Kia Carnival 2005 User Manual

Page 1

Body Shop Manual

FOREWORD

This Body Shop Manual illustrates body structures and service procedures for the CARNIV AL/SEDONA.

This manual illustrates the replacement of major body panels, plastic parts, body dimensions, sealing treatment etc., in a systematic manner which is necessary for effective and lasting body repairs. You are encouraged to become familiar with this manual and understand each section in order to perform proper repair procedures. Keep this manual in a convenient location so that it is readily available.

All information in this manual including specifications, data and illustrations is made based on the vehicles built at the time the manual was printed.

Information regarding the removal/replacement of components not specifically covered in this manual can be found in the CARNIVAL/SEDONA Service Manual. Information regarding electrical harness routing/ connections, etc. can be found in the CARNIV AL/SEDONA Electrical T roubleshooting Manual.

The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. Kia Motors Corporation reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.

CONTENTS

Title Group

General Information

Body Construction

Body Dimensions

Body Panel Repair Procedure

Body Sealing Locations

Corrosion Protection

Body Modification Tools

Plastic Parts

Kia Motors Corporation

SEOUL, KOREA

CAUTION : Severe engine and transaxle damage may result from the use of poor quality fuels and lubricants that do not meet Kia specifications. You must always use high quality fuels and lubricants that meet the specifications described on the specification section in the relevant group of the Workshop Manual.

All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the prior written permission of Kia Motors Corporation.

Page 2

IMPORTANT SAFETY NOTICE

Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair.

Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution as to each case in this manual. Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement part, service procedure, or tool they select.

IN THIS MANUAL

WARNING :

CAUTION :

NOTE :

The following list contains some general WARNINGS that you should follow while working on a vehicle.

Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a specific operation Place supporters against the front and rear surfaces of the tires to help prevent the vehicle from moving Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning. Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on a vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even though the ignition switch is in the OFF position. For this reason care should be taken to ensure that the radiator fan electric motor is completely disconnected when working under the hood and the engine is not running.

Remind you to be especially careful in those areas where carelessness can cause personal injury. To prevent you from making errors that could damage the vehicle as well as personal injury.

Gives you added information that will help you complete a particular procedure.

Page 3

General

Information

FUNDAMENTAL PROCEDURES

VEHICLE PROTECTION..................................GI - 2

A WORD ABOUT SAFETY ...............................GI - 2

WELDING PROCEDURES ..............................GI - 3

BOD Y FRAME STRAIGHTENER.....................GI - 3

ELECTRICAL PROCEDURES ........................GI - 3

FOR BEST RESULTS

DISASSEMBLY.................................................GI - 4

PREPARATION OF ASSEMBLY .......................GI - 6

ASSEMBLY.......................................................GI - 7

RUSTPROOF TREA TMENT AFTER

ASSEMBLY.......................................................GI - 8

VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS

...................GI - 9

JACK SUPPORT POSITIONS ..................GI - 10

BODY COLORS AND MAJOR SPECIFICATIONS

..........................................GI - 11

Page 4

GI-2 GENERAL INFORMATION

FUNDAMENT AL PR OCEDURES

VEHICLE PROTECTION

1. Cover the seats before performing any procedure to keep them from getting dirty .

2. Cover all glasses, seats and mats with a heat resistant cover when welding.

BVQGI6001

3. Protect moldings, garnishes and ornaments.

A WORD ABOUT SAFETY

1. Wear the appropriate safety equipment that is necessary for the procedure being performed.

Safety glasses

Mask

Face shield

2. When welding or performing other procedures that require the use of an open flame near the fuel tank, disconnect and remove the tank and fuel pipe, and cap the pipe to prevent fuel leakage.

Ear protectors

Gloves

Safety shoes

BVQGI6002

BVQGI6003

Page 5

GENERAL INFORMATION GI-3 WELDING PROCEDURES

Observe the following tips when welding.

1. Wear appropriate eye protection.

2. Carefully follow the manufacturers operating instructions for the welding machine you are using.

3. Do not weld, smoke or allow open flames around volatile chemicals, cleaners or solvents or in any area where they have just been used.

BODY FRAME STRAIGHTENER

When using a frame straightener, do not enter the area where the body is being straightened by the chain.

ELECTRICAL PROCEDURES

1. Disconnect the negative battery terminal.

2. Do not pull on wires when disconnecting electrical connectors. Be careful to hold the connector itself when disconnecting it.

3. Insert the connector until it "licks" when connecting the connector.

4. Handle all electrical components with care.

BVQGI6004

Page 6

GI-4 GENERAL INFORMATION

FOR BEST RESUL TS

DISASSEMBLY

Measuring dimensions before beginning

Measure the dimensions of the damaged area according to the body dimension drawings before disassembling and repairing. Adjust dimensions with body frame adjuster if deformed.

Selecting cutting area

Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding. Select an area that would allow the new part to overlap repair area by 1.2~2.0 in (30~50 mm).

Protecting body from damage

Secure the body with clamps and jacks to prevent damage to the body when working on it.

BVQGI6005

Page 7

GENERAL INFORMATION GI-5

Disassembling related parts

Use caution when removing body molding and trim from the area to be worked. Apply masking tape where needed to prevent damage to the part being removed or to the vehicle body. Before starting repairs, check if pipes, hoses or electrical components are present near damaged area.

Wire harness

Repair work area

Cutting area

BVQGI6006

Page 8

GI-6 GENERAL INFORMATION PREPARATION OF ASSEMBLY

Applying spot sealer

Remove paint from the surf ace of new parts and body to be spot welded, and apply spot sealer for rustproofing.

Selecting a welding method

If the thickness of the area to be welded with the panels overlapped is greater than 0.1 in (3 mm), do plug welding using a carbon arc welding machine.

Protecting body from damage

Secure the body with clamps and jacks to prevent damage to the body when working on it.

Thicker than

0.1 in (3mm)

Machining holes for plug welding

Drill a hole of approximately 0.2~0.24 in (5~6 mm) in diameter in those areas which are not suitable for spot welding.

BVQGI6008

BVQGI6007

Adjusting a new part

The new part should be cut larger than the repair area, overlapping the repair area by 1.2~2.0 in (30~50 mm).

1.2~2.0 in

(30~50 mm)

Overlap

body side to modify

new part to modify

1.2~2.0 in

(30~50 mm)

Overlap

BVQGI6009

Page 9

GENERAL INFORMATION GI-7 ASSEMBLY

Measuring dimensions before welding

When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after checking the gaps with nearby parts.

Caution when welding

The number of welding points should be determined based on the criteria below:

Spot welding Plug welding

Increase the number of

spot welds by 30%.

Pitch:

2.0 in (50 mm)

Old part

Pitch:

1.4 in (35 mm)

Repair part

Pitch: Same number of welds as original part.

Repair part more than

0.1 in (3 mm)

BVQGI6010

Caution when spot welding

The tip of the spot welding machine should be maintained to a minimum of 0.1 in (3 mm) because it greatly affects welding strength. When possible , spot welding should be done between the existing spot welded points . Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the welding strength.

0.1 in

(3 mm)

Good

No good

Using a hammer and a chisel

Existing welded spots

New welded spots

0.1 in

(3 mm)

Center

diameter

Using a test piece(test pin)

Nugget diameter to be 4/5 of chip diameter

BVQGI6011

Page 10

GI-8 GENERAL INFORMATION RUSTPROOF TREATMENT AFTER ASSEMBLY

Body sealing

Apply body sealer where necessary.

Applying rustproof material

Apply rustproofing material(wax, oil, etc.) behind welded area.

Applying undercoat

Apply undercoat on the body where necessary .

BVQGI6012

Page 11

GENERAL INFORMATION GI-9 VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS

1. Place the lift blocks under the support points as shown in the illustration

2. Raise the hoist a few inches and rock the v ehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

Lift Block

[Front]

[Rear]

BVQGI6013

Page 12

GI-10 GENERAL INFORMATION JACK SUPPORT POSITIONS

BVQGI6014

Page 13

GENERAL INFORMATION GI-11 BODY COLORS AND MAJOR SPECIFICATIONS

KIA COLOR CODES

Kia code Paint color

7P J9 K5 K9 6C 7V 9B U4

PAINT MANUFACTURE CODES

Kia code

Color name Dupont

Spies

Hecker

Cherry Kiss Cocktail

Evening Sailing Gold

V elvet Indigo Blue

Crystal Blue

Clear Silver

Olive Gray

Midnight Black

White Pearl Clear White

Standox BASF

Akzo

Nobel

PPG

J9 K5 K9 6C 7V 9B U4

Cherry Kiss Cocktail

Evening Sailing Gold

V elvet Indigo Blue

Crystal Blue

Clear Silver

Olive Gray

Midnight Black

White Pearl Clear White

X3089 X3088 X3090 X3091 X1135 X2188 M0510 M7817 F2756

769042 769041 769043 769044 746556 760711

75343 744249 755719

J9 K5 K9 6C 7V 9B U4

7P J9 K5 K9 6C 7V 9B U4

KIA9322 KIA9106 KIA9546 KIA9545 KIA9742 KIA9741 KIA9411 KIA9405 KIA4004

J9 K5 K9 6C 7V 9B U4

Page 14

Body

Construction

BODY COMPONENTS .................................BC - 2

ZINC-GALVANIZED STEEL PANELS ....BC - 4

HIGH STRENGTH STEEL PANELS .......BC - 6

Page 15

BC-2 BODY CONSTRUCTION

BOD Y COMPONENTS

Body construction will sometimes differ depending on specifications and country of destination. Theref ore, please k eep in mind that the information contained herein is based on vehicles for general destination.

111

107

105

108

109

110

106

100

101

102

112

103

5153

104

BVQBC6001

Page 16

BODY CONSTRUCTION BC-3

1. Radiator support side member assembly

2. Head lamp support panel

3. Fender mounting braket assembly

4. Radiator support side member assembly

5. Radiator support lower outer member assembly

6. Radiator upper center member assembly

7. Radiator center stay member assembly

8. Dash panel assembly

9. Dash rainforcement assembly

10. Dash lower member assembly

11. Dash lower outer member assembly

12. Dash lower outer center member assembly

13. Fender apron inner lower panel assembly

14. Fender apron inner upper panel assembly

15. Front shock absorber housing panel assembly

16. Front shock absorber housing upper panel

17. Fender apron inner front support

18. Engine mounting bracket assembly

19. Front side inner member assembly

20. Front side member inner reinforcement assembly

21. Front side member inner rear reinforcement assembly

22. Front side member outer member assembly

23. Side cross front member

24. Center floor panel

25. Front seat cross front member assembly

26. Front seat cross rear member assembly

27. Console mounting front bracket assembly

28. Console mounting rear bracket assembly

29. Center floor side member

30. Center floor side member reinforcement assembly

31. Center floor side member upper reinforcement

32. No.1 cross member reinforcement

33. No.1 cross member reinforcement

34. No.1 cross member support reinforcement

35. No.1 cross member assembly

36. No.3 cross member assembly

37. No.3 cross member assembly

38. No.3 cross member assembly

39. Side sill inner upper panel

40. Side sill inner lower panel

41. Side sill inner rear panel

42. Rail guide lower panel assembly

43. Rear floor panel

44. Rear floor extension assembly

45. Rear floor side reinforcement

46. Rear floor side panel assembly

47. Rear floor rear panel

48. Rear floor rear cross member assembly

49. Rear towing hook bracket assembly

50. Rear floor side member

51. Rear floor side member extension assembly

52. Rear floor side front reinforcement assembly

53. Rear floor side rear reinforcement assembly

54. No.4 cross member assembly

55. No.5 cross member assembly

56. No.6 cross member

57. No.6 cross gusset

58. Back panel

59. Rear transverse member

60. Rear transverse side member

61. Roof panel

62. Roof front lower rail assembly

63. Roof No.2 rail

64. Roof No.2 rail

65. Room lamp mounting bracket

66. Roof rear upper rail assembly 67 Roof rear lower rail

68. Sun roof rack front bracket assembly

69. Cowl top outer panel

70. Cowl top outer reinforcement

71. Cowl inner lower panel assembly

72. Fender panel

73. Hood outer panel

74. Hood inner panel

75. Front door outer panel

76. Front door inner panel

77. Front door quadrant channel

78. Front door reinforcement beam

79. Front door belt outer rail

80. Front door belt inner rail

81. Front door frame assembly

82. Rear door outer panel

83. Rear door inner panel

84. Rear door belt outer rail

85. Rear door belt inner rail assembly

86. Rear door outer rail

87. Rear door beam

88. Tail gate outer panel

89. Tail gate inner panel

90. Front inner upper pillar assembly

91. Side inner upper reinforcement assembly

92. Front inner lower pillar assembly

93. Center pillar inner panel assembly

94. Front seatbelt upper mounting bracket assembly

95. Front pillar inner lower reinforcement assembly

96. Sill side outer front reinforcement

97. Quarter inner front reinforcement

98. Rear side belt upper mounting reinforcement assembly

99. Quarter inner panel

100. Quarter inner belt reinforcement assembly

101. Wheel house outer panel

102. Rear wheel house inner panel assembly

103. Quarter inner rear lower extension assembly

104. D pillar reinforcement gusset assembly

105. Front side outer panel

106. Front side outer panel

107. Fender rear upper reinforcement

108. Front pillar outer upper reinforcement

109. Front pillar outer lower reinforcement

110. Front side outer panel

111. Quarter outer rear upper extension

112. Rear combination lamp housing panel

Page 17

BC-4 BODY CONSTRUCTION

ZINC-GAL VANIZED STEEL PANELS

Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency below.

111

112

107

106

103

101

105

108

109

110

102

BVQBC6002

Page 18

BODY CONSTRUCTION BC-5

1. Radiator support side member assembly

2. Head lamp support panel

3. Fender mounting braket assembly

4. Radiator support side member assembly

5. Radiator support lower outer member assembly

6. Radiator upper center member assembly

7. Radiator center stay member assembly

8. Dash panel assembly

9. Dash rainforcement assembly

10. Dash lower member assembly

11. Dash lower outer member assembly

12. Dash lower outer center member assembly

13. Fender apron inner lower panel assembly

14. Fender apron inner upper panel assembly

15. Front shock absorber housing panel assembly

16. Front shock absorber housing upper panel

17. Fender apron inner front support

18. Engine mounting bracket assembly

19. Front side inner member assembly

20. Front side member inner reinforcement assembly

21. Front side member inner rear reinforcement assembly

22. Front side member outer member assembly

23. Side cross front member

24. Center floor panel

25. Front seat cross front member assembly

26. Front seat cross rear member assembly

27. Console mounting front bracket assembly

28. Console mounting rear bracket assembly

29. Center floor side member

30. Center floor side member reinforcement assembly

31. Center floor side member upper reinforcement

32. No.1 cross member reinforcement

33. No.1 cross member reinforcement

34. No.1 cross member support reinforcement

35. No.1 cross member assembly

36. No.3 cross member assembly

37. No.3 cross member assembly

38. No.3 cross member assembly

39. Side sill inner upper panel

40. Side sill inner lower panel

41. Side sill inner rear panel

42. Rail guide lower panel assembly

43. Rear floor panel

44. Rear floor extension assembly

45. Rear floor side reinforcement

46. Rear floor side panel assembly

47. Rear floor rear panel

48. Rear floor rear cross member assembly

49. Rear towing hook bracket assembly

50. Rear floor side member

51. Rear floor side member extension assembly

52. Rear floor side front reinforcement assembly

53. Rear floor side rear reinforcement assembly

54. No.4 cross member assembly

55. No.5 cross member assembly

56. No.6 cross member

57. No.6 cross gusset

58. Back panel

59. Rear transverse member

60. Rear transverse side member

61. Roof panel

62. Roof front lower rail assembly

63. Roof No.2 rail

64. Roof No.2 rail

65. Room lamp mounting bracket

66. Roof rear upper rail assembly 67 Roof rear lower rail

68. Sun roof rack front bracket assembly

69. Cowl top outer panel

70. Cowl top outer reinforcement

71. Cowl inner lower panel assembly

72. Fender panel

73. Hood outer panel

74. Hood inner panel

75. Front door outer panel

76. Front door inner panel

77. Front door quadrant channel

78. Front door reinforcement beam

79. Front door belt outer rail

80. Front door belt inner rail

81. Front door frame assembly

82. Rear door outer panel

83. Rear door inner panel

84. Rear door belt outer rail

85. Rear door belt inner rail assembly

86. Rear door outer rail

87. Rear door beam

88. Tail gate outer panel

89. Tail gate inner panel

90. Front inner upper pillar assembly

91. Side inner upper reinforcement assembly

92. Front inner lower pillar assembly

93. Center pillar inner panel assembly

94. Front seatbelt upper mounting bracket assembly

95. Front pillar inner lower reinforcement assembly

96. Sill side outer front reinforcement

97. Quarter inner front reinforcement

98. Rear side belt upper mounting reinforcement assembly

99. Quarter inner panel

100. Quarter inner belt reinforcement assembly

101. Wheel house outer panel

102. Rear wheel house inner panel assembly

103. Quarter inner rear lower extension assembly

104. D pillar reinforcement gusset assembly

105. Front side outer panel

106. Front side outer panel

107. Fender rear upper reinforcement

108. Front pillar outer upper reinforcement

109. Front pillar outer lower reinforcement

110. Front side outer panel

111. Quarter outer rear upper extension

112. Rear combination lamp housing panel

Page 19

BC-6 BODY CONSTRUCTION

HIGH STRENGTH STEEL P ANELS

Because high strength steel panel has excellent resistance, it is used in areas which have a high posibility of painting deficiency below .

111

109

108

104

101

BVQBC6003

Page 20

BODY CONSTRUCTION BC-7

1. Radiator support side member assembly

2. Head lamp support panel

3. Fender mounting braket assembly

4. Radiator support side member assembly

5. Radiator support lower outer member assembly

6. Radiator upper center member assembly

7. Radiator center stay member assembly

8. Dash panel assembly

9. Dash rainforcement assembly

10. Dash lower member assembly

11. Dash lower outer member assembly

12. Dash lower outer center member assembly

13. Fender apron inner lower panel assembly

14. Fender apron inner upper panel assembly

15. Front shock absorber housing panel assembly

16. Front shock absorber housing upper panel

17. Fender apron inner front support

18. Engine mounting bracket assembly

19. Front side inner member assembly

20. Front side member inner reinforcement assembly

21. Front side member inner rear reinforcement assembly

22. Front side member outer member assembly

23. Side cross front member

24. Center floor panel

25. Front seat cross front member assembly

26. Front seat cross rear member assembly

27. Console mounting front bracket assembly

28. Console mounting rear bracket assembly

29. Center floor side member

30. Center floor side member reinforcement assembly

31. Center floor side member upper reinforcement

32. No.1 cross member reinforcement

33. No.1 cross member reinforcement

34. No.1 cross member support reinforcement

35. No.1 cross member assembly

36. No.3 cross member assembly

37. No.3 cross member assembly

38. No.3 cross member assembly

39. Side sill inner upper panel

40. Side sill inner lower panel

41. Side sill inner rear panel

42. Rail guide lower panel assembly

43. Rear floor panel

44. Rear floor extension assembly

45. Rear floor side reinforcement

46. Rear floor side panel assembly

47. Rear floor rear panel

48. Rear floor rear cross member assembly

49. Rear towing hook bracket assembly

50. Rear floor side member

51. Rear floor side member extension assembly

52. Rear floor side front reinforcement assembly

53. Rear floor side rear reinforcement assembly

54. No.4 cross member assembly

55. No.5 cross member assembly

56. No.6 cross member

57. No.6 cross gusset

58. Back panel

59. Rear transverse member

60. Rear transverse side member

61. Roof panel

62. Roof front lower rail assembly

63. Roof No.2 rail

64. Roof No.2 rail

65. Room lamp mounting bracket

66. Roof rear upper rail assembly 67 Roof rear lower rail

68. Sun roof rack front bracket assembly

69. Cowl top outer panel

70. Cowl top outer reinforcement

71. Cowl inner lower panel assembly

72. Fender panel

73. Hood outer panel

74. Hood inner panel

75. Front door outer panel

76. Front door inner panel

77. Front door quadrant channel

78. Front door reinforcement beam

79. Front door belt outer rail

80. Front door belt inner rail

81. Front door frame assembly

82. Rear door outer panel

83. Rear door inner panel

84. Rear door belt outer rail

85. Rear door belt inner rail assembly

86. Rear door outer rail

87. Rear door beam

88. Tail gate outer panel

89. Tail gate inner panel

90. Front inner upper pillar assembly

91. Side inner upper reinforcement assembly

92. Front inner lower pillar assembly

93. Center pillar inner panel assembly

94. Front seatbelt upper mounting bracket assembly

95. Front pillar inner lower reinforcement assembly

96. Sill side outer front reinforcement

97. Quarter inner front reinforcement

98. Rear side belt upper mounting reinforcement assembly

99. Quarter inner panel

100. Quarter inner belt reinforcement assembly

101. Wheel house outer panel

102. Rear wheel house inner panel assembly

103. Quarter inner rear lower extension assembly

104. D pillar reinforcement gusset assembly

105. Front side outer panel

106. Front side outer panel

107. Fender rear upper reinforcement

108. Front pillar outer upper reinforcement

109. Front pillar outer lower reinforcement

110. Front side outer panel

111. Quarter outer rear upper extension

112. Rear combination lamp housing panel

Page 21

Body

Dimensions

GENERAL

MEASUREMENT METHOD .......................BD - 2

PROJECTED DIMENSIONS ............................BD - 2

ACTUAL-MEASUREMENT DIMENSIONS......BD - 3

MEASUREMENT POINT..................................BD - 3

FRONT BODY .................................................BD - 4

SIDE BODY (FRONT) ...................................BD - 6

SIDE BODY (REAR) .....................................BD - 8

INTERIOR A .....................................................BD - 10

INTERIOR B .....................................................BD - 12

INTERIOR C .....................................................BD - 14

REAR BODY ....................................................BD - 16

UNDER BODY (PROJECTED DIMENSIONS)

UNDER BODY (STRAIGHT-LINE DIMENSIONS)

.........................................................BD - 2

...................BD - 18

............BD - 21

Page 22

BD-2 BODY DIMENSIONS

GENERAL

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.

MEASUREMENT METHOD

PROJECTED DIMENSIONS

1. These are the dimensions measured when the measurement points are projected into the reference plane, and are the reference dimensions used for body alterations.

2. If the length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the amount equivalent to the difference in height of the two surfaces.

Height

Projected Dimension

BMCBD6001

Page 23

BODY DIMENSIONS BD-3

ACTUAL-MEASUREMENT DIMENSIONS

1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement.

2. Measure by first adjusting both probes to the same length (A=A')

CAUTIO

Check the probes and gauge itself to make sure there is no free play .

Actually-Measured Dimension

MEASUREMENT POINT

1. Measurements should be taken at the hole center.

Hole Center

BMCBD6003

BMCBD6002

Page 24

BD-4 BODY DIMENSIONS

FRONT BODY

* These dimensions indicated in this figure are actual-measurement dimensions.

BVQBD6100

Point symbol Length(mm) Point symbol Length(mm)

A-A'

1660

G-G'

1552.1

A-B

584.4

H-H'

1273

A-B'

584.4

H-G

1562.5

B-B'

1484.8

H-G'

1562.5

C-C' D-D' E-E' F-F'

1071.1 1310.5 1104.1 1120

Page 25

BODY DIMENSIONS BD-5

A,A'

BVQBD6101

Hood hinge mounting hole (ø12)

D,D'

BVQBD6104

B,B'

BVQBD6102

Fender mounting hole (ø8)

BVQBD6105

C,C'

BVQBD6103

Radiator upper member mounting hole (ø8)

BVQBD6106

Front strut mounting hole (ø14)

F,F'

BVQBD6107

Front bumper bracket mounting hole (ø9)

Transaxle bracket mounting hole

(ø12)

G,G'

BVQBD6108

Location notch

Engine bracket mounting hole

(ø18)

H,H'

BVQBD6109

Location notch

Page 26

BD-6 BODY DIMENSIONS

SIDE BODY (FRONT)

* These dimensions indicated in this figure are actual-measurement dimensions.

BVQBD6200

Point symbol Length(mm) Point symbol Length(mm)

A-B

1244.9

A-E

2079.4

A-C A-D B-C C-D B-E C-E D-E

1119.4 1119.0 536.4 301.7 1005.8 1005.8 1126.2

Page 27

BODY DIMENSIONS BD-7

BVQBD6201

Tooling hole (ø16)

BVQBD6204

BVQBD6202

Front fender mounting hole (ø10)

BVQBD6205

BVQBD6203

Front door hinge mounting hole

(ø13)

Front fender mounting hole (ø10)

Front door switch mounting hole (R9.2X9.2)

Page 28

BD-8 BODY DIMENSIONS

SIDE BODY (REAR)

BVQBD6300

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm)

A-B

913.6

D-E

535.3

F-G

231.0

A-C

959.7

D-F

1151.5

A-D

1077

D-G

1153.1

A-E

1479.8

D-H

1327.6

B-C

1377.8

D-K

1353.2

B-D

968

E-H

1432

B-E

1000

E-K

1303.1

C-D

658.9

H-K

398.4

Page 29

BODY DIMENSIONS BD-9

BVQBD6301

Rear door stopper mounting hole (ø10)

BVQBD6304

BVQBD6302

Rear door stopper mounting hole

(ø10)

BVQBD6305

BVQBD6303

Qurter glass guide mounting hole

(S6.2X8)

BVQBD6306

Rear door switch mounting hole

(ø8)

BVQBD6307

Qurter glass stopper mounting hole (ø8.5)

Side garnish mounting hole

(R9X12)

BVQBD6308

Center rail cover mounting hole (ø10)

Qurter glass stopper mounting hole (ø8.5)

BVQBD6309

Rear bumper mounting hole (ø11)

Page 30

BD-10 BODY DIMENSIONS

INTERIOR A

BVQBD6400

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm)

A-A'

1315.9

K-K'

1639.5

B-B'

1525.9

M-M'

1106.0

C-C'

1550.0

N-N'

1293.0

D-D'

1279.7

P-P'

1317.1

E-E' F-F' G-G' H-H'

1572.0 1569.2 1291.2 1593.3

Page 31

BODY DIMENSIONS BD-11

A,A'

BVQBD6401

A pillar trim mounting hole (ø8.5)

D,D'

BVQBD6404

B,B'

BVQBD6402

Curtain airbag mounting hole

E,E'

BVQBD6405

C,C'

BVQBD6403

A pillar trim mounting hole (ø8.5)

(ø6.6)

F,F'

BVQBD6406

B pillar trim mounting hole (ø6.6)

G,G'

BVQBD6407

C pillar trim mounting hole (ø9)

M,M'

Paint stay mounting hole (ø11)

H,H'

Power sliding door module mounting hole (ø9)

BVQBD6408

Seat belt mounting hole (ø12.4)

K,K'

BVQBD6409

Tooling hole (ø12)

BVQBD6410

D pillar trim mounting hole (ø8.5)

BVQBD6411

Net hook mounting hole (ø9)

P,P'

BVQBD6412

Wire harness earth mounting hole (ø9)

Page 32

BD-12 BODY DIMENSIONS

INTERIOR B

BVQBD6500

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm)

M-A'

1482.6

M-K'

1555.2

M'-H

1632.0

M-B'

1539.7

M'-A

1482.6

M'-K

1511.7

M-C'

1350.8

M'-B

1539.7

M-D'

1417.6

M'-C

1350.8

M-E'

1207.5

M'-D

1417.6

M-F'

1010.6

M'-E

1207.5

M-G'

1807.2

M'-F

1010.6

M-H'

1649.3

M'-G

1807.2

Page 33

BODY DIMENSIONS BD-13

A,A'

BVQBD6401

A pillar trim mounting hole (ø8.5)

D,D'

BVQBD6404

B,B'

BVQBD6402

Curtain airbag mounting hole

E,E'

BVQBD6405

C,C'

BVQBD6403

A pillar trim mounting hole (ø8.5)

(ø6.6)

F,F'

BVQBD6406

B pillar trim mounting hole (ø6.6)

G,G'

BVQBD6407

C pillar trim mounting hole (ø9)

Paint stay mounting hole (ø11)

H,H'

Power sliding door module mounting hole (ø9)

BVQBD6408

Seat belt mounting hole (ø12.4)

K,K'

BVQBD6409

Tooling hole (ø12)

BVQBD6501

Seat mounting hole (ø14)

Page 34

BD-14 BODY DIMENSIONS

INTERIOR C

* These dimensions indicated in this figure are actual-measurement dimensions.

G '

BVQBD6600

Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm)

Q-D'

1695.2

Q-P'

1641.4

Q'-N

1737.0

Q-E'

1579.8

Q'-D

1695.2

Q'-P

1637.9

Q-F'

1507.8

Q'-E

1579.8

Q-G'

1412.2

Q'-F

1507.8

Q-H'

1210.9

Q'-G

1412.2

Q-K'

1087.3

Q'-H

1192.4

Q-M'

1720.1

Q'-K

1084.7

Q-N'

1737.0

Q'-M

1720.1

Page 35

BODY DIMENSIONS BD-15

D,D'

BVQBD6404

B pillar trim mounting hole (ø6.6)

G,G'

BVQBD6407

E,E'

BVQBD6405

Paint stay mounting hole (ø11)

H,H'

BVQBD6408

F,F'

BVQBD6406

Seat belt mounting hole (ø12.4)

K,K'

BVQBD6409

C pillar trim mounting hole (ø9)

M,M'

BVQBD6410

D pillar trim mounting hole (ø8.5)

Power sliding door module mounting hole (ø9)

BVQBD6411

Net hook mounting hole (ø9)

Tooling hole (ø12)

P,P'

BVQBD6412

Wire harness earth mounting hole (ø9)

BVQBD6601

Tooling hole (ø20)

Page 36

BD-16 BODY DIMENSIONS

REAR BOD Y

E E'

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm)

A-A'

820.0

C-B'

1391.0

B-B'

1174.7

C-D'

1565.1

BVQBD6700

C-C' D-D' E-E' B-E B-C' B-E'

1394.0 1464.0 976.0 994.4 1391.0 1461.3

Page 37

BODY DIMENSIONS BD-17

A,A'

BVQBD6701

Tail gate hinge mounting hole

D,D'

BVQBD6704

(ø12)

B,B'

BVQBD6702

Gas lift mounting hole (ø9)

E,E'

BVQBD6705

C,C'

BVQBD6703

Rear clamp mounting hole

(R8.5X8.5)

Rear bumper mounting hole (ø14)

Package trim mounting hole

(ø8.5)

Page 38

BD-18 BODY DIMENSIONS

UNDER BODY ( PROJECTED DIMENSIONS )

AB C ED F G H

* These dimensions indicated in this figure are projected dimensions.

Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm) Point symbol

A-A'

1095

K-K'

1325

O-B

-61.3

O-M

13.5

C-E

329.5

N-P

B-B'

1095

M-M'

959

O-C

78.1

O-N

-54.3

E-D

P-Q

C-C'

1048

N-N'

1097.5

O-D

-117.5

O-P

D-F

366.5

Q-R

D-D'

696

P-P'

840

O-E

-87.6

O-Q

81.5

F-G

972

R-S

KMNPQRS

BVQBD6800

E-E'

878

Q-Q'

1060

O-F

-85.8

O-R

G-H

415

F-F'

924.8

R-R'

1338

O-G

-31(LH)/-14(RH)

O-S

39.2

H-K

G-G'

1050

S-S'

1338

O-H

-15(LH)/0(RH)

A-B

138

K-M

605

H-H'

1066

O-A

-33.5

O-K

-1.4

B-C

631

M-N

164.5

Length(mm)

344.5

350

Page 39

BODY DIMENSIONS BD-19

BVQBD6801

Front stay mounting hole (ø13)

BVQBD6803

BVQBD6801A

Sub frame front mounting hole

(ø16)

BVQBD6803A

BVQBD6802

Brake pipe mounting hole (ø7)

BVQBD6804

Rear stay mounting hole (ø12)

BVQBD6805

Tooling hole (S22X20)

Sub frame rear mounting hole

(ø18)

BVQBD6806

Tooling hole (ø20)

Tooling hole (ø13)

BVQBD6806A

Traling arm mounting front hole

(ø14)

BVQBD6807

Sub frame mounting hole (ø18)

BVQBD6807A

Rear bumper stopper mounting hole (ø11)

BVQBD6807B

Brake pipe bolt mounting hole

(ø16)

Page 40

BD-20 BODY DIMENSIONS

BVQBD6808

Tooling hole (S15X17)

BVQBD6808A

Tooling hole (S20X22)

BVQBD6809

Tooling hole (ø10)

Page 41

BODY DIMENSIONS BD-21

UNDER BOD Y ( A CTU AL-MEASUREMENT DIMENSIONS )

BVQBD6900

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm)

A-A'

1095

D'-H

2006.8

H-S'

2017.6

A-C'

1325.2

F-G'

1386.6

M-R'

1286.7

A'-D

1518.8

F'-H

1709.4

M'-S

1478

C-D'

1048.2

F'-M

2282.7

R-S'

1383.1

C'-F

1251.1

G-H'

1136.5

S-S'

1338

C'-G

2020.4

G'-M

1494

D-F'

973.1

H'-R

1749.1

D-G'

1650.5

H-M'

1225.3

Page 42

BD-22 BODY DIMENSIONS

BVQBD6801

Front stay mounting hole (ø13)

BVQBD6804

BVQBD6802

Brake pipe mounting hole (ø7)

BVQBD6805

BVQBD6803

Rear stay mounting hole (ø12)

BVQBD6806

Tooling hole (ø13)

BVQBD6807

Sub frame mounting hole (ø18)

Tooling hole (S22X20)

BVQBD6808A

Tooling hole (S20X22)

Tooling hole (ø20)

BVQBD6809

Tooling hole (ø10)

Page 43

BODY DIMENSIONS BD-23

Page 44

Body Panel Repair

Procedure

REPLACING BODY PANELS

CODES FOR REMOVING AND

INSTALLING BODY PANELS...........................BP - 2

NOTES WHEN WELDING BODY

REMOVING SPOT WELDED AREA ................BP - 3

INSTALLING A NEW BODY FRAME................BP - 5

DETERMINING A WELDING METHOD...........BP - 5

SPOT WELDING ..............................................BP - 5

CARBON ARC WELDING ...............................BP - 6

REPLACING BODY PANEL

REMOVAL...................................................BP - 7

PREPARATION FOR INSTALLATION ........BP - 9

INSTALLATION ...........................................BP - 10

RADIATOR SUPPORT PANEL

ASSEMBLY.......................................................BP - 12

REMOVAL ........................................................BP - 12

INSTALLATION.................................................BP - 14

COWL SIDE OUTER PANEL

REMOVAL ........................................................BP - 15

INSTALLATION.................................................BP - 16

FENDER APRON INNER LOWER PANEL

REMOVAL ........................................................BP - 17

INSTALLATION.................................................BP - 18

QUARTER PANEL

REMOVAL ........................................................BP - 35

INSTALLATION.................................................BP - 37

REAR FLOOR SIDE MEMBER

REMOVAL ........................................................BP - 38

INSTALLATION.................................................BP - 40

REAR COMBINATION LAMP HOUSING PANEL

RREMOVAL......................................................BP - 42

INSTALLATION.................................................BP - 43

BACK PANEL

REMOVAL ........................................................BP - 44

INSTALLATION.................................................BP - 45

FENDER APRON INNER UPPER PANEL

REMOVAL ........................................................BP - 19

INSTALLATION.................................................BP - 20

FRONT SIDE MEMBER...............................BP - 21

REMOVAL ........................................................BP - 22

INSTALLATION.................................................BP - 23

FRONT PILLAR

REMOVAL ........................................................BP - 25

INSTALLATION.................................................BP - 28

CENTER PILLAR

REMOVAL ........................................................BP - 31

INSTALLATION.................................................BP - 33

Page 45

BP-2 BODY PANEL REPAIR PROCEDURE

REPLACING BOD Y PANELS

CODES FOR REMOVING AND INSTALLING BODY PANELS

0.8~1.2 in.

(20~30 mm)

0.8~1.2 in.

(20~30 mm)

Rough cutting location

Location for cut and assembly

BVQBP6001

Page 46

BODY PANEL REPAIR PROCEDURE BP-3

NOTES WHEN WELDING BOD Y

REMOVING SPOT WELDED AREA

Most body parts are spot welded. In order to remov e the damaged area, it is best to remov e the spot welded area from the body frame using a spot cutter or candle type edge drill bit. Do not use a drill bit with a tapered edge. Center punch middle of spot weld to insure the entire spot weld will be removed.

1. Spot cutter 1. Drill(candle type edge) 1. Drill(taper edge)

2. 2. 2.

3. 3. 3.

Correct

Not correct

BVQBP6002

Page 47

BP-4 BODY PANEL REPAIR PROCEDURE

Center punch the middle(nugget) of the spot weld. Otherwise,

This part will not be cut. This part will be cut.

Spot welded area can be removed from the body frame. Spot welded area cannot be removed from the body

frame.

BVQBP6003

Page 48

BODY PANEL REPAIR PROCEDURE BP-5 INSTALLING A NEW BODY FRAME

The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness of plate, shape and size of a cross section, damage of parts, variance of joints, welding method, and/or welding locations. Therefore, a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the body.

DETERMINING A WELDING METHOD

It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the body be used when making repairs, Try to use either spot welding or carbon arc(plug) welding, Do not braze any body components other than the ones brazed at the factory. Do not use an o xy-acetylene torch f or welding.

Welding Symbol Details

Spot welding

Carbon arc welding (Plug welding)

Oxygen-acetylene welding

The most reliable welding method (provides high efficiency and quality of assembled part.)

Use when spot welding cannot be done or spot welding is not necessary.

Not used

SPOT WELDING

1. Commercial spot welding machines do not perform as well as the machines used in the manufacturing process. When spot welding, increase the number of spot welds by 30% (1.3 times the original number of welds).

BVQBP6004

2. When spot welding, weld in the middle of the joint.

Good

BVQBP6006

BVQBP6005

• Spot welding on the edge of the joint will reduce welding strength.

No good

BVQBP6007

Page 49

BP-6 BODY PANEL REPAIR PROCEDURE CARBON ARC WELDING

In areas where spot welding is not suitable, do plug welding using a carbon are welding machine.

1. Clamp the parts to be welded together tightly . Do not exceed 1 mm of space between parts. A tolerance greater than 1 mm will reduce the strength of the welded area.

1mm

Maximum tolerance

BVQBP6008

b) Do not weld on the edge of the flange joint.

No good

BVQBP6009

2. Weld in the middle of the flange joint. a) Drill a hole 5~6 mm on one side of the flange only,

and weld within the hole.

Good

BVQBP6006

Page 50

BODY PANEL REPAIR PROCEDURE BP-7 REPLACING BODY PANEL

REMOVAL

1. Body measurement

a) Before removing, measure the damaged area

according to the dimensions supplied in Body Dimension, section 31. If deformation is present, use a frame straightener to adjust.

b) When removing a panel, apply clamps to prevent

damage of each part, and support the lower end of the frame to prevent deformation during the procedure.

Tracking gauge

3. Cutting rough area for replacement part

Cutting should be done according to the following steps to make removal easy: a) Use care when cutting an area close to a pipe or

wiring harness.

b) Cut an area leaving 30~50 mm of tolerance.

BVQBP6012

4. Removing paint from an area to be spot welded

Using a torch and wire brush, remove paint completely before beginning welding.

2. Cut and welding point selection

Cutting, if necessary, should not be done in a reinforcement area. Select an area which will result in the least amount of deformation after welding.

Cut area

Reinforcement

BVQBP6010

BVQBP6013

BVQBP6011

Page 51

BP-8 BODY PANEL REPAIR PROCEDURE

5 . Determine a cutting method

a) Cutting a spot welded area

Make a hole in the middle of spot welded area with a punch, remove welded area using a spot cutter and remove using a chisel.

BVQBP6014

b) Removing brazed area

Remove using a torch and wire brush, and chisel.

c) Removing arc welded area

Remove plug welded area using a disk grinder and chisel.

BVQBP6015

BVQBP6016

Page 52

BODY PANEL REPAIR PROCEDURE BP-9

PREPARATION FOR INSTALLATION

1. Spot weld finish

Use a disk grinder or similar tool to finish spot weld mark, Do not grind more than is necessary to smooth surface.

2. Panel preparation

Repair any bent or uneven areas with a hammer to improve the installation process.

BVQBP6017

4 . Preparation for spot welding

Remove paint on spot welded area and on the area overlapped by the new part using a belt sander or similar tool.

BVQBP6020

5. Drilling a hole for plug welding

If the thickness of the part to be welded is less than 3 mm, drill a 5~6 mm diameter hole. If the thickness of the part to be welded is greater than 3 mm, drill a hole using a 7 mm diameter drill.

3. Cutting a rough area for a new part

When rough cutting an area for a new part, leave a tolerance of 30~50 mm.

NOT

Do not spot weld where thickness is greater than 3 mm.

BVQBP6018

BVQBP6021

BVQBP6019

Page 53

BP-10 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. Checking welding and fitting in advance

a) When installing a new part, measure the

dimensions of each part according to the body dimensions given in Section 31, and set part to the reference dimensions.

b) Prior to final welding, check the fit of all related

parts.

BVQBP6022

2. Selecting number of welding points Spot welding : Multiply the original number of

factory welds by 1.3 times

Plug welding : Same number as original number

of factory welds

NOT

• Plug welding should be done using a carbon arc

welding machine.

• Brazing should be done only on areas that were

originally brazed at the factory .

Initial welding

pitch:50 mm

Spot welding:initial number of welds x1.3

Welding points-same number as original number of factory welds.

3mm

Welding after repair

pitch:35 mm

Plug welding-used when spot welding is not feasible or material is thicker than 3 mm

BVQBP6024

BVQBP6023

3. Caution when spot welding

a) Do a test welding on a piece of material of the

same type and thickness as the part to be welded and proceed if test weld is good.

b) Before spot welding, check if welding debris, oil

or paint is present on the area where surfaces meet. Clean or sand as necessary .

Using a test piece

Nugget diameter: 4/5 of tip

Center

diameter

Using a hammer

and a chisel

3 mm

BVQBP6025

Page 54

BODY PANEL REPAIR PROCEDURE BP-11

c) The tip of the spot welding machine should be

maintained to a minimum tolerance of 3 mm. Also let area cool after 5 or 6 welds to minimize problems caused by excessive heat.

3mm(0.2 in)

4 . Cutting and welding an removed area

T o align a roof panel and a center pillar together f or butt welding, temporarily fasten a steel flange to the roof panel and then apply the new center pillar panel. Remove the flange when final welding is done.

b) Finish areas that have been brazed by applying

body filler then smooth the area with a flexible file and sander.

BVQBP6029

BVQBP6026

6. Applying anti-rust agent and body sealer

After coating the surface with anti-rust agent, apply body sealer where necessary.

NOT

Apply body sealer before assembly.

5. Finishing after welding

a) Grind any areas that were plug welded or butt

welded using a disk grinder. Grind carefully to avoid removing too much material. This degrades the strength of the weld.

BVQBP6027

BVQBP6028

BVQBP6030

7. Anti-rust treatment

Apply anti-rust agent to inside of doors and sills by spraying through access holes provided.

BVQBP6031

Page 55

BP-12 BODY PANEL REPAIR PROCEDURE

RADIATOR SUPPORT PANEL

ASSEMBLY

NOT

Before repairing, remove Engine and Suspension Components. Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements. The body must be returned to its original dimension before you begin the repair procedure.

REMOVAL

1. Drill out all the spotwelds to separate radiator support panel from front side member(10 points) and fender apron upper outer panel(10 points).

NOT

When spotwelded portions are not apparent, remove paint with a rotary wire brush

BVQBP6033

BVQBP6032

BVQBP6034

BVQBP6035

Page 56

BODY PANEL REPAIR PROCEDURE BP-13

2 . Drill out all the spotwelds to separate radiator support

panel from front side member(7 points).

BVQBP6036

3. Using a belt sander, remov e the front side member by drilling out the spotwelds(4points).

5. Before welding the radiator support panel, apply the epoxy primer to the interior of the radiator support panel

BVQBP6039

4. Clean MIG welds with a disc grinder.

BVQBP6037

BVQBP6038

Page 57

BP-14 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. Drill 6mm holes in the new radiator support panel for MIG plug welding.

2. Remove paint from both sides of all portions that are to be welded such as peripheries of MIG plug weld holes.

BVQBP6040

3. T emporarily install new parts in place.

4. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position

6 . Clean MIG welds with a disc grinder.

NOT

• Be careful not to grind welded portions too much.

• The internal parts will be stronger if the weld traces are not ground.

BVQBP6043

7. After welding the radiator support panel, apply the epoxy primer and anti-corrosion to the radiator support panel

5. MIG plug weld all holes.

BVQBP6041

BVQBP6042

BVQBP6044

Page 58

BODY PANEL REPAIR PROCEDURE BP-15 COWL SIDE OUTER PANEL

REMOVAL

1. Drill out all spotwelds to separate cowl side outer panel from cowl assembly and fender apron inner panel(33 points).

BVQBP6045

2. Using a disc grinder, remove the co wl side outer panel by drilling out the MIG lap welds.(5 points)

4. Before welding the cowl side outer panel, apply the epoxy primer to the interior of the cowl side outer panel.

BVQBP6048

3. Clean MIG welds with a disc grinder.

BVQBP6046

BVQBP6047

Page 59

BP-16 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. Drill 6mm holes in the new cowl side outer panel for MIG plug welding.

2. Remove paint from both sides of all portion that are to be welded such as peripheries of MIG plug weld holes.

BVQBP6049

3. T emporarily install new parts in place.

4. MIG plug weld all holes.

5 . Clean MIG welds with a disc grinder .

NOT

Be careful not to grid welded portion too much. The internal parts will be stronger if the weld traces are not ground.

BVQBP6051

6. After welding the cowl side outer panel, apply the epoxy primer and anti corrosion to the cowl side outer panel.

BVQBP6052

BVQBP6050

Page 60

BODY PANEL REPAIR PROCEDURE BP-17 FENDER APRON INNER LOWER PANEL

REMOVAL

1. Drill out all the spotwelds to separate fender apron inner lower panel from fender apron inner upper panel, shock absorber housing panel and front side member.

BVQBP6053

2 . Clean MIG welds with a disc grinder .

BVQBP6055

3. Before welding the fender apron inner lower panel, apply the epoxy primer to the interior of the fender apron inner lower panel.

BVQBP6054

BVQBP6056

Page 61

BP-18 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. Drill 6mm holes in the new fender apron inner lower panel for MIG plug welding.

2. Remove paint from both sides of all portion that are to be welded such as peripheries of MIG plug weld holes.

BVQBP6058

3. T emporarily install new parts in place.

5 . Clean MIG welds with a disc grinder .

NOT

Be careful not to grid welded portion too much. The internal parts will be stronger if the weld traces are not ground.

BVQBP6061

6. After welding the fender apron inner lower panel, apply the epoxy primer and anti corrosion to the cowl side outer panel

4. MIG plug weld all holes.

7. Prepare the exterior surfaces for priming using wax and grease remover .

8. Apply metal conditioner and water rinse.

9. Apply conversion coating and water rinse.

10. Apply the two-part epoxy primer

BVQBP6059

BVQBP6062

BVQBP6060

Page 62

BODY PANEL REPAIR PROCEDURE BP-19 FENDER APRON INNER UPPER PANEL

REMOVAL

1. Measure and mark the vertical cut lines on fender outer mounting hole edge.

65 mm

BVQBP6063

70 mm

3 . Prepare all surfaces to be welded.

4. Clean MIG with a disc sander.

BVQBP6066

5. Apply the epoxy primer to interior of the fender apron inner upper panel.

BVQBP6064

2 . Cut through the fender apron inner upper panel cutline.

BVQBP6065

BVQBP6067

Page 63

BP-20 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. T emporarily Fit and clamp the fender inner upper panel in place.

2. Measure each measurement point(refer to the BODY DIMENSIONS) and correct the installation position.

BVQBP6068

3. MIG butt weld all seams.

5 . Clean MIG welds with a disc grinder.

NOT

Be careful not to grid welded portion too much. The internal parts will be stronger if the weld traces are not ground.

BVQBP6071

6. Apply the epoxy primer and anti-corrosion to the fender apron inner upper panel.

BVQBP6069

4. After welding the fender apron inner upper panel, measure each measurement point(refer to the BODY DIMENSIONS) and correct the installation position.

7. Prepare the exterior surfaces for priming using wax and grease remover .

8. Apply metal conditioner and water rinse.

9. Apply conversion coating and water rinse.

10. Apply the two-part epoxy primer.

BVQBP6072

BVQBP6070

Page 64

BODY PANEL REPAIR PROCEDURE BP-21 FRONT SIDE MEMBER

35 mm

260 mm

80 mm

MIG plug welding MIG butt welding

50 mm

BVQBP6073

Page 65

BP-22 BODY PANEL REPAIR PROCEDURE

REMOVAL

NOT

This procedure is to be used only for repair of minor damage to the front side member and when it is impossible to straighten the damaged side member. The following procedure illustrates a repair for the front left side member. The procedure may also be applied to the front left side member.

1. Measure and mark the vertical cut lines on front side member inner tooling hole outer side.

3 . Drill out all the spotwelds to separate fender apron inner

panel from front side member.

NOT

• When spotwelded portions are not apparent, remove paint with a rotary wire brush.

• In order to perform cutting and separation of spotwelded points use a spot weld cutter which is larger than the size of the nugget to make a hole only in the panels to be replaced.

BVQBP6074

2. Drill out the spotwelds to separate front side member from engine mounting bracket.(6points)

BVQBP6075

BVQBP6076

BVQBP6077

Page 66

BODY PANEL REPAIR PROCEDURE BP-23

3. Cut through the front side member inner and outer at cutlines.

NOT

Take care not to cut through front side member inner reinforcement.

BVQBP6078

4. Prepare all surfaces to be welded

INSTALLATION

1. Transcribe the front side member inner and outer cut line to the new front side member, cut to length and chamfer butt end to improve weld surface.

2. Drill 8mm holes in new front side member for MIG plug welding.

BVQBP6080

3. Fit and clamp the front side member inner and outer in place.

BVQBP6079

4. MIG plug weld all holes and MIG butt weld all seams.

5. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.

BVQBP6081

Page 67

BP-24 BODY PANEL REPAIR PROCEDURE

6 . Clean and prepare all welds, remove all residue.

7. MIG plug weld all holes.

BVQBP6082

8. Clean MIG welds with a disc grinder.

10. Apply the two-part epoxy primer to the interior of the front side member.

BVQBP6085

11 . Apply an anti-corrosion agent as required

(Refer to the CORROSION PROTECTION).

12. Prepare the exterior surfaces for priming using wax and grease remover .

13. Apply metal conditioner and water rinse.

BVQBP6083

9. MIG plug weld engine mounting bracket from front side member.

14. Apply conversion coating and water rinse.

15. Apply the two-part epoxy primer.

16. Apply the correct seam sealer to all joints carefully (Refer to the BOD Y SEALING LOCATIONS).

17. Reprime over the seam sealer to complete the repair.

BVQBP6084

Page 68

BODY PANEL REPAIR PROCEDURE BP-25

FRONT PILLAR

REMOVAL

1. Measure and mark the each cut line on the front outer pillar at 130mm from the roof panel end line as indicated in the illustration.

130mm

50mm

BVQBP6086

2. Measure and mark the cut line on front side sill outer panel as shown in the illustration.

3. To remove the front pillar, grind away and drill out all welds and cut all laser welds attaching the cowl side upper outer panel as shown in the illustration.

NOT

If it is possible that the cowl side upper outer panel is reusable, be careful not to damage it while removing.

BVQBP6088

4. Drill out all welds attaching the front pillar to cowl cross member bracket.

100mm

5. Remove spotwelds attaching cowl cross member bracket to remo ve side inner pillar .

BVQBP6087

BVQBP6089

Page 69

BP-26 BODY PANEL REPAIR PROCEDURE

6 . Before cutting front pillar, be sure to support roof panel.

BVQBP6090

7. Cut through the front pillar outer at cutline.

9. Before cutting the front side sill outer panel, make a rough cut the side sill outer panel only .

NOT

When cutting the front side sill outer panel, be careful not to cut side outer reinforcement.

BVQBP6093

10. Drill out all the spotwelds to separate side outer panel from side inner panel (82points).

BVQBP6091

8. Cut the front pillar through each cut line, taking care not to damage the other panel as illustration.

Roof side outer

reinforcement

Front pillar

outer panel

Front pillar outer lower

Side inner panel

reinforcement

BVQBP6092

BVQBP6094

11. Cut the side outer reinforcement as shown in the illustration.

BVQBP6095

Page 70

BODY PANEL REPAIR PROCEDURE BP-27

12. Cut the side sill inner panel ver tical cutting line and remove the front pillar .

BVQBP6093

13. Straighten all flanges as necessary , prepare all surfaces to be welded.

15. Apply the two-part epo xy primer to the interior of the front side member

BVQBP6099

14. Clean all welds with a disc grinder.

NOT

• Be careful not to grind welded portions too much.

• The internal parts will be stronger if the weld traces are not ground.

BVQBP6097

BVQBP6098

Page 71

BP-28 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. Transcribe the cut line to the new side inner panel, cut to length and chamfer butt end to improve weld surface.

BVQBP6100

2. Transcribe the cut line to the new side outer reinforcement and new front pillar , adding 30mm overlap to end and cut to length.

3. Drill 8mm holes along outer panel flanges in production location for attachment to other panels.

4. Transcribe the cutline to the ne w side inner panel, adding 30mm overlap to end and cut to length.

5. Drill 8mm holes in the side inner panel for MIG plug welding.

6. Fit and clamp the new side inner panel in place for welding.

7. MIG plug weld all holes and MIG butt weld the seams.

BVQBP6102

8. T emporarily install front pillar outer panel in place.

BVQBP6101

9. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.

10. If necessary , make temporary welds, and then chec k to confirm that the closing and fit for windshield glass, door and fender are correct.

BVQBP6103

Page 72

BODY PANEL REPAIR PROCEDURE BP-29

11 . MIG butt weld front pillar outer panel and side sill outer

reinforcement seams.

12. Reattach the cut away front pillar outer panel section, then MIG butt weld.

Front pillar outer

panel section

100mm

BVQBP6104

13. MIG plug weld all holes and MIG butt weld all seams in the side outer panel.

14. Clean and prepare all welds, remove all residue.

15. Apply body filler to joints and sand as needed.

17 . Clean all welds with a disc grinder.

NOT

• Be careful not to grind welded portions too much.

• The internal parts will be stronger if the weld traces are not ground.

BVQBP6106

18. Before welding the cowl side upper outer panel, apply the two-part epoxy primer and anti-corrosion agent to the interior of the cowl side upper outer panel.

16. Apply the two-part epoxy primer to the interior of the front pillar.

BVQBP6105

BVQBP6107

Page 73

BP-30 BODY PANEL REPAIR PROCEDURE

19. Install the cowl side upper outer panel in place.

20. MIG plug weld all holes.

21. Clean and prepare all welds, remove all residue.

BVQBP6108

22. Apply an anti-corrosion agent to the welded parts and inside of front pillar (Refer to the CORROSION PROTECTION).

27. Apply the correct seam sealer to all joints carefully (Refer to the BOD Y SEALING LOCATIONS).

28. Reprime over the seam sealer to complete the repair.

BVQBP6110

23. Prepare exterior surfaces for priming, using wax and grease remover .

24. Apply metal conditioner and water rinse.

25. Apply conversion coating and water rinse.

26. Apply the two-part epoxy primer.

BVQBP6109

Page 74

BODY PANEL REPAIR PROCEDURE BP-31

CENTER PILLAR

REMOVAL

1. Measure and mark the horizontal cutting line on center pillar outer panel as indicated in the illustration.

150mm

50mm 50mm

BVQBP6111

2. Measure and mark the vertical cutline on side sill outer panel 80mm from the front door step trim mounting hole.

4 . Drill out all spotwelds and cut all laser welds attaching

the center outer pillar to the body to remove center outer pillar.

BVQBP6114

5. Cut through center outer pillar and side sill outer panel at cutlines.

NOT

When cutting side sill outer panel take care not to cut through mating flanges or side outer reinforcement.

100mm

80mm

BVQBP6112

3. Before cutting center pillar , be sure to support roof panel.

BVQBP6113

BVQBP6115

6. After cutting side outer panel (center pillar outer & side sill), cut the center pillar outer reinforcement and center pillar inner panel.

BVQBP6116

Page 75

BP-32 BODY PANEL REPAIR PROCEDURE

7 . Remov e the center pillar.

NOT

When cutting center inner pillar, be careful not to cut front seat belt mounting upper bracket.

Center pillar

Side outer

reinforcement

8. Determine if the side outer reinforcement is damaged and needs to be replaced. If replacing is necessary, mark out the damaged portion of the reinforcement. Cut at cutlines and remove damaged portion.

outer panel

Side inner panel

BVQBP6117

9. Straighten all flanges as necessary .

10. Prepare all surfaces to be welded.

BVQBP6118

Page 76

BODY PANEL REPAIR PROCEDURE BP-33

INSTALLATION

1. In order to install center inner pillar drill out all spotwelds attaching the roof side outer rail to center inner pillar to separate them.

BVQBP6119

2. Transcribe the center outer pillar cutlines to the new center outer pillar, adding 50mm o verlap at center lower pillar ends.

3. Cut and chamfer butt end to improve weld surface.

6 . Clean MIG welds with a disc grinder.

BVQBP6122

7. Apply the epoxy primer to the side inner reinforcement.

4. Drill 6mm holes in overlap area and along outer panel flanges.

BVQBP6120

5. MIG butt weld all seams in center inner pillar and sill side outer reinforcement as shown in the illustration.

BVQBP6123

8. T emporarily install new center outer panel in place .

9. Screw center pillar in place.

10. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.

BVQBP6121

BVQBP6113

Page 77

BP-34 BODY PANEL REPAIR PROCEDURE

11. Check the fit of the front and rear doors.

12. Reinstall center outer pillar and screw in place.

13. MIG plug weld all holes and MIG butt weld all seams.

14. Clean and prepare all welds, and remove all residue.

15. Apply body filler to the outer center pillar seam. Sand and finish.

BVQBP6125

16. Apply the two-part epoxy primer to the interior of the center pillar.

17. Apply an anti-corrosion agent to the welded parts and interior of the center pillar (Refer to the CORROSION PROTECTION).

18. Prepare exterior surfaces for priming, using wax and grease remover .

19. Apply metal conditioner and water rinse.

20. Apply conversion coating and water rinse.

21. Apply the two-part epoxy primer.

22. Apply the correct seam sealer to all joints carefully (Refer to the BOD Y SEALING LOCATIONS).

23. Reprime over the seam sealer to complete the repair.

BVQBP6126

BVQBP6127

BVQBP6128

Page 78

BODY PANEL REPAIR PROCEDURE BP-35 QUARTER PANEL

REMOVAL

1. Depending on the extent of damage, measure and mark cutlines on the quarter outer panel as indicated in the illustration

170mm

70mm

2. Drill out all attaching spdtwelds the quarter outer panel .

110mm

BVQBP6129

BVQBP6130

Page 79

BP-36 BODY PANEL REPAIR PROCEDURE

3 . Cut the quarter outer panel at cutlines and remove the

quarter outer panel as illustration.

NOT

When cutting the quarter outer panel, be careful not to cut side inner panel.

4. Prepare all surfaces to be welded.

5 . Clean MIG welds with a disc grinder.

BVQBP6132

6. Apply the two-part epoxy primer to the quarter inner panel.

BVQBP6131

BVQBP6133

Page 80

BODY PANEL REPAIR PROCEDURE BP-37

INSTALLATION

1. Transcribe the cutline to the new quarter outer panel, adding 30mm for overlap at the old joint.

2. Drill 6 mm holes in overlap areas and along upper and lower flanges of the new quarter outer panel for MIG plug welding.

BVQBP6134

3. Fit and clamp the quarter outer panel in place.

6 . Apply body filler to the welded seam. Sand and finish.

Apply the two-part epoxy primer to the interior of the quarter outer panel.

BVQBP6132

7. Apply an anti-corrosion agent to the welded parts and interior of the quarter outer panel (Refer to the CORROSION PROTECTION).

8. Prepare exterior surfaces for priming, using wax and grease remover .

4. MIG plug weld all holes and MIG butt weld seams. At the wheel well the edge must be crimped over the wheel housing. This joint may be welded after crimping or applying a bead of adhesive which may be applied to the joint before or after crimping.

5. Clean and prepare all welds, remove all residue.

BVQBP6135

9. Apply metal conditioner and water rinse.

10. Apply conversion coating and water rinse. 11 . Apply the two-part epoxy primer.

BVQBP6133

Page 81

BP-38 BODY PANEL REPAIR PROCEDURE

REAR FLOOR SIDE MEMBER

REMOVAL

NOT

Because the rear floor side members are designed to absorb energy during a rear collision, care must be used when deciding to use this repair method. This repair is recommended only for moderate damage to the vehicle, where distortions do not extend forward of the trunk region. If the damage is more severe, then the entire side member assembly should be replaced at the factory seams without employing this sectioning procedure. The following procedure applies when only one rear floor side member needs to be replaced. If both side members are damaged and need to be replaced, then the procedure of rear floor side members and rear floor section should be followed. Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements. The body must be returned to its original dimensions before beginning the repair procedure.

1. Depending on the extent of damage, if the right side member is to be replaced it should be measured and marked 15mm from the rear floor side member end.

2. Cut through rear floor side member at cutline being careful not to cut rear floor side member reinforcement.

BVQBP6139

3. Remove the rear floor side member by drilling out all attaching spotwelds.

15 mm

BVQBP6138

NOT

The flowing procedure illustrates a repair for the right rear floor side member. The procedure may also be applied the left rear floor side member.

BVQBP6140

4. Using a belt sander, remove the rear floor side member by drilling out the spotwelds.

5. Prepare all surfaces to be welded.

BVQBP6141

Page 82

BODY PANEL REPAIR PROCEDURE BP-39

6 . Clean MIG welds with a disc grinder .

BVQBP6142

7. Apply the two-part epoxy primer to the rear floor side member.

BVQBP6143

Page 83

BP-40 BODY PANEL REPAIR PROCEDURE

INSTALLATION

1. T ranscribe the cutline to the new rear floor side member. Cut at line and drill out the spotwelds attaching the reinforcement and separate it.

BVQBP6144

2. Fit and clamp the new rear floor side member in place for welding. Measure to ensure dimensions are accurate as given in the body dimension charts.

4. Clean and prepare all surfaces to be welded and remove all residue.

BVQBP6147

5. Apply the two-part epoxy primer to the interior of the rear floor side member.

6. Prepare exterior surfaces for priming, using wax and grease remover .

7. Apply metal conditioner and water rinse.

BVQBP6145

3. MIG plug weld at the holes and MIG butt weld the seam in the side member.

8. Apply conversion coating and water rinse.

9. Apply the two-part epoxy primer.

BVQBP6148

BVQBP6146

Page 84

BODY PANEL REPAIR PROCEDURE BP-41

10. Apply the correct seam sealer to all joints.

11. Reprime over the seam sealer to complete the repair.

BVQBP6149

12. After completing body repairs, carefully apply undercoating to the underbody .

13. In order to improve corrosion resistance, if necessary , apply on underbody anti-corrosion agent to the panel which is repaired or replaced.

BVQBP6150

Page 85

BP-42 BODY PANEL REPAIR PROCEDURE

REAR COMBINA TION LAMP HOUSING P ANEL

REMOVAL

1. Drill out all spotwelds to separate rear combination lamp housing panel from side inner panel, quarter panel and back panel

NOT

When spotwelded portions are not apparent, remove paint with a rotary wire brush.

3. Apply the two-part epoxy primer to the interior of the rear floor side member.

BVQBP6153

2. Clean MIG welds with s disc grinder.

BVQBP6151

BVQBP6152

Page 86

BODY PANEL REPAIR PROCEDURE BP-43

INSTALLATION

1. Drill 6mm holes in the new rear combination lamp housing panel for MIG plug welding.

BVQBP6154

2. Fit and clamp the new rear combination lamp housing panel in place for welding. Measure to ensure dimensions are accurate as given in the body dimension charts.

4. Clean and prepare all surfaces to be welded and remove all residue.

BVQBP6157

5. Apply the two-part epoxy primer to the interior of the rear floor side member.

6. Prepare the exterior surfoces for priming using wax and grease remover .

7. Apply metal conditioner and water rinse.

3. MIG plug weld all holes

8. Apply conversion coating and water rinse.

9. Apply the two-part epoxy primer.

BVQBP6155

BVQBP6158

BVQBP6156

Page 87

BP-44 BODY PANEL REPAIR PROCEDURE

BACK PANEL

REMOVAL

1. Drill out all spotwelds to separate back panel from side inner panel, quarter panel and back panel.

NOT

When spotwelded portions are not apparent, remove paint with a rotary wire brush.

BVQBP6159

3. Apply the two-part epoxy primer to the interior of the rear floor side member.

BVQBP6161

2. Clean MIG welds with s disc grinder.

BVQBP6160

Page 88

BODY PANEL REPAIR PROCEDURE BP-45

INSTALLATION

1. Drill 6mm holes in the new Back panel for MIG plug welding.

BVQBP6162

2. Fit and clamp the new back panel in place for welding. Measure to ensure dimensions are accurate as given in the body dimension charts.

4. Clean and prepare all surfaces to be welded and remove all residue.

BVQBP6165

5. Apply the two-part epoxy primer to the interior of the rear floor side member.

6. Prepare the exterior surfaces for priming using wax and grease remover .

7. Apply metal conditioner and water rinse.

3. MIG plug weld all holes.

8. Apply conversion coating and water rinse.

9. Apply the two-port epoxy primer.

BVQBP6163

BVQBP6166

BVQBP6164

Page 89

Body Sealing

Locations

FLOOR

FRONT AND SIDE BODY ...........................BS - 4

DOOR ..............................................................BS - 7

HOOD ..............................................................BS - 10

TAIL GATE ........................................................BS - 11

..............................................................BS - 2

Page 90

BS-2 BODY SEALING LOCATIONS

FLOOR

BVQBS6100

A B

BVQBS6102

BVQBS6101

BVQBS6103

Page 91

BODY SEALING LOCATIONS BS-3

C D

BVQBS6105BVQBS6104

E F

BVQBS6107BVQBS6106

BVQBS6108

Page 92

BS-4 BODY SEALING LOCATIONS

FRONT AND SIDE BODY

M N O

BVQBS6200

E,F

A B

BVQBS6202

BVQBS6201

BVQBS6203

Page 93

BODY SEALING LOCATIONS BS-5

C D

BVQBS6205BVQBS6204

E F

G H

BVQBS6208

K M

BVQBS6207BVQBS6206

BVQBS6209

BVQBS6210

BVQBS6211

Page 94

BS-6 BODY SEALING LOCATIONS

N O

BVQBS6213BVQBS6212

P Q

R S

BVQBS6215BVQBS6214

BVQBS6217BVQBS6216

Page 95

BODY SEALING LOCATIONS BS-7

DOOR

< Views >

A B

BVQBS6301

C D

BVQBS6300

BVQBS6302

BVQBS6303

BVQBS6304

Page 96

BS-8 BODY SEALING LOCATIONS

< Section >

A B

BVQBS6305

Door outer panel

Door inner panel

Door inner

A - A'

panel

Door outer

panel

C - C'

B - B'

BVQBS6307BVQBS6306

5mm

1.5 mm

2.5 mm

BVQBS6308

Page 97

BODY SEALING LOCATIONS BS-9

D E

2.5 mm 5mm

1.5 mm

D - D'

E - E'

BVQBS6310

F - F'

BVQBS6311BVQBS6309

5mm

1.5 mm

2.5 mm

G - G'

5mm

1.5 mm

2.5 mm

H - H'

BVQBS6312

BVQBS6313

Page 98

BS-10 BODY SEALING LOCATIONS

HOOD

< Section >

BVQBS6400

1.5 mm

5 mm

B - B'

BVQBS6402

A - A'

BVQBS6401

5 m

1.5 mm

C - C'

BVQBS6403

Page 99

BODY SEALING LOCATIONS BS-11

TAIL GATE

< Section >

5 mm

1.5 m

5 mm

1.5 mm

B - B'

BVQBS6500

BVQBS6502

A - A' C - C'

BVQBS64501

BVQBS6503

Page 100

Corrosion

protection

ZINC-GALVANIZED STEEL PANELS ZINC-PHOSPHATE COAT & CATIONIC

ELECTRODEPOSITION PRIMER

ANTI-CORROSION PRIMER ....................CP - 5

ANTIVIBRATION PADS-LOCATION & SECTION

ATTACHMENT OF ANTIVIBRATION PADS

UNDER BODY COAT

FLOOR .............................................................CP - 8

SIDE BODY ......................................................CP - 9

CAVITY WAX INJECTION...........................CP - 10

UNDER BODY ANTI-CORROSION AGENT

......................................................CP - 6

..............................................................CP - 7

..............................................................CP - 13

....CP - 2

...........CP - 4