Wiring Diagram Needed for Fuse Box to Front Bumper Harness Plug Replacement

ymasjidi871 wrote:

@ElektrodaBot @ElektrodaBot
I have a plug broken that comes out from the fuse box and connects to the front bumper wiring harnes I have a new plug but need diagram or instructions to connect the w...

Initial assessment of available information
- You have a broken multi‑pin plug that exits the front (motor) compartment fuse/junction box and mates to the front bumper wiring harness on a 2024 Kia EV9 (VIN KNAAE8151R6015354). You already have a replacement plug and want the correct wire‑to‑cavity assignment.
- Public owner manuals list fuse/relay names but do not publish connector pinouts. Those are in Kia’s service information (GSW/KGSIS) or licensed third‑party manuals. The exact pinout depends on build options tied to your VIN (trim, ADAS package, fog/DRL type, tow, etc.). (ownersmanual.kia.com)
- The front bumper harness for EV9 appears as OEM parts 91890‑DO010/‑DO030/‑DO140 depending on trim/market, but the part listing does not include the electrical pin map. (kia.parts)

Direct answer to the question
- The safest way to obtain the precise pinout for your exact connector (by VIN) is to pull the “connector view” and “wiring diagram” pages from Kia’s Global Service information. For North America this is Kia GSW/KGSIS (72‑hour subscription available; Canada example shown below), which provides VIN‑specific connector IDs, cavity numbering, wire color/gauge, and circuit destinations. With those two pages you can repin the new plug correctly. (gsw-kia.ca)
- If you prefer not to subscribe, a dealer service department or an online manual provider can print or provide the two pages for your VIN (connector view and system schematic). Example commercial aggregators exist (e.g., RepairSurge) if dealer access is inconvenient. (repairsurge.com)

Detailed problem analysis
1. What this connector likely carries
- The single harness from the motor‑room fuse/junction block toward the bumper typically distributes power/ground and data to: front lighting (DRL/fog/markers), front radar and parking sensors, front camera(s), horn, active air flaps/cooling, and washer components. The exact population of cavities varies with options.
- Twisted pairs indicate CAN/LIN or Ethernet‑style links (ADAS). Coax or heavily shielded pairs indicate camera/radar RF. Do not untwist or break shields near the connector during repair.

2. How Kia numbers and identifies connectors (helps you orient the new plug)
- Kia connector views are drawn from the terminal side. Cavity numbers are molded into the housing; numbering order depends on male vs female terminal sides. The service documents also show connector code syntax (location letter + serial number) and the wire color abbreviations (B=Black, R=Red, L=Blue, G=Green, Br=Brown, etc.). Use these to align colors and positions. (scribd.com)

3. Safe power‑down before any repinning
- Key off, remove smart key 2+ m from the vehicle. Disconnect the 12 V negative terminal. For additional safety on EVs, remove the high‑voltage service interlock connector and wait at least 5 minutes for capacitors to discharge. Kia’s Emergency Response Guide describes acceptable disable sequences and the motor‑room fuse box IG1/IG2 fuse pull option in emergencies. (manuals.plus)

4. Two practical methods to restore the wiring
- “Transfer method” (if the old shell still shows original positions): Move one wire at a time from the damaged shell to the new one, matching cavity numbers. Photograph both faces before starting. This avoids schematic hunting.
- “Map‑and‑verify method” (if wires are loose or shell missing):
1) Identify the connector code on the harness label (white tag near the plug).
2) Pull the “connector view” and “system” pages for that code in GSW/KGSIS (or have a dealer print them).
3) Confirm each wire by color and destination using a multimeter for continuity (e.g., to fog lamp or horn connectors) and by identifying grounds (continuity to chassis). Maintain twist rate of data pairs and shield bonds for camera/radar lines.

5. Terminal handling and tools
- Use the correct depinning tools and open‑barrel terminal crimpers. An example aftermarket kit explicitly for Hyundai/Kia terminals is the Rennsteig 11‑piece removal set (references Hyundai WRKRT tools). It prevents tang damage and poor retention. (rennsteig.us)
- For sealed connectors, ensure each wire’s rubber seal is intact and fully seated; replace any missing cavity plugs to keep IP‑rated sealing.

6. What not to do
- Don’t guess pinouts by wire color alone; Kia reuses colors across circuits. Don’t solder to the terminal blades; use proper crimp terminals. Avoid long untwists on CAN/LIN pairs and never break a camera/radar shield.
- Don’t power the vehicle until every cavity is populated or properly cavity‑plugged; water ingress at the bumper area is common.

7. Post‑repair checks
- Reconnect 12 V, perform health check: horn, DRL/fog, washer, active flaps. Scan for DTCs. If the bumper/radar/camera was disturbed or removed, plan for static/dynamic ADAS calibration with a Kia‑capable scan tool after reassembly. This is normal after front‑end service.

Current information and trends
- EV9 front bumper harnesses are sold as complete sub‑assemblies; common EV9 front bumper harness P/Ns include 91890‑DO010 (noted “with GT‑Line”) and variants DO030/DO140 depending on build. If your damage extends beyond the connector, a pre‑terminated OEM pigtail or full sub‑harness can be more reliable than field repinning. (kia.parts)
- Owner‑facing fuse panel documentation exists (engine room junction block, relay/fuse names), but it does not include the connector pin map—plan on using service information for the connector view. (ownersmanual.kia.com)

Supporting explanations and details
- Connector orientation: Verify “Pin 1” by molded numerals and latch/key orientation per Kia’s connector view conventions. The “Connector View and Numbering Order” pages in Kia EWDs show male/female numbering mirroring—use that to avoid 180° errors. (scribd.com)
- Wire colors: Kia uses two‑letter abbreviations; rely on the EWD legend to match colors when the harness has multiple similar hues. (scribd.com)
- Tooling: Use manufacturer‑equivalent removal tools to avoid spreading tangs; the Rennsteig kit provides equivalents to Hyundai/Kia WRKRT tools. (rennsteig.us)

Interdisciplinary connections
- ADAS/radar/camera lines behave like RF/data lines; maintaining controlled impedance (twist and shield) is as important as continuity. Treat camera coax and radar coax/spread pairs like RF cables in instrumentation.

Ethical and legal aspects
- Miswired ADAS or lighting can compromise safety and road legality. If you are unsure about any cavity, obtain the official diagram or have a Kia‑certified technician finish the pinning and perform required calibrations.

Practical guidelines
- Quick checklist:
- Photograph both sides of the old and new plugs.
- Find connector cavity numbers on the plastic—mark Pin 1 and row/column.
- If available, read the harness connector code on the white label.
- Pull the GSW/KGSIS connector view for your VIN; print it and tick off each wire as you insert it. (gsw-kia.ca)
- Use correct depin tools and open‑barrel crimps; light dielectric grease on seals; insert until an audible/tactile click; perform gentle pull test per cavity. (rennsteig.us)
- Reassemble, reconnect 12 V, scan for DTCs, and function‑test.

Possible disclaimers or additional notes
- High‑voltage safety: Even though you’re working at the 12 V harness, follow EV disable procedures (12 V negative off; HV interlock open; 5‑minute wait). This is manufacturer‑recommended safety practice. (manuals.plus)

Suggestions for further research
- Obtain VIN‑specific EWD pages via:
- Kia Global Service Information System (KGSIS/GSW). Non‑dealer access is possible via regional portals/subscriptions; Canadian example shown; US access is via Kia service information providers. (gsw-kia.ca)
- A reputable manual aggregator (example). Ensure it includes wiring diagrams and connector views, not just workshop procedures. (repairsurge.com)
- If needed, verify your VIN’s build/options with a public VIN decoder to know which ADAS and lighting packages are present before you map signals. (nhtsa.gov)

Brief summary
- The exact wire‑to‑cavity assignment for your broken plug is VIN‑specific and published in Kia’s service information (connector view + wiring diagram). Obtain those two pages (GSW/KGSIS or dealer printout), repin using proper tools and numbering conventions, maintain twist/shield for data lines, then function‑test and calibrate ADAS if required. (gsw-kia.ca)

Questions for the user
Please provide the following so I can tailor a step‑by‑step pin map or confirm the correct connector page to pull:
- A clear photo of the new plug (front/terminal side and back/wire side).
- Any markings or part numbers on the plug (inside the latch area or on the rear).
- Pin count and the list of wire colors/gauges present.
- A photo of the mating connector on the bumper harness and the white label near it (often shows the connector code).
- Which functions on the bumper currently do not work (fog/DRL, horn, sensors, camera, active air flap)?

With that, I can identify the connector code and tell you exactly which EWD pages to grab (or, if the photos are clear enough, guide you cavity‑by‑cavity).