Installation Instructions for Kia K5 (2021-Current)

Part Numbers:

• 25001
• 78294
• CQT25001

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 11/16"
• Grinder
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Tin Snips
• Utility Knife
• Marker
• Tape Measure

Step-by-Step Instructions:

1. Remove Underbody Panel:

   • Using a flat head screwdriver and a 10mm socket, remove (4) rivets and (2) nuts from the driver-side underbody panel.
   • Remove the panel and set it aside.

2. Lower Exhaust:

   • Use exhaust removal pliers to remove (2) rubber hangers from the muffler's rear.
   • Spray lubricant or soapy water on the rubber hangers to ease removal.
   • Support the exhaust properly before removing the hangers.

3. Remove Heat Shield:

   • Using a 10mm socket, remove (3) nuts securing the heat shield.
   • Remove the heat shield and set it aside.

4. Enlarge Holes:

   • Remove the rubber plugs and covers from the rearward attachment holes and access holes on both sides using a flat head screwdriver.
   • Use a grinder to enlarge the forward attachment hole diameter to 1/2” on both sides.

5. Trim Underbody Panel and Heat Shield:

   • Measure and mark the areas to be trimmed using a tape measure and marker.
   • Use tin snips and a utility knife to trim the underbody panel and heat shield as shown in the provided instructions.

6. Install Hitch:

   • Feed the 7/16" carriage bolts and spacers through the access holes into the attachment holes using pull wires.
   • Leave the pull wires attached.
   • Reinstall the trimmed heat shield using (1) nut at the trunk pan stud location.
   • Raise the hitch into position and guide the pull wires through the bracket holes.
   • Remove the pull wires and loosely install conical washers (teeth side toward hitch) and hex nuts onto the hitch.

7. Tighten Fasteners:

   • Torque all 7/16"-14 GR5 fasteners to 50 ft-lb (68 N*m).

8. Reinstall Underbody Panel and Exhaust:

   • Reattach the underbody panel using the original fasteners. Note that (2) nuts and (1) rivet from the panel, and (2) nuts from the heat shield, will not be reinstalled after trimming.
   • Raise the exhaust back into position and reattach the rubber hangers.

Hardware List:

• (4) Carriage Bolt, 7/16"-14 x 1.25 GR5
• (4) Spacer, 1.00" x 2.00" x 0.179"
• (4) Conical Washer, 7/16"
• (4) Hex Nut, 7/16"-14 GR2
• (4) Pull Wire, 7/16"-14

Safety Notes:

• Always wear safety glasses during installation.
• Check the hitch frequently to ensure all fasteners and the ball are securely tightened.
• Plug any removed holes in the trunk pan or body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Do not cut access or attachment holes with a torch.

Specifications:

• Installation Time: 60 minutes
• Max Gross Trailer Weight: 2,000 lb (907 kg)
• Max Tongue Weight: 200 lb (90.7 kg)
• Complies with SAE J684 and VESC Regulation V-5 standards.

Installation Instructions for T-One® T-Connector for Kia K5 Sedan

Part Numbers:

• 118837

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Trunk:

   • Temporarily remove the rear threshold plate.
   • Partially remove the felt trunk liner behind the driver-side taillight.

2. Locate the Vehicle’s Wiring Harness:

   • On the driver’s side, locate the taillight wiring harness connection point.
   • Carefully separate the connector, ensuring not to damage the locking tabs.
   • Clean all connector surfaces to remove dirt or debris.

3. Connect the Driver-Side T-Connector:

   • Insert the T-One® Connector end with the yellow wire between the driver-side wiring connectors.
   • Ensure the connectors are fully inserted, and the locking tabs are securely engaged.

4. Route the Passenger-Side T-Connector:

   • Route the green wire connector along the threshold to the passenger side.
   • Insert the T-Connector end with the green wire between the passenger-side taillight socket and vehicle wiring harness.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or crossmember.
   • Clean dirt and rustproofing from the grounding area.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution: Verify the area behind any surface before drilling to avoid damage or injury.

6. Route the Power Wire:

   • Locate the black 12-gauge power wire from the T-One® Connector black box.
   • Attach the provided black wire and route it along the exterior frame or existing wiring to the engine compartment, avoiding hot pipes, heat shields, and areas that may pinch or damage the wire.

7. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s Negative (-) battery cable.
   • Remove the fuse from the yellow fuse holder (provided).
   • Attach the ring terminal to the Positive (+) battery cable and secure it.
   • Connect the other end of the fuse holder to the black wire using the provided yellow butt connector.

   Warning: Follow all warnings printed on the tow vehicle’s battery.

8. Reconnect the Battery and Test:

   • Reconnect the Negative (-) battery cable.
   • Insert the 15-amp fuse into the fuse holder.
   • Test the installation using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

9. Mount the T-One® Black Box:

   • Locate a flat surface in an out-of-the-way location and mount the black box module using the provided double-sided tape.

10. Secure the Harness:

    • Use the provided cable ties to secure the T-One® Connector harness, avoiding areas where it could pinch, cut, or melt.

11. Reassemble the Vehicle:

    • Replace all panels, spare tire cover, cargo floor hatch, and cargo nets removed during installation.
    • Ensure no wires are pinched or damaged.

12. Store the 4-Flat Connector:

    • Store the 4-flat connector in the rear cargo area when not in use.
    • When in use, pull the 4-flat connector through the door and close carefully, avoiding pinching the harness in the door latch.

Safety Notes:

• Overloading circuits can cause fires. Do not exceed stated product ratings.
• Always wear safety glasses and follow safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and the instruction sheet for additional details.
• Store these instructions for future reference.
• Always read and follow all warnings and instructions printed on the tow vehicle’s battery.