Page 1 of 68 - JustAnswer - About Us | JustAnswerww2.justanswer.com/uploads/ebrock63/2012-06-18_220414...2012/06/18 · SPORTAGE(AL) >2000 > G 2.0 DOHC > Body (Interior and Exterior)

SPORTAGE(AL) >2000 > G 2.0 DOHC > Body (Interior and Exterior)

REMOVAL

Trim

1. Disconnect the negative battery cable.

2. Remove two instrument cluster trim mounting screws.

3. Disconnect instrument cluster switch connectors.

4. Remove the trim.

REMOVAL

Ashtray

1. Remove the ashtray from the center panel trim.

REMOVAL

Center Panel

1. Remove mounting screws.

2. Remove the center panel from the instrument panel.

REMOVAL

Center Panel Trim

Page 1 of 68

6/18/2012https://www.kiatechinfo.com/viewer/content.asp?IsPrint=true&imgnum=1&print_title=&v...

1. Disconnect battery.

Disconnect electrical wire harness connectors from the center control unit.

2. Remove the trim from the instrument panel.

REMOVAL

Front Console

1. Remove the knobs from the shift lever and the transfer lever.

2. Remove two mounting screws from the front console.

3. Slide the boots for the shift lever and transfer lever over the levers and remove the front console cover unit.

Page 2 of 68


REMOVAL

Glove Box

1. Remove the two mounting screws.

2. Remove the glove box from the instrument panel.

REMOVAL

Hood Release Handle

1. Remove the hood release handle lockscrew.

Page 3 of 68


2. Remove the hood release handle.

3. Remove the nut holding the hood release cable assembly in position.

REMOVAL

Horn Cap, Steering Wheel, Turn Signal Assembly, and Upper/Lower Column Covers

1. Remove the horn cap, steering wheel, turn signal assembly, and upper/lower column covers. Refer to Steering System.

2. Lower the steering column assembly.

REMOVAL

instrument Panel Assembly

1. Remove the rear console, Refer to "Rear Console" in this section.

2. Remove the front console. Refer to "Front Console" in this section.

3. Remove the knee bolster assembly. Refer to "Knee Bolster Assembly" in this section.

4. Remove the T-bar section. Refer to "T-bar Section" in this section.

5. Remove the relay bracket. Refer to "Relay Bracket" in this section.


7. Remove the hood release handle lockscrew, hood release handle, and cable assembly nut.

8. Remove the left front pillar trim. Refer to "Left Front Pillar Trim" in this section.

9. Remove the lower LH cover. Refer to "Lower LH Cover" in this section.

10. Remove two mounting bolts from the left side of the T-bar as shown.

Page 4 of 68


11. Remove three mounting bolts from the left side of the instrument panel as shown.

12. Remove the ashtray to make center panel trim removal possible.

13. Remove the center panel trim. Refer to "Center Panel Trim" in this section.

14. Remove the ventilation control panel. Refer to "Ventilation Control Panel" in this section.

15. Remove the cap from the center of the instrument panel next to the windshield.

16. Remove a mounting bolt from the area under the center cap.

Page 5 of 68


17. Remove the glove box. Refer to "Glove Box" in this section.

18. Remove the right front pillar trim. Refer to "Right Front Pillar Trim" in this section.

19. Remove the lower RH cover. Refer to "Lower RH Cover" in this section.

20. Remove two mounting bolts on the right side of the T-bar as shown.

21. Remove three mounting bolts from the right of the instrument panel assembly as shown.

Page 6 of 68


22. Remove two mounting bolts on either side of the steering column, which hold the instrument panel and the steering

column together. Lower the steering column to floor level.

23. Remove two mounting bolts under the instrument panel behind the location of the bolts described in step 22.

24. Disconnect all connectors between the instrument panel and the vehicle bulkhead electrical wire harness.

25. Remove the instrument panel.

REMOVAL

Left Front Pillar Trim

1. Remove the left front pillar trim by manually pulling it away from the installed position.

Page 7 of 68


REMOVAL

Lower LH Cover


2. Remove the lower LH cover.

REMOVAL

Lower RH Cover

1. Remove the glove box.

2. Remove the five mounting screws.

3. Remove the lower RH cover from the instrument panel.

Page 8 of 68


REMOVAL

Radio


Remove the four mounting screws.

2. Remove the radio partway from the mounting position.

3. Disconnect the antenna cable connector and all electrical wire harness connectors form the rear of the radio.

4. Remove the radio from the instrument panel.

REMOVAL

Rear Console

1. Remove the rear console cover.

2. Remove two screws from the rear of the rear console.

Page 9 of 68


3. Raise the emergency brake handle.

4. Remove the rear console.

REMOVAL

Relay Bracket


Remove three mounting screws and remove relay bracket.

REMOVAL

Right Front Pillar Trim

1. Remove the right front pillar trim by manually pulling it away from the mounting position.

REMOVAL

T-Bar Section


2. Remove one screw from each end of the T-bar frame short section under the steering column.

3. Remove the T-bar section. Allowing the steering column to drop completely.

Page 10 of 68


REMOVAL

Ventilation Control Panel


Remove the center panel trim. Refer to "Center Panel Trim" in this section.

2. Remove four mounting screws.

3. Remove the ventilation control panel from the mounting space.

4. Disconnect the electrical wire harness connector from the rear of the unit.

5. Remove the glove box by removing two installation screws.

6. Remove the temperature cable from the heater unit by carefully depressing the plastic retaining tab and remove the

cable from the retaining clip.

7. Disconnect the fresh air/recirculation cable from the blower motor assembly by carefully depressing the plastic tab and

remove the cable from the retaining clip.

8. Remove the ventilation control panel from the instrument panel.

REMOVAL

ABS Control Unit


2. Remove the ABS control unit mounting screws.

Page 11 of 68


3. Wearing grounded wrist strap. Disconnect the connector from the ABS control unit.

4. Remove the ABS control unit.

REMOVAL

Air Conditioner Sensor Unit

1. Remove the center panel. Refer to “Center panel” in this section.

2. Remove two mounting screws holding the sensor unit to the center panel.

3. Remove the opposite end of the sensor unit hose from the air conditioning unit.

4. Remove the air conditioner sensor unit from the instrument panel.

REMOVAL

Cigarette Lighter Assembly


2. Remove the center panel trim. Refer to “Center Panel Trim” in this section.

3. Remove the cigarette lighter assembly.

REMOVAL

Clock

1. Disconnect battery. Remove the center panel trim.

2. Remove two screws from clock.

Page 12 of 68


3. Disconnect wiring from clock. Remove Clock.

REMOVAL

Cruise Main and Interior Light Dimmer Switches


2. Press on lower LH cover switch mounting tabs while pushing on the switch until the tabs clear the trim.

3. Remove the switch from the trim.

4. Disconnect wiring.

5. Remove and replace the bulb unit as necessary. If the bulb and switch are one unit, remove and replace that

bulb/switch unit as necessary.

REMOVAL

Defroster Grills (LH/RH)

1. Remove two speed nuts from the rear of the defroster grille.

2. Remove the defroster grille from the instrument panel using care to avoid marring. Start removal of the grille at one end

and continue applying pressure to the grille clips until the entire unit is removed from the mounting space.d and

continue applying pressure to the grille clips until the entire unit is removed from the mounting space.inue applying

pressure to the grille clips until the entire unit is removed from the mounting space.

REMOVAL

Page 13 of 68


Defroster Grille (LH/RH Side)

1. Press the side defroster grille until it pops out of position.

REMOVAL

Door Lock Timer Unit


2. Remove the door lock timer unit mounting screws.

3. Disconnect the connector from the door lock timer unit.

4. Remove the door lock timer unit.

REMOVAL

Ducts

1. Remove mounting screws holding the duct parts to the instrument panel.

2. Remove the LH demi duct and LH defrost ducts.

Page 14 of 68


3. Remove the RH demi duct and RH defrost ducts.

4. Remove the center defrost duct.

5. Remove the LH air duct.

6. Remove the RH air duct.

7. Remove the center air duct.

REMOVAL

Hood Release Cable

1. Remove the hood release handle. Refer to “Hood Release Handle” in this section.

2. Remove the nut holding the hood release cable in place at the LH side of the instrument panel.

3. Peed the hood release cable through the bulkhead.

4. Release the clips holding the hood release cable in place along the top portion of the engine compartment.

5. Remove the hood release cable from position along the left top portion of the engine compartment.

6. Remove the end of the hood release cable from the hood release on the front portion of the engine compartment.

7. Repair or replace the hood release cable as necessary.

REMOVAL

Vent Grille

Page 15 of 68


1. Remove three mounting screws from the back of the air vent grille.

2. Apply pressure to the front of the air vent grille until the grille is removed from the rear of the instrument panel.

REMOVAL

Trim




4. Remove the trim.

REMOVAL

Ashtray


REMOVAL

Center Panel



REMOVAL

Page 16 of 68


Center Panel Trim




REMOVAL

Front Console




Page 17 of 68


REMOVAL

Glove Box



REMOVAL

Hood Release Handle


Page 18 of 68




REMOVAL




REMOVAL












Page 19 of 68








Page 20 of 68







Page 21 of 68







REMOVAL



Page 22 of 68


REMOVAL

Lower LH Cover



REMOVAL

Lower RH Cover




Page 23 of 68


REMOVAL

Radio






REMOVAL

Rear Console



Page 24 of 68




REMOVAL

Relay Bracket



REMOVAL



REMOVAL

T-Bar Section




Page 25 of 68


REMOVAL













REMOVAL

ABS Control Unit



Page 26 of 68




REMOVAL






REMOVAL





REMOVAL

Clock



Page 27 of 68



REMOVAL








REMOVAL







REMOVAL

Page 28 of 68




REMOVAL






REMOVAL

Ducts



Page 29 of 68







REMOVAL

Hood Release Cable








REMOVAL

Vent Grille

Page 30 of 68




REMOVAL

Trim




4. Remove the trim.

REMOVAL

Ashtray


REMOVAL

Center Panel



REMOVAL

Page 31 of 68


Center Panel Trim




REMOVAL

Front Console




Page 32 of 68


REMOVAL

Glove Box



REMOVAL

Hood Release Handle


Page 33 of 68




REMOVAL




REMOVAL












Page 34 of 68








Page 35 of 68







Page 36 of 68







REMOVAL



Page 37 of 68


REMOVAL

Lower LH Cover



REMOVAL

Lower RH Cover




Page 38 of 68


REMOVAL

Radio






REMOVAL

Rear Console



Page 39 of 68




REMOVAL

Relay Bracket



REMOVAL



REMOVAL

T-Bar Section




Page 40 of 68


REMOVAL













REMOVAL

ABS Control Unit



Page 41 of 68




REMOVAL






REMOVAL





REMOVAL

Clock



Page 42 of 68



REMOVAL








REMOVAL







REMOVAL

Page 43 of 68




REMOVAL






REMOVAL

Ducts



Page 44 of 68







REMOVAL

Hood Release Cable








REMOVAL

Vent Grille

Page 45 of 68




INSTALLATION

Trim

1. Connect the five switch connectors.

2. Place the instrument cluster trim into place in front of the instrument cluster.

3. Install two screws.

INSTALLATION

Ashtray

1. Install the ashtray in the center panel trim.

INSTALLATION

Center Panel

1. Mount the center panel in the instrument panel.

2. Install center panel mounting screws.

INSTALLATION

Center Panel Trim

1. Connect two electrical wire harness connectors to the rear of the cigarette lighter.

2. Mount the trim in position.

INSTALLATION

Front Console

1. Slide the boots for the shift lever and transfer lever over the levers and mount the front console cover unit into place in

its mounting area.

2. Position the front console and install two mounting screws.

3. Install the shift lever knob and the transfer lever knob.

INSTALLATION

Glove Box

1. Mount the glove box in the instrument panel.

2. Install two mounting screws.

INSTALLATION

Hood Release Handle

1. Install the hood release handle.

2. Install the hood release handle lockscrew.

INSTALLATION


1. Raise the steering column assembly.

2. Install the horn cap, steering wheel, turn signal assembly, and upper/lower column covers. Refer to Steering System.

INSTALLATION

Page 46 of 68



1. Mount the instrument panel into position.

Make sure the steering column is mounted correctly through the T-bar with the electrical wire harness in position

beforeattempting to position the instrument panel in place. If this is not done, the column cannot be positioned correctly.

attempting to position the instrument panel in place. If this is not done, the column cannot be positioned

correctly.ttempting to position the instrument panel in place. If this is not done, the column cannot be positioned

correctly.

2. Connect the linking connectors between the vehicle electrical wire harness and the instrument panel.

Each connector is keyed so an electrical harness connector mates with the correct instrument panel connector.

3. Install two mounting bolts under the instrument panel behind the steering column.

Tighten the bolts to 102 lb � in (11.5 N � m)

4. Install two mounting bolts, one on either side of the steering column, which hold the instrument panel and the steering

column together.

Tighten bolts to 102 lb � in (11.5 N � m)

5. Install three mounting bolts to the right side of the instrument panel as shown.


Page 47 of 68


6. Install two mounting bolts on the right side of the instrument panel as shown.


7. Install a mounting bolt in the center of the instrument panel next to the windshield as shown.

Tighten bolts to 44 lb � in (5 N � m)

8. Install the cap into the space over the bolt installed in step 7.

9. Install the lower RH cover. Refer to "Lower RH Cover" in this section.

10. Install the right front pillar time. Refer to "Right Front Pillar Trim" in this section.

11. Install the glove box. Refer to "Glove Box" in this section.

12. Install the ventilation control panel. Refer to "Ventilation Control Panel" in this section.

13. Install the center panel trim. Refer to "Center Panel Trim" in this section.

14. Install the ashtray. Refer to "Ashtray" in this section.

15. Install three mounting bolts to the left side of the instrument panel.


Page 48 of 68


16. Install two bolts on the left side of the T-bar.


17. Install the relay bracket with three mounting screws.

18. Install the lower LH cover. Refer to "Lower LH Cover" in this section.

19. Install the left front pillar trim. Refer to "Left Front Pillar Trim" in this section.

20. Install the section of T-bar with two mounting screws.

21. Install the knee bolster assembly. Refer to "Knee Bolster Assembly" in this section.

22. Install the retaining nut holding the hood release cable in position.

23. Install the hood release handle. Refer to "Hood Release handle" in this section.

24. Install the horn cap, steering wheel, turn signal assembly and upper/lower column covers. Refer to Steering System.

25. Install the front console. Refer to "Front Console" in this section.

26. Install the rear console. Refer to "Rear console" in this section.

27. Install the negative cable onto the battery terminal.

INSTALLTION


Page 49 of 68


1. Install the left front pillar trim by pressing it until it snaps into place.

INSTALLATION

Lower LH Cover

1. Mount the lower LH cover.

2. Install mounting screws.

INSTALLTION

Lower RH Cover

1. Mount the lower RH cover into place in the instrument panel.

2. Install five mounting screws to the lower RH cover.

INSTALLATION

Radio

1. Connect electrical wire harness connectors and antenna cable connector to the rear of the radio.

2. Mount the radio into position in the instrument panel.

3. Install four mounting screws.

INSTALLATION

Rear Console

1. Install the rear console and tighten the two screws.

2. Install the rear console cover.

INSTALLATION

Relay Bracket


INSTALLATION


1. Install the right front pillar trim by pressing it until it snaps into position.

INSTALLATION

T-Bar Section

1. Mount the short section of the T-bar.

2. Install the two mounting screws.


INSTALLATION


1. Mount the ventilation control panel in position in the instrument panel.

2. Depress the plastic tab on the blower motor assembly and connect the fresh air/recirculation cable in place into the

retaining clip.

3. Depress the plastic tab on the heater assembly and connect the temperature cable in place in the retaining clip.

4. Install the glove box by installing two mounting screws.

5. Connect the electrical wire harness connector to the rear of the ventilation control panel.

Page 50 of 68


6. Mount the ventilation control panel into position and install four mounting screws.


INSTALLATION

ABS Control Unit

1. Mount the ABS control unit in position.

2. Connect at connector to the ABS control unit.

3. Install the mounting screws for the ABS control unit.

INSTALLATION


1. Mount the air conditioner sensor unit into the center panel area.

2. Connect one end of the sensor unit hose to the air conditioning unit.

3. Install two mounting screws to attach the sensor unit to the center panel.

4. Install the center panel. Refer to “Center Panel” in this section.

INSTALLATION

Cigaretta Lighter Assembly

1. Install the cigarette lighter assembly.

2. Install the center panel trim. Refer to “Center Panel Trim” in this section.

INSTALLATION

Clock

1. Install the clock in the center panel trim.

2. Connect the electrical connector and install center panel trim in the instrument panel

INSTALLATION


1. Install the bulb unit into the switch as is applicable for the switch. If the bulb and switch are one unit, install that unit.

2. Connect wiring.

3. Mount the switch in the mounting hole.

4. Push the switch into its mounting hole in the cover until the tabs snap into place.

INSTALLATION

Defroster Grilles (LH/RH)

1. Press the defroster grille into the mounting space.

2. Install two speed nuts onto the rear of the defroster grille.

INSTALLATION


1. Press the side defroster grille until it snaps into place in the instrument panel.

INSTALLATION


1. Mount the door lock timer unit in position.

Page 51 of 68


2. Connect the connector to the door lock timer unit.

3. Install the door lock timer unit mounting screws.

INSTALLATION

Ducts

1. Install the center air duct.

2. Install the RH air duct.

3. Install the LH air duct.

4. Install the center defrost duct.

5. Install the RH demi duct and RH defrost ducts.

6. Install the LH demi duct and LH defrost ducts.

7. Install mounting screws holding the duct parts to the instrument panel.

INSTALLATION

Hood Release Cable

1. Install the hood release cable to the hood release on the front portion of the engine compartment.

2. Route and clip the hood release cable along the pathway from the hood release to the bulkhead.

3. Feed the hood release cable through the bulkhead into the interior of the vehicle.

4. Install the mounting nut to secure the hood release cable to the instrument panel.

5. Install the hood release handle. Refer to “Hood Release Handle” in this section.

INSTALLATION

Vent Grille

1. Apply pressure to the rear of the air vent grille until the grille in inserted into the instrument panel and the grille holes

match up with the mounting holes on the instrument panel.holes match up with the mounting holes on the instrument

panel.

2. Install the three mounting screws.

INSTALLATION

Trim




INSTALLATION

Ashtray


INSTALLATION

Center Panel



INSTALLATION

Center Panel Trim

Page 52 of 68




INSTALLATION

Front Console


its mounting area.



INSTALLATION

Glove Box



INSTALLATION

Hood Release Handle



INSTALLATION




INSTALLATION







correctly.






column together.


Page 53 of 68






Page 54 of 68













Page 55 of 68















INSTALLTION


Page 56 of 68



INSTALLATION

Lower LH Cover



INSTALLTION

Lower RH Cover



INSTALLATION

Radio




INSTALLATION

Rear Console



INSTALLATION

Relay Bracket


INSTALLATION



INSTALLATION

T-Bar Section




INSTALLATION




retaining clip.




Page 57 of 68




INSTALLATION

ABS Control Unit




INSTALLATION






INSTALLATION




INSTALLATION

Clock



INSTALLATION



2. Connect wiring.



INSTALLATION




INSTALLATION



INSTALLATION



Page 58 of 68




INSTALLATION

Ducts








INSTALLATION

Hood Release Cable






INSTALLATION

Vent Grille



panel.


INSTALLATION

Trim




INSTALLATION

Ashtray


INSTALLATION

Center Panel



INSTALLATION

Center Panel Trim

Page 59 of 68




INSTALLATION

Front Console


its mounting area.



INSTALLATION

Glove Box



INSTALLATION

Hood Release Handle



INSTALLATION




INSTALLATION







correctly.






column together.


Page 60 of 68






Page 61 of 68













Page 62 of 68















INSTALLTION


Page 63 of 68



INSTALLATION

Lower LH Cover



INSTALLTION

Lower RH Cover



INSTALLATION

Radio




INSTALLATION

Rear Console



INSTALLATION

Relay Bracket


INSTALLATION



INSTALLATION

T-Bar Section




INSTALLATION




retaining clip.




Page 64 of 68




INSTALLATION

ABS Control Unit




INSTALLATION






INSTALLATION




INSTALLATION

Clock



INSTALLATION



2. Connect wiring.



INSTALLATION




INSTALLATION



INSTALLATION



Page 65 of 68




INSTALLATION

Ducts








INSTALLATION

Hood Release Cable






INSTALLATION

Vent Grille



panel.


INSPECTION

Glove Box

1. Inspect for signs of any damage or wear and replace as necessary.

INSPECTION

Glove Box

1. Inspect for signs of any damage or wear and replace as necessary.

DISASSEMBLY

Instrument Panel

Page 66 of 68


1. Remove the radio. Refer to “Radio” in this section.

2. Remove the center panel. Refer to ”Center Panel ” in this section.

3. Remove the air conditioner sensor unit tube as required. Refer to “Air Conditioner Sensor Unit” in this section.

4. Remove the instrument cluster trim. Refer to “Instrument Panel Trim” in this section.

5. Remove the instrument cluster. Refer to “Instrument Cluster” in this section.

6. Remove the ABS control unit from the instrument panel. Refer to “ABS Control Unit” in this section.

7. Remove the door lock timer unit. Refer to “Door Lock Timer Unit” in this section.

Page 67 of 68


8. Remove the clock. Refer to “Instrument Clock” in this section.

9. Remove the electrical wire harness.

10. Remove attaching screws connecting the instrument panel to the T-bar.

11. Remove the grip. Refer to “Grip Assembly” in this section.

12. Separate the instrument panel from the T-bar

13. Remove the ducts from the instrument panel. Refer to “Ducts” in this section.

14. Remove the left and right air vent grilles. Refer to “Vent Grille” in this section.

15. Remove the defroster grilles. Refer to “Defroster Grilles” in this section.

REASSEMBLY

Instrument Panel

1. Install the defroster grilles. Refer to “Defroster Grilles” in this section.

2. Install the left and right air vent grilles. Refer to “Vent Grille” in this section.

3. Install the air/defroster ducts to the instrument panel. Refer to “Ducts” in this section.

4. Place the T-bar and the instrument panel in position to be mounted together.

5. Install the grip assembly. Refer to “Grip Assembly” in this section.

6. Install mounting screws to attach the instrument panel to the T-bar.

7. Install the electrical wire harness.

8. Install the clock. Refer to “Clock” in this section.

9. Install the door lock timer unit. Refer to “Door Lock Timer Unit” in this section.

10. Install the ABS control unit to the instrument panel. Refer to “ABS Control Unit” in this section.

11. Install the instrument cluster. Refer to “Instrument Cluster” in this section.

12. Install the instrument cluster trim. Refer to “Instrument Panel Trim” in this section.

13. Install the air conditioner sensor unit tube. Refer to “Air Conditioner Sensor Unit” in this section.


15. Install the radio. Refer to “Radio” in this section.

16. Install the instrument panel into the vehicle. Refer to “Instrument Panel” in this section.

Page 68 of 68


Documents

Page 1 of 68 - JustAnswer - About Us | JustAnswerww2.justanswer.com/uploads/ebrock63/2012-06-18_220414...2012/06/18 · SPORTAGE(AL) >2000 > G 2.0 DOHC > Body (Interior and Exterior)