Kia Sorento 2003-05

Removal & Installation

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Click image to see an enlarged view

Fig. Instrument panel exploded view

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the heater hoses.
  8.  
  9. Remove the A pillar trim.
  10.  
  11. Remove the cowl side trim.
  12.  
  13. Remove the front door scuff trim.
  14.  
  15. Remove the shroud cover.
  16.  
  17. Remove the left side cover.
  18.  
  19. Remove the hood release cable.
  20.  
  21. Remove the lower panel screws (4), disconnect electrical connectors and remove the lower instrument panel.
  22.  
  23. Remove the driver air bag module.
  24.  
  25. Remove the steering wheel.
  26.  
  27. Remove the steering shroud cover.
  28.  
  29. Remove the lower instrument panel and steering shaft.
  30.  
  31. Remove the facia panel screws (2) and remove the instrument cluster facia panel.
  32.  
  33. Remove the cluster screws (4), disconnect electrical connector and remove the instrument cluster assembly.
  34.  
  35. Open ashtray, the remove instrument center facia side panel.
  36.  
  37. Remove audio facia panel screws (8), disconnect the electrical connector and remove audio facia panel.
  38.  
  39. Remove the radio mounting screws (4), disconnect the electrical connector, antenna cable and remove the radio unit.
  40.  
  41. Remove the screws (4), disconnect the electrical connector and remove heater controller.
  42.  
  43. Remove the screws (6), disconnect the electrical connector and remove center facia panel.
  44.  
  45. Remove the screws (4), then remove the left center lower panel.
  46.  
  47. Remove the glove box.
  48.  
  49. Remove the right side cover, instrument right lower panel screws (10), disconnect the electrical connector and remove the instrument right lower panel.
  50.  
  51. Disconnect the electrical connector and remove the main instrument panel assembly.
  52.  
  53. Remove crossbar side mounting bolts (4).
  54.  
  55. Remove crossbar lower mounting bolts (4).
  56.  
  57. Remove crossbar bracket bolts (2).
  58.  
  59. Remove the heater unit.
  60.  


    Click image to see an enlarged view

    Fig. Heater unit mounting exploded view


To install:

  1. Install the heater unit.
  2.  
  3. Install the crossbar and tighten the mounting bolts to 12-19 ft. lbs. (17-26 Nm).
  4.  
  5. Install the main instrument panel assembly and reconnect the wiring harness connector.
  6.  
  7. Install the instrument right lower panel, reconnect the wiring harness connector and install the right side cover.
  8.  
  9. Install the glove box.
  10.  
  11. Install the left center lower panel.
  12.  
  13. Install the center facia panel.
  14.  
  15. Install the heater controller.
  16.  
  17. Install the radio.
  18.  
  19. Install the audio facia panel.
  20.  
  21. Install the instrument center facia side panel.
  22.  
  23. Install the instrument cluster assembly.
  24.  
  25. Install the instrument cluster facia panel.
  26.  
  27. Install the steering shaft and lower instrument panel.
  28.  
  29. Install the steering shroud cover.
  30.  
  31. Install the steering wheel.
  32.  
  33. Install the driver air bag module.
  34.  
  35. Install the lower instrument panel.
  36.  
  37. Install the hood release cable.
  38.  
  39. Install the left side cover.
  40.  
  41. Install the shroud cover.
  42.  
  43. Install the front door scuff trim.
  44.  
  45. Install the cowl side trim.
  46.  
  47. Install the A pillar trim.
  48.  
  49. Install the heater hoses.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Fill the cooling system.
  54.  
  55. Start the engine and check for leaks and proper heater operation.
  56.  



Click image to see an enlarged view

Fig. Instrument panel and related components

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the heater hoses.
  8.  
  9. Remove the A pillar trim.
  10.  
  11. Remove the cowl side trim.
  12.  
  13. Remove the front door scuff trim.
  14.  
  15. Remove the shroud cover.
  16.  
  17. Remove the left side cover.
  18.  
  19. Remove the hood release cable.
  20.  
  21. Remove the lower panel screws (4), disconnect electrical connectors and remove the lower instrument panel.
  22.  
  23. Remove the driver air bag module.
  24.  
  25. Remove the steering wheel.
  26.  
  27. Remove the steering shroud cover.
  28.  
  29. Remove the lower instrument panel and steering shaft.
  30.  
  31. Remove the facia panel screws (2) and remove the instrument cluster facia panel.
  32.  
  33. Remove the cluster screws (4), disconnect electrical connector and remove the instrument cluster assembly.
  34.  
  35. Open ashtray, the remove instrument center facia side panel.
  36.  
  37. Remove audio facia panel screws (8), disconnect the electrical connector and remove audio facia panel.
  38.  
  39. Remove the radio mounting screws (4), disconnect the electrical connector, antenna cable and remove the radio unit.
  40.  
  41. Remove the screws (4), disconnect the electrical connector and remove heater controller.
  42.  
  43. Remove the screws (6), disconnect the electrical connector and remove center facia panel.
  44.  
  45. Remove the screws (4), then remove the left center lower panel.
  46.  
  47. Remove the glove box.
  48.  
  49. Remove the right side cover, instrument right lower panel screws (10), disconnect the electrical connector and remove the instrument right lower panel.
  50.  
  51. Disconnect the electrical connector and remove the main instrument panel assembly.
  52.  
  53. Remove crossbar side mounting bolts (4).
  54.  
  55. Remove crossbar lower mounting bolts (4).
  56.  
  57. Remove crossbar bracket bolts (2).
  58.  
  59. Remove the heater unit.

    Click image to see an enlarged view

    Fig. Heater/AC unit and related components

  60.  

To install:

  1. Install the heater unit.
  2.  
  3. Install the crossbar and tighten the mounting bolts to 12-19 ft. lbs. (17-26 Nm).
  4.  
  5. Install the main instrument panel assembly and reconnect the wiring harness connector.
  6.  
  7. Install the instrument right lower panel, reconnect the wiring harness connector and install the right side cover.
  8.  
  9. Install the glove box.
  10.  
  11. Install the left center lower panel.
  12.  
  13. Install the center facia panel.
  14.  
  15. Install the heater controller.
  16.  
  17. Install the radio.
  18.  
  19. Install the audio facia panel.
  20.  
  21. Install the instrument center facia side panel.
  22.  
  23. Install the instrument cluster assembly.
  24.  
  25. Install the instrument cluster facia panel.
  26.  
  27. Install the steering shaft and lower instrument panel.
  28.  
  29. Install the steering shroud cover.
  30.  
  31. Install the steering wheel.
  32.  
  33. Install the driver air bag module.
  34.  
  35. Install the lower instrument panel.
  36.  
  37. Install the hood release cable.
  38.  
  39. Install the left side cover.
  40.  
  41. Install the shroud cover.
  42.  
  43. Install the front door scuff trim.
  44.  
  45. Install the cowl side trim.
  46.  
  47. Install the A pillar trim.
  48.  
  49. Install the heater hoses.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Fill the cooling system.
  54.  
  55. Start the engine and check for leaks and proper heater operation.
  56.  

 
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