14.
Remove the rear air duct (A) and then separate the floor carpet (B) backwards.
15.
Loosen the mounting nuts and remove the rear heating duct (A).
16.
Press the lock pin and separate the airbag control module(SRSCM) connector (A).
17.
Disconnect the connector (A) and the mounting wiring fasteners in the front pillar.
[Driver's]

[Passenger's]

18.
Disconnect the passenger compartment junction box connectors (A).
19.
Disconnect the multi box connectors (A).
[Driver's]

[Passenger's]

20.
Disconnect the heater and blower unit connector.
(1)
Loosen the mounting screw, remove the shower duct (A).
[LH]

[RH]
(2)
Press the lock pin, separate the evaporator sensor connector (A).
(3)
Press the lock pin, separate the driver's temperature actuator connector (A).
(4)
Press the lock pin, separate the mode control actuator connector (A).
(5)
Press the lock pin, separate the intake actuator connector (A).
(6)
Press the lock pin, separate the power mosfet connector (A).
(7)
Press the lock pin, separate the PTC heater connector (A).
(8)
Press the lock pin, separate the blower motor connector (A).
(9)
Press the lock pin, separate the PM sensor connector (A).
(10)
Press the lock pin, separate the auto defogging actuator connector (A) and passenger's temperature actuator connector (B).
21.
Loosen the heater & blower unit front mounting bolt (A).
Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)

22.
Loosening the cowl cross bar side mounting bolt (B) after loosening the plug hole (A).
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

23.
Loosen the mounting bolts and remove the cowl croos bar assembly (A).
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

24.
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

    ..

    Roof Trim

    ..

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    Interior Overview

    1. Inside door handle
    2. Power window switches
    3. Power window lock button/Electronic child safety lock button
    4. Side view mirror folding button
    5. Side view mirror control switch
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