Hyundai i20 Quiz
Body Work (Interior and Exterior)

Headliner Rail Repair Procedures

In this manual: Body Work (Interior and Exterior)
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
24steps
~144min
5/5difficulty
Done 0 of 24

REPLACEMENT

  1. Disconnect the negative (-) battery terminal.
  2. Recover the refrigerant using the refrigerant recovery/recycling/charging system.
  3. When the engine has cooled, drain the coolant from the radiator. (Refer to Engine Cooling System - "Coolant")
  4. Remove the headliner cover. (Refer to Headliner group - "Headliner 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 flexible hoses from the heater. (Refer to Heating, Ventilation and Air Conditioning - "Heater Unit")
  7. Remove the wiper motor. (Refer to Body Electrical System - "Wiper Motor")
  8. Loosen the hood crossmember mounting bolts.
  9. Remove both front seat assemblies. (Refer to Front Seat - "Front Seat")
  10. Remove the instrument panel assembly from the protective pad. (Refer to Instrument Panel - "Main Panel")
  11. Disconnect the steering column connectors. (Refer to Steering System group - Steering Column and Shaft)
  12. Lower the steering column after loosening the column mounting bolts. (Refer to Steering System group - Steering Column and Shaft)
  13. Remove the shift lever assembly. (Refer to Automatic Transmission System - "Shift Lever")
  14. Separate the radiator to make room for removing the air guard.
  15. Remove the rear air duct (A) by releasing the clips.
  16. Disconnect the connector (A) from the SRS control module (SRSCM).
  17. Disconnect the connector (A) and the retaining clips on the pillar. [Driver]
    [Passenger]
  18. Disconnect the connectors of the passenger compartment junction box (A).
  19. Disconnect the multi-box connectors (A). [Driver]
    [Passenger]
  20. Remove the drain hose (A).
  21. After removing the nuts and bolts, remove the hood crossmember and blower and heater unit (A) together.
  22. Disconnect the blower and heater unit connectors.
    1. Disconnect the blower motor connector (A), then remove the wiring harness clips.
    2. Disconnect the power MOSFET connector (A), the evaporator temperature sensor connector (B), then remove the wiring harness clips.
    3. Disconnect the intake actuator connector (A), the mode actuator connector (B), then remove the wiring harness retaining clips.
    4. Disconnect the temperature control actuator connector (A), then remove the wiring harness mounting clips.
  23. Remove the blower and heater unit (A) from the hood crossmember after loosening the mounting nuts and bolts.
  24. To install, perform the removal procedure in reverse order.

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