General Notes
Read through the fitting instructions before installation of the accessory. Install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.
Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.
It is always recommended that this accessory is fitted by a qualified Kia Technician.
Safely store and protect any removed vehicle components.
Ensure all bare metal surfaces are protected using automotive bare metal primer and touch-up paint, or suitable automotive rust inhibitor.
Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.
Safety Notes
Check that all work practices comply with safety standards.
Please wear appropriate clothing and use safety equipment.
VEHICLE PREPARTION
IMPORTANT
Always refer to the vehicle’s Workshop Manual when removing vehicle components.
Step 1
Open the bonnet.
Disconnect the negative terminal on the battery (A).
Tools Used
Wrench
10mm Socket
Step 2
Remove and retain the ten plastic push clips (A) from the engine bay plastic cover (B).
Tools Used
Trim Removal Tool.
Step 3
Gently pry the corner of the engine bays plastic cover (B) upwards to disengage the trim clips.
Continue towards the other side of the vehicle.
Remove and retain the engine bay plastic cover (B).
Tools Used
Trim Removal Tool
Step 4
Remove and retain the eight silver M6 hex bolts (A) securing the bumper.
Tools Used
Wrench
10mm Socket
Step 5
Remove and discard the three hex bolts (A) securing the lower bumper trim.
Remove and retain the four hex bolts (B) securing the metal under-body plate.
Disengage the under-body plate and hook.
Remove and retain the under-body plate (C).
Tools Used
Wrench
12mm Socket
Step 6
Remove the two bolts (B) from underneath the factory tow hook (A).
Discard bolts and hook.
Repeat on RHS.
Tools Used
Wrench
14mm Socket
Step 7
Remove and discard hex bolt (A).
Remove and retain three scrivets (B).
Remove and discard two Phillips head screws (C).
Repeat on RHS.
Tools Used
Phillips Head Screwdriver
Wrench
8mm Socket
Trim Removal Tool
Step 8
Pop the top clip (A) of the grille, out of its housing.
Gently pull the bumper away from the vehicle, then pull forwards slowly popping the clips away, from underneath the headlight.
Repeat on RHS.
Tools Used
Trim Removal Tool.
Step 9
Once the clips are popped out, gently pull the grille and bumper assembly (A) forward, away from the vehicle.
Pull the grille and bumper assembly (A) forward a small distance and then disconnect the vehicle loom (B) from the left side of the bumper.
Tools Used
Flat Head Screwdriver.
Step 10
Remove and retain two hex bolts (A) and two hex bolts (B) securing the upper air guide (C).
Remove and retain the upper air guide (C).
Note : Hex bolts A & B are different lengths.
Tools Used
Wrench
10mm Socket
Step 11
Remove and retain the seven hex bolts (A) securing the lower air guide (B).
Remove and retain the five plastic push clips (C).
Remove and retain the lower air guide (B).
Tools Used
Wrench
10mm Socket
Trim Removal Tool
Step 12
Disconnect the front radar connector (A).
Remove and retain three bolts (B) holding the front radar bracket (C).
Retain the front radar.
Tools Used
Wrench
10mm Socket
Flat Screw Driver
Step 13
Unclip harness (A) from lower beam LHS.
Remove and discard four bolts (B) per side holding the lower beam.
Discard the lower beam.
Tools Used
Wrench
14mm Socket
Trim Removal Tool
Step 14
Remove and discard the two phillips head screws (A) holding the head light bezel (C).
Remove and discard head light bezel (C) and white clip (B).
Repeat on RHS.
Tools Used
Phillip Head Screwdriver
Trim Removal Tool
Step 15
Mark the lower air guide as shown and cut along the line to remove the excess trim.
De-burr the edges.
Repeat for RHS.
Tools Used
Multi-Tool
Deburring Tool
Step 16
Unclip the harness (C) from the upper grille (Refer image 1).
Remove and discard screws fixing lower bumper to the upper grille (refer image 2).
Remove and discard screws fixing Antenna to upper grille (refer image 3).
Release tabs to allow separation of upper grille (A) and lower bumper (B) (refer image 4).
Separate the upper grille (A) from the lower bumper (B).
Tools Used
Phillips Head Screw Driver
Flat Head Screw Driver
Trim Remover Tool
Step 17
Mark and trim the upper front grill (A) as shown in detail view.
Discard the lower area (B) and retain the upper grille (A).
De-burr edges.
Tools Used
Multi-tool
Deburring Tool
Step 18
Reinstall the trimmed air guide (B) using the retained three hex bolts (A) and retained five plastic push clips (C)
Note: Do not install bolts in Location shown.
Tools Used
Tools Used Wrench
10mm Socket
Step 19
Reinstall the upper air guide (C) using the retained four hex bolts (A and B).
Note: When installing, short bolts are used in position A, long bolts are used in position B.
Tools Used
Wrench
10mm Socket
Step 20
Assemble Grille Bracket Upper (16) to Grille Bracket Lower (17) using a M6x20 Allen Screw (29) and M6 Flat Washer (42).
Define the centre of the upper air guide (D) and trim the rubber part only by removing 25mm from it. Cut all the way to the vertical wall as shown in detail.
Fit assembled Grille Bracket (A) using the retained hex bolt (B) from the lower air guide. Use Cable Tie (54) to fix the Grille Bracket to the lower air guide (C).
Tools Used
Wrench,10mm Socket
4mm Hex key
Multi-Tool
Tape Measure
Non Permanent Marker
Step 21
Install the Grille Bracket LH (18) using the retained hex bolt (A) from lower air guide. Repeat on RHS. Note: When installing Grille Bracket (18) use the top view shown for correct orientation. Note: When installing Bracket use the top view shown for correct orientation.
Step 22
Place the grille (A) into position on the vehicle.
Looking from under the grille use a marker pen to locate where to drill the four holes in the grille so as to match up with the holes in the brackets.
Remove grille and drill four 8mm holes in locations marked.
Tools Used
Marker Pen
Drill
8mm Drill bit
Step 23
Install the grille (A) into position on the vehicle. Push all clips to lock it in position.
Secure the centre Grille Bracket to the grille using two M6x16 Hex Bolt (40) and M6 Flat Washer (42) as shown in Image 1.
Secure the Grille bracket LH to the grille using M6x20 Allen Screw (29) and M6 Flat Washer (42) shown in image 2.
Repeat for RHS.
Note: Adjust the Grille Bracket LH position if needed. Ensure the Grille Bracket is positioned over the top of the grille.
Tools Used
Wrench
4mm Hex Key
10mm Spanner
Step 24
Install the retained eight silver M6 hex bolts (A) securing the grille (B)
Tools Used
Wrench
10mm Socket
Step 25
Reinstall the engine bay plastic cover (B) using the ten push clips (A).
Step 26
Trim the wheel arch liner as per measurements and discard the bottom part.
Deburr edges
Repeat for RHS
Tools Used
Tin Snips
Deburring Tool
Step 27
Connect the Radar Extension Harness (27) to the existing harness (A) for the radar.
Step 28
Adjust the steering wheel to the highest position.
Adjust the driver seat position as far back as possible.
Remove crash pad lower panel (A) (Refer to Workshop Manual → Body [Interior / Exterior / Electrical] → Crash Pad Panel).
Tools Used
Phillips Head screwdriver
Trim Removal Tool
Step 29
Remove the Centre Console Assembly (A) (Refer to Workshop Manual → Body [Interior / Exterior / Electrical] → Floor Console → Floor Console Assembly)
Note: During the Centre console assembly removal it may be necessary to remove the T-Bar (B) Gear Stick by pulling in an upwards motion like shown.
Note: When removing the centre console take extreme care when disconnecting blue USB cable located behind the USB charge ports. Refer to Step 31 for details on disconnecting the blue USB cable.
Step 30
When removing the centre console, take extreme care when disconnecting blue USB cable located behind the USB charge ports, press the tab in and remove connector (Image below with arrow).
Step 31
Remove the Crash Pad Centre Panel (A) (Refer to Workshop Manual → Body [Interior / Exterior / Electrical] → Crash Pad Panel)
Note: During the Crash Pad Centre Panel removal Grip the hose (C) at the base where it meets the panel and pull away from Crash Pad Centre Panel.
Tools Used
Phillips Head screwdriver
Trim Removal Tool
Step 32
Reach underneath and disconnect ADAS_DRV Connector (A).
Step 33
Wrap the connector (A) twice around using the tape (P/N DVA53APK95 supplied separatly) ensuring the connector is fully covered and secure wiring as shown in image.
Reinstall the removed parts by following the steps 29-33 in reverse.
Step 34
Reconnect the negative terminal on the battery (A) and connect VCI/KDS.
Note: Bull Bar installation involves procedures that require the use of KDS. Please refer to both this manual and the “Bull Bar installation guide (For new installation - intergrated workflow)” located in KDS under S/W managment > FR_CMR.
Tools Used
Wrench
10mm Socket
BULLBAR PREPARATION
IMPORTANT
Always refer to the vehicle’s Workshop Manual when removing vehicle components.
Step 35
Remove and retain four screws (per light) securing the fog lights (A). Unclip the harness from bumper and fog lights (A).
Disconnect the fog lights (A), parking sensors (B), corner radar (C). Disconnect and remove front camera and antenna if fitted (D).
Remove each parking sensor by noting down the direction and install on the Bull Bar parking sensor bezels.
Note: When removing the parking sensors from the bumper note the orientation. Note: Check “Bull Bar installation guide” step 1 in KDS.
Tools Used
Phillips Head Screwdriver
Trim Removal Tool
Step 36
Note the of orientation of the plugs, ensure positioning of sensors is accurate. (blue wire position).
Mount the Fog lights (C) using the retained screws (D).
Install the replacement OEM harness into the Bull Bar
- 91980 DV020
- 91980 DV080
- 91980 DV670
Note: The vehicle loom connector (E) position is on the LHS
Tools Used
Phillips Head Screwdriver
Step 37
Install the parking sensors (A) into the parking sensor bezel that are fixed in the Bull Bar (C), ensure sensors are positioned and pointing in the same direction as when removed from the factory bumper.
Refer to printed information.
One sensor has a blue wire (B) this is to be fitted under the light as per factory bumper.
Repeat for RHS.
Step 38
Install Parking Sensor Extension Harness (24) to the main harness (A) when fitting the outer most parking sensors to the Bull Bar Assembly.
Note: Engage the lock (B) after connection.
Step 39
IMPORTANT
THIS STEP ONLY TO BE CARRIED OUT IF THERE IS NO FRONT CAMERA TO BE FITTED.
Install Front Camera Plug (23) into the front hole of the Bull Bar Assembly using M6 Flat Washer (43) and Flange Nut (50).
Tools Used
Wrench
10mm Socket
Step 40
Mount the front camera (A) to the Front Camera Bracket (21) using two M5x14 Allen Screws (28) and two M5 Flat Washers (41) and two M5 Flange Nuts (49).
Tools Used
Wrench
3mm Hex Key
Step 41
Connect the front camera (B) to the main harness (C).
Place the antenna (A) over the Front Camera Bracket (21) and install to Bull Bar Assembly using two M6x20 Allen Screw (29) and M6 Flat Washers (42).
Connect the antenna (A) to the main harness (C).
Tools Used
Wrench
4mm Hex Key
Step 42
Main harness is to be secured with Cable Ties (54) to the loops (A) provided on the underside of the Bull Bar Assembly.
Note: Harness removed for clarity in Image 1.
Note: Check “Bull Bar installation Guide” step 2, 3 in KDS.
Step 43
Prime the Area (A) on the Bull Bar Assembly.
Note: After application keep primed area clean for when the Radar Cover (26) will be installed.
Tools Used
Primer
Step 44
Install the Radar Shroud (25) onto the M6 studs (A) that are on the Bull Bar Assembly using two M6 Flange Nuts (50) as shown.
Loosely fit two M6 Hex Nuts a few turns to ensure Shroud (25) cannot fall off (do not tighten)
Tools Used
Wrench
10mm Socket
Step 45
Secure the front radar (A) to the Bull bar Assembly using the retained three M6 bolts (B) .
Tighten the M6 bolts to 8 Nm.
Tools Used
Torque Wrench
10mm Socket
BULLBAR INSTALLATION
Step 46
Loosely attach the Recovery Hook LH (5) to the chassis frame using M10x50 Hex Bolt (36) Fine Thread, M10 Flat Washer (46) through the downward fixing hole.
Repeat on RHS.
Note: Ensure a gap is left between the bolt head and the part to allow for an adjustment.
Tools Used
Wrench
16mm Socket
Step 47
Insert a Spacer with Wire (22) into the opening on the chassis frame feeding the spacer onto the M12x110 Hex Bolt (38) with M12 Flat Washer (48).
Ensure that the bolt passes through the Recovery Hook (5).
Once the first Spacer with Wire (22) is installed onto the bolt insert the second Spacer with Wire (22) and push the bolt fully through the chassis frame.
Install the M12 Flat Washer (48) and M12 Hex Nut (52), see section view. Torque two M10 Hex Bolts (36) to 50Nm, (fitted in previous step).
Torque M12 Hex Bolt (38) to 74Nm.
Repeat on RHS.
Note: Spacer with Wire (22) flange head should face against the chassis wall refer the section view image.
Tools Used
16mm Socket
18mm Socket
18mm Spanner
Torque Wrench
Step 48
Insert a Spacer with Wire (22) into the opening on the chassis frame feeding the Spacer with Wire (22) onto an M12x85 Hex Bolt (37) with M12 Flat Washer (48).
Ensure that the bolt passes through the Outer Bracket LH (12).
Once the first Spacer with Wire (22) is installed onto the bolt insert the second Spacer with Wire (22) and push the bolt fully through the chassis frame, see the section view.
Install the Inner Bracket LH (14) onto the end of the Bolt (37) and loosely secure with an M12 Flat Washer (48) and M12 Hex Nut (52).
Place the Inner Bracket (14) against the chassis rail if the holes are not aligned to the front chassis holes then Shim (4) should be installed.
Note: One or two shims (4) may be required to align holes correctly.
Do not tighten the bolt.
Repeat on RHS.
Note: Spacer with Wire (22) flange head should face against the chassis wall. Refer to section view.
Tools Used
Wrench
18mm Socket.
Step 49
Loosely secure the Bull Bar Mount (2) onto the front end plate of chassis frame using M10x50 Hex Bolt (36) fine thread, M10 Flat Washer (46).
Once the M10x50 Hex Bolt (36) has engaged into the thread of the front end plate of chassis frame then slide Spacer Plate (11) over and into the correct position.
Do not tighten the bolts. LHS shown for clarity, both sides need to be completed.
Note: Heavy load-Two people are required.
Tools Used
Wrench
16mm Socket
Step 50
Install two M8x40 Hex Bolts (31) and two M8 Flat Washers (45).
Install a M8x50 Hex Bolt (32) and a M8 flat Washer (45).
The Bolts should be finger tightened only.
Repeat on RHS.
Tools Used
Wrench
13mm Socket
Step 51
Install a M10x50 Hex Bolt (36) fine thread and a M10 Flat Washer (46).
Install two M10x30 Hex Bolts (34) fine thread and two M10 Flat Washers (46). Do not tighten the bolts.
Repeat on RHS.
Tools Used
Wrench
16mm Socket.
Step 52
Measure from the Bull Bar Mount (2) to the front grille (A) and position centrally.
Tools Used
Tape Measure
Ruler
Step 53
Tighten the M10 Hex Bolts (36 and 34) shown to 50Nm.
Repeat on RHS.
Tools Used
16mm Socket
Torque wrench
Step 54
Tighten the M8 Hex Bolts (32 and 31) shown to 20Nm.
Repeat on RHS.
Tools Used
13mm Socket
Torque Wrench
Step 55
Tighten the M12 Hex Bolt (37) fixing the Outer Bracket to 74Nm.
Repeat on RHS.
Note: Ensure Bull Bar mount is still mounted centrally to the front grille.
Tools Used
18mm Socket
18mm Spanner
Torque Wrench
Step 56
Install Mount Strap (3) onto the Bull Bar Mount (2) using two M10x30 Hex Bolt (33) with three M10 Flat Washer (46) and two M10 Hex Nut (51).
Torque two M10 Hex Bolts to 50Nm.
Repeat on RHS.
Tools Used
16mm Socket
Torque Wrench
16mm Spanner
Step 57
Loosen (Do not remove) the two M4 Screws (A) on the Bull Bar Mount (2) holding the M10 Nut Plate.
Repeat on RHS.
Tools Used
Wrench
2.5mm Hex key
IMPORTANT
Heavy Load - Two person lift or mechanical lift aid required. Unsecured Load - Keep clear of unsecured object. Spotter or mechanical lift aid required
Step 58
Lift and position the Bull Bar Assembly (1) onto the Bull Bar Mount (2) using two people,and a mechanical aid.
Once in position, a third person is required.
Install Bolts M10x40 Hex Bolt (35) and M10 Flat Washers (47) to the RHS and LHS of Bull Bar Assembly.
Once all six M10 Hex Bolts (35) are installed, the four M4 Screws (C) holding the M10 Nut plates can be removed.
Note: Bolts are to be installed through the opening at the front of the Bull Bar Assembly
Tools Used
Wrench
16mm Socket
Jack
2.5mm Hex key
Step 59
Connect the radar Extension Harness (B) to Radar (A).
Step 60
Connect the vehicle harness (B) to the harness (A) Installed on the Bull bar Assembly.
Secure the vehicle harness to the vehicle body using a cable tie (52).
Step 61
Adjust the vertical and horizontal position of the Bull Bar Assembly (1) so that you obtain the below.
Clearance between Bull Bar Assembly (1) and vehicle is to be no less than 10mm.
The front face of the Bull Bar Assembly (1) needs to be perpendicular to the ground whilst the top surface of the Bull Bar Assembly (1) is required to be level with the upper grille (A) See centre section for clarity.
Once correctly positioned, tighten the six M10 Hex Bolts (35) so that the Bull Bar Assembly (1) does not move.
Remove Jack.
Measure the vertical angle of the radar (B) using a digital inclinometer (DVA53APK90) and ensure it is within +/- 2 degrees. Adjust the Bull Bar M10 x Bolts if the initial setting does not meet the requirments.
Note: Ensure clearances between Bull Bar Assembly (1) and vehicle body no less than 10mm.
Note: Check “Bull Bar Installation Guide” step 4, 5 in KDS.
Tools Used
Wrench
16mm Socket
Spirit Level
Ruler
Step 62
Tighten the six M10 Hex bolts (35) by following the steps below one bolt at a time.
Remove a bolt, apply thread lock to the bolt and tighten to 62 Nm. Complete one bolt at a time following an alternating sequence LH to RH.
Note: Recheck the radar vertical angle to ensure it is within +/- 2 degrees.
Tools Used
16mm Socket
Torque Wrench
Step 63
With the Bull Bar Assembly (1) installed on the vehicle use a Digital Inclinometer (DVA53APK90) to adjust the angle of the radar.
Refer to the workshop manual radar calibration steps and reflector setup, adjust the radar to:
+/- 0.8 degrees horizontal
+/- 0.4 degrees vertical
Using the adjustment screws on the radar (refer to workshop manual).Verify and adjust radar position using reflector.
Note: Refer to the workshop manual radar calibration steps with”Bull Bar installation Guide” step 6 (Front radar Calibration) in KDS.
IMPORTANT
If the central axis is not secured using the reflector or the vertical angle of the front radar mounted on the bull bar is outside the allowable range (+0.4 to -0.4), the front radar may not function properly.
Step 64
Ensure ignition is off to not induce faults.
Disconnect radar connector (A).
Disconnect parking sensor (B).
Step 65
Partially Peel the tape liner from the double sided tape which is on the Radar Cover (26).
Install the Radar Cover (26) into position, which is in front of the Radar Shroud to the Bull Bar Assembly.
Once in position peel the rest of the liner for the double sided and press firmly to ensure the Radar Cover (26) is fitted correctly.
IMPORTANT
Ensure the radar cover is not damaged while feeding between radar shroud.
Step 66
Install M6x20 Allen Screw (29) and M6 Flat Washer (42) and torque to 5Nm.
Evenly tighten the two M6 Flange Nuts (50) and torque to 5Nm.
Tools Used
4mm Hex Bit Socket
10mm Socket
Torque Wrench
Step 67
Reconnect radar connector (A).
Reconnect parking sensor (B).
Note: Check “Bull Bar installation Guide” step 7-10 in KDS If vehicle has SVM features (ADAS_PRK), please conduct “Bull Bar Installation Guide” step 10-1, 10-2.
Step 68
Install Mesh (20) to Bull Bar Assembly (1) using six M6x20 Allen Screws (29).
Torque six M6x20 Allen Screws (29) to 8Nm.
Tools Used
4mm Hex Bit Socket
Torque Wrench
Step 69
Install the Under cover LH (8) to the Bull Bar Assembly (1) using five M6x20 Allen Screws (29) and M6 Flat Washers (42).
Torque five M6x20 Allen Screws (29) to 8Nm.
Repeat on RHS.
Tools Used
4mm Hex Bit Socket
Torque Wrench
Step 70
Install the Bash Plate (7) to the Bull Bar Assembly (1) using three M6x20 Allen Screws (29) and M6 Large Flat Washers (44).
The M6x20 Allen Screws (29) should be finger tightened only.
Tools Used
Wrench
4mm Hex key
Step 71
Install metal under body plate (B) to Bash Plate (7) using four previously removed bolts (A), and three M8x30 Hex Bolts(30), M8 Flat Washer (45).
Torque three M8 Hex Bolts (43) to 20Nm.
Torque four Bolts (A) refer to vehicle user manual.
Tools Used
12mm Socket
13mm Socket
Torque Wrench
Step 72
Torque three M6x20 Allen Screws (29) to 8Nm.
Tools Used
4mm Hex Bit Socket
Torque Wrench
Step 73
Attach the Number Plate Bracket Assembly (10) to the Bull Bar Assembly (1) using M6X20 Allen Screws (29) and M6 Flat Washers (42).
Use the two M6 Screws (A) and Nuts (B) preinstalled in the front of the Number Plate Bracket Assembly (10) to install the Number Plate onto the Number Plate Bracket Assembly (1) as shown in Image 1.
OR
Use the two M6x20 Allen Screws (29) and two M6 Flat Washers (42) to install the Number Plate onto the Bull Bar Assembly (1) as shown in Image 2.
Tools Used
Wrench
4mm Hex key
Step 74
Trace the hole on the Bull Bar Assembly (1) onto the wheel arch liner (A) & drill a 9mm hole in the wheel arch liner.
Install previously removed scrivet (B).
Install two Decals Sticker (55) to the wheel arch as shown.
Repeat on RHS.
Tools Used
Drill
9mm Drill Bit
Pen
Step 75
Press the Settings (A) on the infotainment screen.
Step 76
Press the Vehicle (A) button.
Step 77
Press the Driver Assistance (A) button.
Step 78
Press the Driving Convenience (A) button.
Step 79
Press the SCC (Smart Cruise Control) (A) button.
Step 80
Set the Acceleration (A) to 1 by sliding your finger across the screen.
Set the Response speed (B) to 1 by sliding your finger across the screen.
Step 81
Once both Acceleration and Response speed are set to 1 then press the home button (A).
Step 82
Upon completion of the Bull Bar installation, please offer the vehicle owner the option to retain the OE front bumper along with all sensors and wiring harness, OTHERWISE DISCARD the front bumper, all sensors and wiring harness accordingly.
Step 83
Please insert the provided leaflet into the service manual booklet located in the glove box.
Place the Fitting Instructions in the glove box after installation is completed.