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Sportage
This body service manual illustrates body struc-tures and service procedures of Sportage madefor those who are engaged in servicingvehicles(body parts) built by Kia.
This manual illustrates replacements of majorbody panels, sealing treatment, plastic parts, bodydimensions etc. in a systematic manner which arenecessary for repairing the body.Firstly, you are encouraged to get familiar withhow to read this manual and understand eachsection, then you will get to know the proper ser-vice procedures. Keep this manual at a conve-nient place so that you can access easily at anytime to provide safer and more reliable service.
All contents such as specifications, data andsketches etc. included in this manual are madebased on those vehicles built at the time when thismanual is issued. Also, specifications or struc-tures are subject to change without prior notice byKia Motors. Therefore, there may be area wherecontents may not same as vehicles built todayonward, and in this case, body service manual tobe issued later shall be referred.
Kia Motors CorporationService Technical Dept.
1993, Kia Motors Corporation412A-EOZ-9312
Preface
Reference:Sportage service manual
212A-EOZ-9312Sportage electrical wiring diagram
512A-EOZ-9311
Sportage
BODY REPAIR MANUAL
You may find the Notes, Notices and Warnings inthe contents of this manual; the Notes for helpfulinformation during the service, the Notices foravoiding possible mistakes in advance which maydamage the vehicle during the service, and thewarnings for preventing possible carelessnesswhich may cause injury. Read carefully and doyour job safely.
Followings are the general safety tips you shouldobserve during the work:
Leave the ignit ion switch to OFF unless necessary.Use a safety stand for under body works.Wear protection glasses to protect your eyes.If you need the engine running do it in a well ventilated area to prevent danger which may be caused by the emission such as carbon monoxide etc.When the engine is running keep your hands or clothes away from the moving parts such as fan or belts.Be careful not to get burned when you are working on hot metal parts such as radiator, manifold, or catalytic converter etc.Do not smoke in a service area.
For your
Safety
Sportage
BODY REPAIR MANUAL
General Description 0000
Body Structure 1111
Replacing Body Panels 2121
Body Dimension 3131
Waterproof and Rustproof 4141
Body Modification Tools 5151
Wheel Alignment 6161
Plastic Parts 7171
Contents
GENERAL A
Notice During Works . . . . . . . . . . . . . . . . . 00- 3
Vehicle Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3
Safe works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3
Welding works . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3
Body Frame Straightener . . . . . . . . . . . . . . . . . 00- 4
Electrical Works. . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 4
For Efficient and Precise works . . . . . . . 00- 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 5
Preparation of Assembly . . . . . . . . . . . . . . . . . . 00- 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 7
Rustproof Treatment after Assembly. . . . . . . 00- 8
Support Points . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9
Support Points for Jackup
and Safety Stand . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9
Support points for Auto Lift(2 Post Lift) . . . . 00-10
Tow and Vin Number Stamping Location. . . . . . . . . . . . . . . . . . . . . . . 00-10
Tow Hooks for Tow Rope. . . . . . . . . . . . . . . . . . 00-10
Engine Number Stamping Location. . . . . . . . 00-10
Vin Number Stamping Location. . . . . . . . . . . . 00-11
Body Colors and Major Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12
Body Colors and Codes . . . . . . . . . . . . . . . . . . . 00-12
Major Specifications . . . . . . . . . . . . . . . . . . . . . . 00-12
00
00005
NOTICE DURING WORKS
Vehicle care
1. Cover the seats before doing the works to keep them fromgetting dirty.
2. Cover the glasses, seats and mats with heat resistant coverwhen doing welding works.
3. Also protect moldings, garnishes and ornaments.
Safe works
1. Wear safety cap and safety shoes at all times, and weargloves, safety glasses, ear protectors, face shield etc.depending on the works.
2. When you do welding works or other works using fires nearthe fuel tank,disconnect the tank and pipe and cap the pipeto prevent fuel leakage.
Welding works
Observe the following tips when doing welding works:1. Check if gas is leaking2. Handle equipment with care and check3. Use ignitor to ignite oxigen welding machine
00001
00002
00003
00004
Ear protectors
Gloves
Safety shoes
Safety glasses
Face shield
Mask
00-3NOTICE DURING WORKS GENERAL DESCRIPTION
Body frame straightener
Do not enter an area where the body is straightened by thechain when doing the body works using the frame straightener.
Electrical works
1. Disconnect the negative terminal of the battery.2. Do not pull the cable when disconnecting the connector.3. Insert the connector until it clicks when connecting the
connector.4. Handle the sensors and relays with care.
00006
00007
00-4 GENERAL DESCRIPTION NOTICE DURING WORKS
00009
FOR EFFICIENT AND PRECISEWORKS
Disassembly
Measuring dimensions before works Measure the dimensions of the damaged areaaccording to the body dimemsion drawings beforedoing disassembly and repair works, and adjustdimensions with body frame adjuster if deformed.
Selecting cutting areaSelect cut area of a panel where you have less dis-tortion when doing welding works and where you cando the works easily.
Protecting body from deformationSecure the body with clamps and jacks to preventdeformation of the body when doing disassembly orcorrection works.
Disassembling related parts
When the related parts such as moldings or ornaments are dis-assembled, apply protection tapes on the Preparation forassembly tools so that the body and parts being disassembledare not damaged.
Adjusting damaged panel
Before starting repair works, check if pipes, hoses, wire harnessetc. are present behind it, and start repair works allowing anoverlap as much as 30 50mm at the cutting area.
00008
Wire harness
Cutting areaRepair work area
00-5FOR EFFICIENT AND PRECISE WORKS GENERAL GENERAL DESCRIPTION
00012
PREPARATION OF ASSEMBLY
Applying spot sealer
Remove paints from all surfaces of new parts andbody to be spot welded, and apply spot sealer forrustproof.
Selecting a welding method
If the thickness of the area to be welded with the pan-els overlapped is greater than 3mm, do the plugwelding using a carbon arc welding machine.
Machining holes for plug welding
Machine a hole of 5~6mm dia using a drill for those area whichis not suitable for a spot welding.
Adjusting a new part
Adjust a new part allowing an overlap with a body part as muchas 30~50mm at the cutting area.
00011
00010
30 50mmoverlap
body side to modifynew part to modify
30 50mmoverlap
00-6 GENERAL DESCRIPTION FOR EFFICIENT AND PRECISE WORKS
ASSEMBLY
Measuring dimemisions before welding
When assembling a new part, assemble it correctlyaccording to the body dimension drawing, and startwelding after checking the gaps with nearby parts.
Notice when welding
The number of welding points shall be determinedbased on the criteria as below:
More than 1.3X of weldingpoints for a new part
Repair part
Pitch: less than 35mm
New part
Pitch: 50mm
Spot welding
Repair part
More than 1.3X of weldingpoints for a new part
More than 3mm
Plug welding
Notice when spot welding
The tip of a chip of the spot welding machine shallbe maintained correctly as it affects weldingstrength greatly.In principle, the spot welding shall be done onthose spots avoiding the existing spot weldedpoints.
Before and after the spot welding, weld a testpiece (test pin) of the same material as the bodypanel and check the welding strength.
00013
Using a test piece(test pin)Using a hammer and a chisel
Existing welded sports
New welded spots
Nuggit diameter to be4/5 of chip diameter
3mm
Center diameter3mm
00-7GENERAL DESCRIPTIONFOR EFFICIENT AND PRECISE WORKS
00014
RUSTPROOF TREATMENT AFTERASSEMBLY
Body sealing
Apply body sealer on the body where necessary.(Refer to P41-3~9).
Applying rustproof material
Apply rustproof material(wax, oil etc.) behind weldedarea.
Applying undercoat
Apply undercoat on the body where necessary. (Refer to P41-10).
00015
00016
00-8 GENERAL DESCRIPTION FOR EFFICIENT AND PRECISE WORKS
SUPPORT POINTS
Support points for Jackup and safety stand
FrontJackup point : cross member
Safety stand : body frame
RearJackup point : Differential center
Safety stand : body frame
00017
00018
00019
00020
00-9GENERAL DESCRIPTIONSUPPORT POINTS
Support points for auto lift(2 post lift)
FrontRight and left frame.
RearRight and left frame.
TOW AND VIN NUMBER STAMPINGLOCATION
Tow hooks for tow rope
frontLink a rope through tow hooks assembled in the side member.
Rear
Engine number stamping location
Gasoline engine (FE)
Do not turn sharply when towing.
Do not use rear suspension as a towing hook.
Use a right hook as rear left hook is close to the silencer
and it might be touched when turning.
Notice
00021
00022
00023
00024
00-10 GENERAL DESCRIPTION TOW AND VIN NUMBER STAMPING LOCATION
00025
00027
Diesel engine (Magma)
VIN number stamping location00026
00-11GENERAL DESCRIPTIONTOW AND VIN NUMBER STAMPING LOCATION
BODY COLORS AND MAJOR SPECIFICATIONS
Body colors and codes
Major specifications
Turquiose blue L2 2.5B 3.5/9
Whisper green 5L 7.10B 1.18 / 1.27
Hot red R7 5R 2.5 / 8
Dove gray V2 N 4.77
Brave blue II B4 2.59 B 1.5 / 2
Name Color Code Munsel No.
Interior color code :JB3 (BLUE)
Length (mm) 4.045
Width (mm) 1.735
Height (mm) 1.655
Wheel base (mm) 2.650
Tread (mm) Front 1.440
Rear 1.440
Min. ground clearance (mm) 200
Curb weight (kg) 1.400 1.420 1.390
Total weight (kg) 1.675 1.695 1.665
Displacement (cc) 1.998 2.184
Max. speed (km/h) 156 170 130
Gradability (tan ) 1.087 1.200 1.111
Highway fuel consumption (km/ ) 15.2 15.5 21.0
Engine Type 4 Door
Item FE SOHC FE DOHC MAGMA
00-12 GENERAL DESCRIPTION BODY COLORS AND MAJOR SPECIFICATIONS
BODY STRUCTURE B
Body Composition. . . . . . . . . . . . . . . . . . . . 11- 3
Body Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3
Body Service Holes . . . . . . . . . . . . . . . . . . . . . . . 11- 3
High Tension Steel Sheet Used Area . . . . . . 11- 4
Plated Steel Sheet Used Area. . . . . . . . . . . . . 11- 6
Steel cold plate used area . . . . . . . . . . . . . . . . 11- 8
11
BODY COMPOSITION
Body shell
Body consists of frames, body, members etc. assembled thus providing safety, durability, noise protection, rustproofand vibrationproof.
11001
Body service holes
Body service holes are provided in the under panel to improve serviceability of the body.
11-3BODY STRUCTUREBODY COMPOSITION
11002
High tension steel sheet used area
Roof panel
Cowl grille
Bonnet Roof reinforcement
Rear header
Front header
Side sill inner
Cowl panel
Cowl panel rear
Cowl panel front
Dash lower panel
Front wheel house
Side inner rail
Side outer rail
Front fender panel
Front wheel house assemblyd
Shroud member upper No.1
Shroud member upper No.2
Shroud member upper No.1
Shroud center stay Shroud lower panel
Shroud sidepanel
Shroudsidepanel
Side sill inner
Front floor panel
High tension steel sheet used area
11-4 BODY STRUCTURE BODY COMPOSITION
11003
Rear end plate
Rear cross memberRear end panel
Rear floor side member
Service box
Rear floorcross member
Frame assembly
Rear rain rail
Rear side panel inner
Rear inner rail
Center pillar
A pillar inner
A pillar outer
Sill side panel
Rear side pannel
Rear door
Gusset sidepanel
Rear lamphouse
Rear drainpanel
Rear wheelhouse inner
Front door
Back door
Rear endplate
Rear floorside member
High tension steel sheet used area
11-5BODY STRUCTUREBODY COMPOSITION
11004
Plated steel sheat used area
Roof panel
Cowl grille
Bonnet Roof reinforcement
Rear header
Front header
Side sill inner
Cowl panel
Cowl panel rear
Cowl panel front
Dash lower panel
Front wheel house
Side inner rail
Side outer rail
Front fender panel
Front wheel house assemblyd
Shroud member upper No.1
Shroud member upper No.2
Shroud member upper No.1
Shroud center stay Shroud lower panel
Shroud sidepanel
Shroudsidepanel
Side sill inner
Front floor panel
Plated steel sheat used area
11-6 BODY STRUCTURE BODY COMPOSITION
11005
11006
Rear end plate
Rear cross memberRear end panel
Rear floor side member
Service box
Rear floorcross member
Frame assembly
Rear rain rail
Rear side panel inner
Rear inner rail
Center pillar
A pillar inner
A pillar outer
Sill side panel
Rear side pannel
Rear door
Gusset sidepanel
Rear lamphouse
Rear drainpanel
Rear wheelhouse inner
Front door
Back door
Rear endplate
Rear floorside member
Plated steel sheat used area
11-7BODY STRUCTUREBODY COMPOSITION
11008
Steel cold plate used area
Rear end plate
Rear cross memberRear end panel
Rear floor side member
Service box
Rear floorcross member
Frame assembly
Rear rain rail
Rear side panel inner
Rear inner rail
Center pillar
A pillar inner
A pillar outer
Sill side panel
Rear side pannel
Rear door
Gusset sidepanel
Rear lamphouse
Rear drainpanel
Rear wheelhouse inner
Front door
Back door
Rear endplate
Rear floorside member
Steel cold plate used area
11-8 BODY STRUCTURE BODY COMPOSITION
REPLACING BODY PANELS C
Replacing Body Panels......................................21- 3Welding Codes for Disassembling and Assembling Body Panels............................................21- 3Descriptions on each Part
when Disassembling Body Parts...........................21- 3Descriptions on each Part
when Disassembling Body Parts...........................21- 4Notes when Welding Body................................21- 5
Disassembling Body Frame .......................................21- 5Disassembling Spot Welding Area.............................21- 5Using a Spot Cutter Drill .............................................21- 6Assembling a new Body Frame.................................21- 7Determining a welding Method...................................21- 7Spot Welding...............................................................21- 7CO2 gas Arc Welding..................................................21- 8Replacing a Body Panel Efficiently ............................21- 9
Replacing a Body Panel.....................................21- 16Shroud upper plate ....................................................21- 16Shroud lower panel ....................................................21- 18Shroud panel ..............................................................21- 20Side rail outer panel ...................................................21- 22Side rail inner panel ...................................................21- 24Wheel house ..............................................................21- 26Front pillar ...................................................................21- 28Center pillar ................................................................21- 30Front side sill panel ....................................................21- 32Rear side sill panel .....................................................21- 34Rear fander panel and lamp housing ........................21- 36Rear end panel ...........................................................21- 38Roof panel ..................................................................21- 40
21
REPLACING PANELS
Welding codes for disassembling and assembling body panels
Descriptions on each part when disassembling body parts
front pillar
name of area disassembled location of area disassembled
. . . . . . spot welding . . . . . . Continuous CO2 gas arc welding
. . . . . . CO2 gas arc welding (plug welding) . . . . . . lower union welding
. . . . . . CO2 gas union welding . . . . . . repair
21052
Disassembly
Drill the area marked with with care so that a hole is not made as plug welding work shall be done toassemble a new part.Do a repair work 20~30 mm inside of cut area as shown.Repairing the front pillar outer shall be done on the upper side (roof side) than the front pillar inner.
Notes and Notice
FRONT
Outer panel
Inner panel
14 points
14 points
5 points
14 points
13 points
4 points
4 points
1 point
2 points
3 points
3 points
3 points
3 points
4 points
3 points
20~30mm
20~30mm
20~30mm
21-3REPLACING BODY PANELSREPLACING PANELS
Descriptions on each part when assembling body parts
When assembling a new part, assemble a new part correctly, measure dimensions of each part according tothe body dimension drawings and set to the reference dimensions.After assembling a new part, check status of assembly with related parts (hood, front fender etc.).Weld the section (A), and wipe on the surface after applying the sealant.
Assembly
Notes and Notice21002
FRONT
Section (A)
18 Points
3 Points
3 Points
18 Points3Points
3Points
2 Points1 Point
17 Points
18 Points
3 Points
7 Points
4 Points
4 Points
4 Points
21-4 REPLACING BODY PANELS REPLACING PANELS
NOTES WHEN WELDING BODY
Disassembling body frame
Most body parts are spot welded. Therefore, in order to disassemble the damaged area it is best todisassemble spot welded area from the body frame using a spot cutter and a drill.
Disassembling spot welded area
In order to disassemble spot welded area drill a hole only at an area to be disassembled. Note that a holeshould not made in the opposite side. A hole may be made although you are trying to avoid it, but a drill with ataper edge should not be used.
1. Spot cutter 1. Drill (Candle type edge) 1. Drill (taper edge)
2.
3. 3. 3.
2. 2.
21-5REPLACING BODY PANELSNOTES WHEN WELDING BODY
21003
Using a spot cutter drill
Punch in the middle of a spot welded area(nugget) to prevent adrilling by the spot cutter drill.
21004
It is important to punch in the middle Otherwise,
of a spot welded area(nugget).
Spot welded area are coming off the body frame. Spot welded area will not come off the body
frame.
This part will notbe cut.
This part willbe cut.
21-6 REPLACING BODY PANELS NOTES WHEN WELDING BODY
21005
Spot welding
1. A commercial spot welding machine used for repair does nothave as good performance as those for manufacturers.Therefore, welding shall be done on more points thanmanufacturers.
2. Especially, in order to provide sufficient strength theimportant parts and edges of a body shall be welded.
3. Set a flange to weld correctly and spot weld in the middle ofeach flange joint.(1) It is important to spot weld in the middle of each flange
joint.
(2) Spot welding on the edge of the flange joint wil l deteriorate welding strength.
Good
No good
21006
21007
Assembling a new body frame
The efficiency of the transmission and load distribution are determined by many complicated factors (such asthickness of plate, shape and size of a cross section, deformation of parts, variance of joints, welding method,welding locations). Therefore, a new part shall be fitted on to the body frame in a proper procedure in order notto deteriorate strength of a new body.
Determining a welding method
A welding method of a new part to a body frame is determined by the reliability, job efficiency, quality of finishedparts. Especially, welding method providing high reliability shall be selected for a body frame of a high strenthsteel.
spot welding the most reliable welding method(provides high efficiency of work and quality of assembled part.)
CO2 gas arc welding use when spot welding cannot be done or spot welding is notnecessary.
oxygen-acetylene welding X not used
welding reliabililty details
21-7REPLACING BODY PANELSNOTES WHEN WELDING BODY
21008
CO2 gas arc welding
In case it is not possible to do a spot welding do a plug weldingusing a CO2 gas arc welding.1. Weld 50% more than those spots welded at the factory.2. Set the flange correctly to minimize tolerance. A tolerance
greater than 1mm will deteriorate strength of the weldedarea.
3. Weld in the middle of the flange joint as same as the way
(1) Drill a hole of 5~6mm on one side only of the flange and weld from the next of it.
(2) Do not weld on the edge as shown in figure.
Minimize tolerance
21009
21010
21011
21-8 REPLACING BODY PANELS NOTES WHEN WELDING BODY
REPLACING BODY PANEL EFFICIENTLY
1. Body measurement
1) Before disassembling or cutting a rough area check and measure the damaged area according to the dimensions on the drawing, and if deformation is present then use a frame made for modifying a rough area.
2) When disassembling a panel fix a clamp to prevent deformation of each part, and support the lower end of a frame to prevent deformation during the work.
2. Cut and welding point selection
Cutting, if necessary, shall be done on an area apart fromreinforcements as much as possible, and select an areawhere deformation after welding is minimized.
3. Cutting rough area of replacement part
Cutting shall be done according to the following steps tomake disassembly easy:1) Cut an area close to a pipe or wiring harness with care
considering possible damage caused by heat when welding and working condition.
2) Cut an area leaving 30~50mm of tolerance considering welding work.
3) Determine a cutting method of an area to cut.
4. Removing paint from an area to spot weldUsing a torch and wire brush remove paint completely forwelding work on those area.
Disassembly
Clamp
Cut area
Reinforcement
Reinforcement
Wiring harness
Wire brush
Cutting torch
21012
21013
21014
21015
Tracking gage
21-9REPLACING BODY PANELSREPLACING BODY PANEL EFFICIENTLY
21016
5. Cutting a spot welded area
Make a scar in the middle of spot welded area with a punch,disassemble welded area using a spot welding cutter andremove using a chisel.
6. Removing brazed area
Disassemble using a torch and wire brush and remove witha chisel.
7. Removing arc welded area
Remove arc welded area using a disk grinder anddisassemble with a chisel.
Punch
Spot weldingcutter
21017
Torch
Wire brush
21018
Chisel
21019
21-10 REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY
1. Weld mark finish
Use a disk grinder or similar tool to finish spot weld mark,brazed mark smoothly. Grind with care not to grind morethan enough.
2. Drilling hole finish
When ready finish a drilling hole using an (even) grinder anda welding torch.
3. Panel preparation
Repair an area where welding is removed (not even area) ora bent area with a hammer to improve assembly of a newpart.
4. Cutting a rough area of a new part
Cut an area to cut or to weld using a hand saw or electricsaw leaving 30~50mm of tolerance.
5. Preparation for spot welding
Remove paint on spot welded area and on an areaoverlapped with a new part using a belt sander or similartool.
Preparation for assembly
Welding torch
Belt sander
21020
21021
21022
21023
21-11REPLACING BODY PANELSREPLACING BODY PANEL EFFICIENTLY
21024
6. Drilling a hole for plug welding
Drill a hole of 5~6mm dia(new part or side body) using ahand punch or a drill where it is not possible to spot weld.
7. Determining a welding method
If the thickness of a welding area is greater than 3mm, drill ahole using a 7mm dia drill for welding.
8. Cutting and cutting an welded area
Weld a new part temporarily on an area to be cut or welded. Check eveness and clearance and cut an area using a handsaw or air saw.
Do not weld where thickness is thicker than3mm(because of poor welding strength).
Notice
21025
21026
Cut and assembly area
Cut andassembly area
21027
3mm or less
3mm or less
Sport
Plug welding
21-12 REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY
1. Checking welding and fitting in advance
1) Set reference dimension to the body dimension drawing. Assemble a new part at its position.
2) Assemble a door, fix a rear door and other parts at their positions and check the clearance and surface if done correctly.
2. Selecting number of welding points
Select the number of welding points as follows:spot welding : initial number of welding points x 1.3 ormore plug welding : initial number of welding points ormore
3. Notice when spot welding
1) Do a preliminary welding before spot welding, and proceed welding if good.
2) Before spot welding check if welding debris, oil or paint are not present on area where surfaces meet.
3) The tip shall be maintained as welding strength is affected by the shape of a spot welding tip. Also take a cooling time after welding 5 or 6 times to minimize problems caused by excessive heat.
Assembly
Plug welding works shall be done using a CO2 gas arc
spatter protection device.
Welding a hard panel shall be done on designated
locations only.
Notice
Welding after repairPitch: 35mm
Initial weldingPitch: 50mm
Spot welding: initial number of welding x 1.3
Initial welding1.3mm or more
Welding after repair
Initial number of weldingpoints or more
Plug welding
Using a test pieceUsing a hammerand a chisel
Centerdiameter
Nugget diameter:4/5 of tip
3mm
Wet cloth
3mm
21028
21029
21030
21031
21-13REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY
21032
4) As same as general rules spot welding shall be done bigger than the existing welding points.
4. Checking temporary welding and fitting condition
Temporary fitting and welding necessary for an arc weldingor spot welding shall be checked along with fitness of relatedparts and measurement of prior to final welding.
5. Cutting and welding an assembled area
Welding a cut area and assembled area end to end maycause a problem at the welded area, therefore it is requiredto weld against a flange at the back and cut it if final weldingis done.
6. Finishing after welding
1) Check if welding is done properly.2) Grind the area pulg welded and welded end to end using
a disk grinder. Grind with care not to grind more than enough as it degrades welding strength.
7. Finishing area where welded end to end
Heat the welded area and make the surface even using aflexible file or sander.
Existing spot welding
New spot welding
21033
21034
Steel panel
21035
Welded area
Flexible file
21036
21-14 REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY
21037
8. Applying agent and body sealer on surfaceAfter the coating of agent on the surface is done, apply bodysealer where necessary.
9. Antirust treatmentApply antirust coating on the other side of the welded area.At this time utilize a hole or a gap on the side.
Apply body sealer before assembly otherwise it will bedifficult to do that.
Notice
Coating areabefore assembly
Bodysealer
21038
21039
21-15REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY
REPLACING A BODY PANELShroud upper panel
21040
Disassembly
Right view only as the left is opposite to the right.
7 points
9 points
3 points
21-16 REPLACING BODY PANELS REPLACING A BODY PANEL
21041
Assembly
When assembling a new part measure dimensions of each part according to the body dimension drawings
and set to the reference dimensions.
9 points
12 points
4 points
21-17REPLACING BODY PANELS REPLACING A BODY PANEL
Shroud lower panel
Disassembly
Section (A) indicates a drilling work inside the engine room.Right view only as the left is opposite to the right.
21042
3 points
11 points
9 points
7 points
Section A
21-18 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21043
When assembling a new part measure dimensions of each part according to the body dimension drawings and set to the reference dimensions.Section (A) requires a plug welding work inside the engine room.When doing a plug welding on section (B), spot weld shroud panel and front side frame first and weld it with a plate for assembly.
3 points
14 points
9 points
9 points
Section B
Section A
21-19REPLACING BODY PANELSREPLACING A BODY PANEL
Shroud panel
Disassembly
21044
Right view only as the left is opposite to the right.
Section indicates a drilling work inside the engine room.
3 points
Section A
8 points
9 points
5 points
21-20 REPLACING BODY PANELS REPLACING A BODY PANEL
3 points
7 points
9 points
10 points
Assembly
21045
When assembling a new part measure dimensions of each port according to the body dimension drawings
and set to the reference dimensions.
Set to the reference dimensions and check status of assembly with related parts.
(shroud upper plate, radiator etc.)
REPLACING BODY PANELS 21-21REPLACING A BODY PANEL
Side rail outer panel
Disassembly
21046
Replace parts with care so that other parts are not damaged.
12 points
12 points
4 points
21-22 REPLACING BODY PANELS REPLACING A BODY PANEL
16 points
16 points
4 points
When assembling a new part measure dimensions of each part according to the body dimension drawings
and set to the reference dimensions.
After setting to the reference dimensions, check status of assembly with related parts (hood, front fender
etc.)
Assembly
21047
21-23REPLACING BODY PANELSREPLACING A BODY PANEL
Side rail inner panel
Replace parts with care so that other parts are not damaged.
Section indicates a drilling work inside the engine room.
Disassembly
21048
3 points
19 points
1 point
6 points
Section A
4 points
21-24 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21049
Assemble a wheel apron panel correctly, measure dimensions of each part according to the body dimension
drawings and set to the reference dimensions.
After setting to the reference dimensions, check status of assembly with related parts (hood, front fender etc.)
Weld the section (A), and wipe on the surface after applying the sealant.
4 points
3 points
2 points
24 points6 points
Section A
21-25REPLACING BODY PANELSREPLACING A BODY PANEL
Wheel house
Disassembly
Replace part with care so that other parts are not damaged.
Drilling work on the area marked with requires making a hole to allow plug welding when assembly.
21050
19 points
3 points
4 points
4 points
6 points
5 points
13 points
21-26 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
When assembling a new part measure dimensions of each part according to the body dimension drawings
and set to the reference dimensions.
After setting to the reference dimensions, check status of assembly with related parts (bonnet, front fender
etc.)
21051
24 points
3 points
4 points
8 points
13 points
4 points
6 points
21-27REPLACING BODY PANELSREPLACING A BODY PANEL
Front pillar
Drill the area marked with with care so that a hole is not made as plug welding work shall be done to
assemble a new part.
Do a repair work 20~30mm inside of cut area as shown.
Repairing the front pillar outer shall be done on the upper side (roof side) than the front pillar inner.
Disassembly
21052
20~30mm
20~30mm
20~30mm
Outer panel
Inner panel
FRONT
14 points
14 points
14 points
5 points
3 points
3 points
3 points4 points2 points
4 points
1 point
2 points
3 points
13 points
3 points
4 points
21-28 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21053
When assembling a new part, assemble a new part correctly, measure dimensions of each part according to
the body dimension drawings and set to the reference dimensions.
After assembling a new part, check status of assembly with related parts (bonnet, front fender etc.)
Weld the section (A), and wipe on the surface after applying the sealant.
FRONT
18 points
3 points
3 points
18 pointsSection (A)
18 points
1 point2 points
4 points
3 points
3 points
3 points
4 points
14 points
4 points
7 points
21-29REPLACING BODY PANELSREPLACING A BODY PANEL
Center pillar
Disassembly
Do a drilling work on the area marked with with care so that holes are not made through considering plug
welding works required to assemble a new part.
Do a repair work at 20 30mm inside of the cut area.
Select a cut area on a side sill area away from a hole as shown.
21054
FRONT
30 points
3 points
4 points 4 points
6 points
5 points
5 points
6 points
5 points
2 points
6 points
9 points
32 points
21-30 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21055
When cutting a new and existing parts, assemble a new part correctly, measure dimensions of each part
according to the body dimension drawings and set to the reference dimensions.
After assembling a new part, check status of assembly with related parts (front door).
FRONT
39 points42 points
12 points
5 points
4 points
5 points7 points5 points
8 points
6 points
7 points
2 points
6 points
21-31REPLACING BODY PANELSREPLACING A BODY PANEL
Front side sill panel
Disassembly
Select a cut and assembly area away from a hole as shown.
Do a repair work at 20~30mm inside of the cut area.
FRONT
Cut and assembly area
Rough cut area
12 points
20~30mm 20~30mm
13 points
Cut or assemble within this range
21056
21-32 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21057
FRONT
Cut and assembly area
17 points
15 points
Cut or assemble within this range
After assembling a new part, check status of assembly with related parts (esp. front door).
21-33REPLACING BODY PANELSREPLACING A BODY PANEL
Rear side sill panel
Select a cut area on a side sill area away from a hole as shown.
Do a repair work at 20~30mm inside of the cut area.
21058
Disassembly
FRONT
Cut and assembly area
9 points
20~30mm
20~30mm
12 points
6 points
2 points
Rough cut area
21-34 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21059
After assembling a new part, check status of assembly with related parts (esp. rear door).
FRONT
16 points
8 points
2 points12 points
Cut and assembly area
21-35REPLACING BODY PANELSREPLACING A BODY PANEL
Rear fender panel and lamp housing
Disassembly
21060
Select a cut area of the pillar approximately 50mm away from the roof and rear fender assembled area as
shown, and cut with care so that the reinforcement is not damaged.
Do a repair work at 20~30mm inside of the cut area.
FRONT 9 points
3 points
2 points
19 points
3 points
2 points
3 points
1 point2 points
3 points 2 points
22 points11 points
6 points
6 points
20~30mm
20~30mm
21-36 REPLACING BODY PANELS REPLACING A BODY PANEL
FRONT
approx. 50mm
approx. 50mm 8 points 8 points
29 points
14 points
12 points
4 points
4 points4 points
2 points
2 points3 points
1 point
2 points
2 points
25 points
Assembly
21061
Before assembling a new part, apply sealer on the tire attachment area.
When cutting a new and existing parts, assemble a new part correctly, measure dimensions of each part
according to the body dimension drawings and set to the reference dimensions.
After assembling a new part, check status of assembly with related parts(rear door, back door, rear
combination lamp, rear bumper etc.)
21-37REPLACING BODY PANELSREPLACING A BODY PANEL
Rear and panel
Disassembly
21062
3 points
3 points
21 points
19 points
3 points
3 points
21-38 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21063
When assembling a new part correctly, measure dimensions of each part according to the body dimension
drawings and set to the reference dimensions.
After assembling a new part, check status of assembly with related parts(trunk lid, rear bumper etc.).
25 points
27 points
4 points
3 points
4 points
3 points
21-39REPLACING BODY PANELSREPLACING A BODY PANEL
Roof panel
Disassembly
21064
Grind the lower area assembled with the rear fender to disassemble.
FRONT
25 points
18 points
8 points
5 points5 points
23 points
18 points
8 points
21-40 REPLACING BODY PANELS REPLACING A BODY PANEL
Assembly
21065
Before assembling the roof panel, apply body sealer on the gap between the roof panel and reinforcements.
FRONT
33 points
23 points23 points
8 points
6 points
30 points
6 points
8 points
21-41REPLACING BODY PANELSREPLACING A BODY PANEL
BODY DIMENSION D
Body Dimension Indication ..............................31- 3
Plane Dimension .......................................................31- 3
Actual Measured Dimension
(Straight Line Dimension) .....................................31- 3
Straight Line Dimension(Front Body).............31- 4
Straight Line Dimension(Side Frame).............31- 6
Straight Line Dimension(Interior A) ................31- 7
Straight Line Dimension(Interior B) ................31- 8
Straight Line Dimension(Rear Body) ..............31- 10
Plane Dimension(Frame) ..................................31- 11
Straight Line Dimension(Frame)......................31- 13
31
BODY DIMENSION INDICATION
Plane dimensionThe plane dimension indicates a dimension projected on a plane from a reference point of a body(Height etc. maybe different in some cases.)
Actual measured dimension(straight line dimension)The actual measured dimension indicates a straight line dimension between the measurement reference points.
Assembly nut of front fender
Straight line dimension
Plane dimension
31001
Straightline line dimension(front body dimension)
Front fender mounting nut M10
Front suspension mounting block assembly hole 8
Front fender mounting nut M10
Shroud member upper No.2 mounting nut M10
Shroud side panel reference hole 9
Shroud member door reference hole 8
Dash panel reference hole 7
Description Size of hole and nut(mm)Measurement
A-A'
B-B'
C-C'
D-D'
E-E'
F-F'
H
31-3BODY DIMENSIONBODY DIMENSION INDICATION
STRAIGHT LINE DIMENSION (FRONT BODY)
31002
AA'
DD' EE' FF'
BB' CC'
Dimension (mm)
Dimension (mm)
Measurement point
Measurement point
31-4 BODY DIMENSION STRAIGHT LINE DIMENSION (FRONT BODY)
Unit : mm
28
8
3
6
9
1012
11 13
7
5 4 2
1
HA'
C'
D'
E'
F'
F
B'D
E B
C
A
31003
31-5BODY DIMENSIONSTRAIGHT LINE DIMENSION (FRONT BODY)
STRAIGHT LINE DIMENSION (SIDE FRAME)
31004
10
5
1
2
3
4
9
8
7
13 15
1412
11
6
C D
E
FH
G
A
B
Dimension (mm)
Dimension (mm)
Measurement point
Measurement point
31-6 BODY DIMENSION STRAIGHT LINE DIMENSION (SIDE FRAME)
STRAIGHT LINE DIMENSION (INTERIOR A)
31005
1 109
8
76
54
3
C'
B'
2
A'
H'
H
F
JG
ED
A
G'
E'
D'
F'
B
C
J'
Dimension (mm)
Dimension (mm)
Measurement point
Measurement point
31-7BODY DIMENSIONSTRAIGHT LINE DIMENSION (INTERIOR A)
STRAIGHT LINE DIMENSION (INTERIOR B)
31006
2
3
9
104
56
7
8
1
A'
B'
B
D'
E'
C'
C
D
F
E
A
Dimension (mm)
Dimension (mm)
Measurement point
Measurement point
31-8 BODY DIMENSION STRAIGHT LINE DIMENSION (INTERIOR B)
31007
4
A
B
D'
D
H
C
E
G
F
J
I
3
2
10
1
8
9
5
6
7
Dimension (mm)
Dimension (mm)
Measurement point
Measurement point
31-9BODY DIMENSIONSTRAIGHT LINE DIMENSION (INTERIOR B)
STRAIGHT LINE DIMENSION (REAR BODY)
31008
Dimension (mm)
Dimension (mm)
Measurement point
Measurement point
1
5
2
7
8
3
9
6 11
B'
A'
C'
D
C
B
A
10 44
31-10 BODY DIMENSION STRAIGHT LINE DIMENSION (REAR BODY)
PLANE DIMENSION (FRAME)
A Body mounting bracket hole No.1 28
B Suspension mounting hole 65.6
C Body mounting bracket hole No.2 28
D Body mounting bracket hole No.3 28
E Lower arm bracket mounting hole 13
F Rear spring bracket hole 13
G Rear shock absorber bracket hole 19
H Body mounting bracket hole No.4
Description Size of hole (mm)Measurement point
A
B
C
D
E
F
G
H28 : LH
28 32 (SLOT) : RH
31-11BODY DIMENSIONPLANE DIMENSION (FRAME)
PLANE DIMENSION (FRAME)
Unit : mm
31009
31-12 BODY DIMENSION PLANE DIMENSION (FRAME)
STRAIGHT LINE DIMENSION (FRAME)
Body mounting bracket hole No.1 28
Suspension mounting hole 65
Body mounting bracket hole No.2 28
Body mounting bracket hole No.3 28
Rear spring bracket hole 19
Body mounting bracket hole No.4
Measurement point
A
B
C
D
E
F
Description Size of hole(mm)
28 : LH28 32 (SLOT) : RH
31-13BODY DIMENSIONSTRAIGHT LINE DIMENSION (FRAME)
STRAIGHT LINE DIMENSION (FRAME)
Unit : mm
31010
31-14 BODY DIMENSION STRAIGHT LINE DIMENSION (FRAME)
WATERPROOF AND RUSTPROOF E
Body sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3
Bonnet, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3
Body Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 4
Under Coating . . . . . . . . . . . . . . . . . . . . . . . . . 41-10
Applying urethane . . . . . . . . . . . . . . . . . . . . . 41- 11
Applying Antirust Agent . . . . . . . . . . . . . . . 41-12 41
BODY SEALING
Apply sealer on assembled area of the body panel and on the hemming area in (contact with the body) such asdoors(inner, outer), bonnet(inner, outer) for waterproof and rustproof.
Bonnet and door
* Trim each edge
sec A - A'
sec C - C'
C
C'
D
D'
sec D - D'
sec B - B' HINGE
HINGE
HINGE
30
30
30
50
30
30
30 30
30 30
30
20 20
50
30
30
2020
60
20
20
20
20
20
20
30 30
30
30
30
30
30
3030
A B
B'A'
BONNET
REAR DOORFRONT DOOR
BACK DOOR
41-3WATERPROOF AND RUSTPROOFBODY SEALING
41001
Body parts
sec A - A'
A
A'
41002
41-4 WATERPROOF AND RUSTPROOF BODY SEALING
A
sec. A-A'
A'
41003
41-5WATERPROOF AND RUSTPROOFBODY SEALING
A
A'
sec A - A'
41004
41-6 WATERPROOF AND RUSTPROOF BODY SEALING
sec A - A'
A'C C'A
B
B'
sec B - B'
sec C - C'
41005
41-7WATERPROOF AND RUSTPROOFBODY SEALING
sec E - E'
E
C
D
D'
B
B'A
A'
C'
E'
sec A - A' sec B - B' sec D - D'
sec C - C'
41006
41-8 WATERPROOF AND RUSTPROOF BODY SEALING
41007
41-9WATERPROOF AND RUSTPROOFBODY SEALING
UNDER COATING
Apply coating on the underbody for soundproof and rustproof.
sec D - D'
D
D'C
C'
AA'
B'
B
sec E - E'
sec C - C'
sec A - A'
sec B - B'E
E'
41008
41-10 WATERPROOF AND RUSTPROOF UNDER COATING
APPLYING URETHANE
41009
A
A'1800mm
sec A - A'
160mm
100mm
41-11WATERPROOF AND RUSTPROOFAPPLYING URETHANE
APPLYING ANTIRUST AGENT
41010
sec B - B'
B D
D'B'
A
A'
C
C'
sec A - A'sec C - C'
sec D - D'
41-12 WATERPROOF AND RUSTPROOF APPLYING ANTIRUST AGENT
41011
sec A - A'
200
sec B - B'
sec F - F'sec E - E'
sec D - D'
200
200
150
A
A'
E
E'
F
F'
100
300
C C'D
D'
B B'
sec C - C'
HINGE
HINGE
BONNET
FRONT DOOR REAR DOOR
BACK DOORHINGE
41-13WATERPROOF AND RUSTPROOFAPPLYING ANTIRUST AGENT
BODY MODIFICATION TOOLS F
Body Modification Tools. . . . . . . . . . . . . . 51- 3
Modification Tools. . . . . . . . . . . . . . . . . . . . . . . . . 51- 3
Cut and Disassembly Tools . . . . . . . . . . . . . . . 51- 4
Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 5
Measurement Tools . . . . . . . . . . . . . . . . . . . . . . . 51- 5
Welding Machine . . . . . . . . . . . . . . . . . . . . . . . . . 51- 6
Buffing and Grinding Tools . . . . . . . . . . . . . . . . 51- 7
Handheld Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 9
Repair Tool Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-10 51
BODY MODIFICATION TOOLS
Modification tools
Name Used for Figure
Frame straightener Modify twisted or bented body
Push out, stretch, pull indamaged area
Stretch damaged area
Port power
Body puller
51-3BODY MODIFICATION TOOLSBODY MODIFICATION TOOLS
Cut and disassembly tools
Name Used for Figure
Air saw
Air diesel
Rotary cutter
Hand saw and metal scissors
Air drill
Spot cutter
Cut a panel
Cut or bend a panel, cut anddisassemble spot welded area
cut a panel
cut a panel
fix a spot cutter or drill to cut ordisassemble spot welding area,to finish a hole.
cut and disassemble spotwelded area
51-4 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS
Assembly tools
Name Used for Figure
Vice pliers
Air bench
Quick bench
Flanging tool
Fix a panel or area to weld
Finish contact area of flangeand finish a hole for plugwelding
Finish a hole for plug welding
Finish contact area of flange
Name Used for Figure
Centering gauge
Tracking gauge
Measure distortion of body andframe
Measure body and frame
Measurement tools
51-5BODY MODIFICATION TOOLSBODY MODIFICATION TOOLS
Name Used for Figure
Gas weldingmachine
Spot weldingmachine
CO2 gas arc weldingmachine
Stud weldingmachine
Cut a panel
Weld a panel
Weld a panel
Stretch a panel, weld a stud boltto fix front window mold clip
Welding machine
51-6 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS
Buffing and grinding tools
Name Used for Figure
Disk grinder
Disk sander
Belt sander
Small sized grinder
Double actionsander
Orbital sander(short)
Buff
Buff
Buff paints
Buff paints or smooth finishing
Grind rough area of putteeassembled area
Grind rough area of putteeassembled area
51-7BODY MODIFICATION TOOLSBODY MODIFICATION TOOLS
Name Used for Figure
Orbital sander(long)
Flexible file
Surform tool
Hand file
Used for puttee grinding of widearea
Grind touch up area, uneven area of a panel
Buff rough area of puttee area
Grind body puttee, pulley, finishputtee
51-8 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS
Handheld tools
Name Used for Figure
Body hammer anddolly
Center punch
Plane chisel
Weight hammer
Bowl pin hammer
Spoon
Punch a hole in the middle of aspot welding area
Cut and disassemble a panel
Used when greater force isrequired
Used when smaller force isrequired
Used for an area where notreached by hand
51-9BODY MODIFICATION TOOLSBODY MODIFICATION TOOLS
Name Used for Figure
Body chisel
Wire brush
Bend rough body line damagedor sheet metal etc.
Remove paints, rust, slag onwelded area which are hard torecognize
Repair tool set
Name Used for Figure
Window tool set
Repair tool set forplastics
Repair window collar
Repair plastic parts
51-10 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS
WHELL ALIGNMENT G
Checks and Adjustments for Wheel Alighment. . . . . . . . . . . . . . . 61- 3
Preparation before Checking . . . . . . . . . . . . . . 61- 3
Checks and Adjustment . . . . . . . . . . . . . . . . . . . 61- 3
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 4
Major Specifications . . . . . . . . . . . . . . . . . . . . . . 61- 4
61
CHECKS AND ADJUSTMENTS FOR WHEELALIGNMENT
Preparation before checking
1. Empty the vehicle and park at a leveled area with the wheelsfacing straight forward.
2. Set the tire pressure to the rated pressure, and set move-ment of the tires and disk wheels correctly.
3. Adjust the front and rear suspensions correctly.
4. Check if the shock absorbers work properly by pushing thebody.
5. Check if the height of the vehicle is 1,665 mm.
6. Check if the wheelbase is 2,650 mm.
Checks and adjustment
Checks and adjsutment should also be done on the front andrear according to the service manual released together.
Cutters should not be present on the wheel bearing,lower arm ball joint, rubber bush, pillow ball etc.
Notice
Notice
The difference between the right and the left of the dis-tance from the wheel center and the fender arch(A, B)as shown should be less than 10mm.If the difference is greater than 10mm, check if the sus-pensions are assembled correctly and if the status of thesprings are good, and adjust them correctly if notacceptable.
Notice
The difference between the wheelbase of the left andthe right should be less than 10mm.
61001
61002
Wheel base
61-3WHEEL ALIGNMENTCHECKS AND ADJUSTMENTS FOR WHEEL ALIGNMENT
Tire pressure
Major Specifications
Air pressure kPa (kg/cm2, psi)
Front Rear
P205 / 75R15 177 (1.8, 26)
Tire size
Item Specifications
Suspension type Double wishborne coil spring
Toe-in No passenger load 2.5 2.5mm (0.09 0.09 in)
2 passenger load 0 2.5 mm (0 0.090 in)
Camber No passenger load 0.44 0.5
2 passenger load 0 0.5
Caster No passenger load 3.58 0.5
2 passenger load 3.85 0.5
Front shock absorber type Double - acting, oil filed
Stabilizer type Torsion bar
Suspension type 4 Link coil spring
Toe-in (mm, in) 0
Camber 0
Rear shock absorber type Double - acting, oil filed
WheelalignmentFront
RearWheelalignment
61-4 WHEEL ALIGNMENT CHECKS AND ADJUSTMENTS FOR WHEEL ALIGNMENT
PLASTIC PARTS H
Heat Deformation Temperatures Table of Plastic Parts . . . . . . . . . . . . . . 71- 3
Name of Plastics and Materials. . . . . . . . 71- 4
Range of Repairability of Polyprophylene(PP) Bumper . . . . 71- 5
Repair Procedure of PP Bumper . . . . . . 71- 6
Repair Method of PP Bumper . . . . . . . . . . 71- 7
71
HEAT DEFORMATION TEMPERATURES TABLE OF PLASTIC PARTS
The heat deformation temperature indicates the temperature at which deformation may occur during the
Polyprophylene PP P-PR 60
ABS ABS P-AB 90
Nylon PA P-AM 70
Chlorovinyl PVC P-VC 60
Thermoplastic elastomer TPE P-TE 60
Acetal POM P-AC 110
Polybutylene tereftalate PBT P-BT 120
Acryl PMMA P-MA 80
Phenol PF P-PF 120
Polyethylene PE P-ET 50
Polycarbonate PC P-CT 120
Polyphenylene oxide PPO P-PC 115
PlasticAbbreviation
KS KES(Kia's code)
Heat deformationtemperature( )
71-3PLASTIC PARTSHEAT DEFORMATION TEMPERATURES TABLE OF PLASTIC PARTS
works.NAME OF PLASTICS AND MATERIALS
Instrument panel(ABS + Urethane foam)
Head lampLens : PCHousing : BMC Cowl grille (PPO)
Radiator grille (ABS)
Front bumper (PP)
Back glass molding (PVC)
Front combination lampLens : PMMAHousing : ABS
Rear combination lampLens : PMMAHousing : ABS
Rear bumper (PP)
Side protactingmolding (PVC)
Rear flap (TPE)
Front flap (TPE)
Side protector (PVC)
Front windshield molding (PVC)
Out side mirror(ABS)
Quarter Glass molding (PVC)
71001
71-4 PLASTIC PARTS NAME OF PLASTICS AND MATERIALS
RANGE OF REPAIRABILITY OF POLYPROPHYLENE(PP) BUMPER
Three types of bumpers damaged as shown below may be repaired. Bumpers damaged more than that may beable to be repaired but replacing is encouraged. Because repair may degrade beauty or quality of a bumperdue to degradation of adhesiveness. Also, such repair may cause more cost.
Bumper heightCrack on section
71002
71003
71004
1. If a hole on a bumper is less than 50mm.
2. If a crack on a bumper is less than 100mm.
3. If a crack on a bumper section is less than 100mm(lessthan half of bumper height) bumper height crack on section
71-5PLASTIC PARTSRANGE OF REPAIRABILITY OF POLYPROPHYLENE (PP) BUMPER
REPAIR PROCEDURE OF PP BUMPER
Replace damaged bumper with
a new bumper.
Apply primer for polyprophylene
over a bumper surface.
Surface ofbumper is notvisible.
Surface of bumper isvisible.
Remove paint
Make damaged area smooth.
Apply aluminum tape on the rearside of bumper.
Weld damaged area.
Grind damaged area with a rough sandpaper.
Remove oil from a damaged area(use TCE de-oil material).
Apply primer for polyprophylene over damaged area.
Apply solvent over damaged area to dry it.
Spray primer surface over a bumper and dry it.
Grind surface of a bumper with a sandpaper.
Remove oil with TCE de-oil material.
Wipe the surface of a bumper quickly with a clean cloth.
Paint the bumper with a paint of the same color and dry it.
71-6 PLASTIC PARTS REPAIR PROCEDURE OF PP BUMPER
REPAIR METHOD OF PP BUMPER
If a scar on a PP bumper reached the surface of polyprophylene, it cannot be recovered by painting.
1. If there is a scar made by a knife, make the area smooth, cut a rough area and grind the damaged area at45 with a sander.
Hole Crack Scar
Section A-A'Section B-B'Section C-C'
Section D-D'
Upper layer(coating) Primer surface layerPrimer layer Polyprophylene layer
Cut with a knife . A-A'Section B-B'
C-C'
Surface of polyprophlene
Section D-D'Cut with a knife.
Make an angle with a sander.Make an angle with a sander.
Angle of 45 is required for accumulation of welding rod of polyprophylene.
71-7PLASTIC PARTSREPAIR METHOD OF PP BUMPER
2. Welding damaged area1) To repair cracked area, melt the area using a heater gun and attachment.
2) To repair a hole, remove oil from the damaged area, apply aluminum tape on the rear side and remove oil on the rear side of the bumper.
3. Melt polyprophylene welding rod using a heater gun and fill it in a cracked area.
Heater gun
Apply on surface.
Surface of polyprophylene
Melt the surface using a heater gun.
Section view after melt
Remove oil.Section A-A'
Apply aluminum tape on the rear side of the damaged area.
Polyprophylene welding rod
A-A'Section B-B'
C-C'
Polyprophylene welding rod
Melt here.
Melt here.
Polyprophylene welding rod
Tape
Section A-A'
Plane view
Polyprophylene welding rod
Surface ofpolyprophylene
Note
1) Heat and melt the area indicated.2) Melt the welding rod with care so that it is not overmelted. If the welding rod is overmelted like a jelly,
then the welding strength is deteriorated.3) Use a heater gun 10~20mm away from the repair area to be welded.4) Welding rod should not move until the welded area is cooled.
71-8 PLASTIC PARTS REPAIR METHOD OF PP BUMPER
4. Grind polyprophylene surface little by little. Because it easily melts due to the frictioin heat. If melted,remove that area. Also, grind an area where solvent is applied.
5. Apply polyprophylene primer evenly with a brush over the area wider than the area to repair. Dry it at 20for more than 10 minutes.
6. Mix main solvent and hardener at a ratio depending on paint specifications. Mix solvent and apply over thedamaged area.
Solvent consists of two types of epoxy.When the solvent is hardened, you will have desirable finish having flexibility like polyprophylene.Solvent for polyprophylene bumper consists of main solvent and hardener. However, as this is different from solvent for urethane bumper you will not have desirous adhesive if different type of solvent is used.
Do not grind continuously. Paint
Area to apply solvent
Grind area painted and roughsurface.
Apply primer wider than the area to repair.
Polyprophylene primer
Do not have bubbles created
Surface of polyprophylene
Solvent
Weld
Note
1) Mix main solvent and hardener such that bubbles are not made.2) Work immediately after mixing solvent as the solvent gets hardened fast (in about 5 minutes).3) Dry it at 20 for about 30 minutes before grinding.
71-9PLASTIC PARTSREPAIR METHOD OF PP BUMPER
7. Grind the damaged area with sand paper of #180~#240.
8. Remove oil on the painted surface.
9. Mix polyprophylene primer and hardener at a ratio depending on paint specifications.Apply polyprophylene primer using a brush and a spray on the surface of the damaged area and the bumper.
Use a primer within 16 hours after it is mixed.
10. Apply polyprophylene primer.
Note
1) The surface will not be even if excessive force is applied during grinding.2) If there are fuzz in the damaged area, heat it a little bit with a heater gun and melt it.
Polyprophylene primer Primer hardener
Note
Use water only to clean after applying polyprophylene primer. Solvent if used will melt the primer.
71-10 PLASTIC PARTS REPAIR METHOD OF PP BUMPER
11. Grind slightly the sprayed area using a primer surfacer, and finish the surface of the bumper with a sandpaper(#400~#600). And the polyprophylene surface should not be disposed. (either wet sanding or dry sanding is all right.)
12. Use agent(TCE(Tri Chloro Ethane) de-oil material) to remove the oil, and wipe the finished surface of thebumper quickly with a clean cloth.
13. Do a painting work suitable for polyprophylene bumper.
14. Dry in the air at 20 for about 8 hours, and positive dry in 60 for about 2 hours.(However, drying time varies paint by paint).
Note
The painting method for the polyprophylene bumper to repair is same as that for the urethanebumper.Therefore, use urethane primer only for urethane bumper and use polyprophylene primer forpolyprophylene bumper for painting.Flexible polyprophylene bumper is suitable for painting the bumper to repair.If hard type bumper is used in place of the polyprophylene bumper, the paint film may be crackedor peeled off by a small deformation or impact.To repair polyprophylene bumper, do a positive drying or air drying type painting forpolyprophylene. (This can also be done on the urethane bumper. This is called urethanepainting.)
Note
Do a drying in the air if possible. Positive drying may create air bubble on the top layer.
71-11PLASTIC PARTSREPAIR METHOD OF PP BUMPER
Applying urethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 11Applying antirust agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 12
Body color and major specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 12Body colors and codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 12Major specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 12
Body composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3Body shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3Body service holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3High tension steel sheet used area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4Plated steel sheet used area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 6Steel cold plate used area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
Body dimension indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 3Plane dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 3Actual measured dimension(straight line dimension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 3
Body sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3Bonnet, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3Body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 4
Body modification tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 3Modification tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 3Cut and disassembly tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 4Assembly tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 5Measurement tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 5Welding machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 6Buffing and grinding tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 7Handheld tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 9Repair tools set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 10
INDEX
A
B
Check and adjustments for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 3Preparation before checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 3Checks and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 3Tire pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 4Major specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 4
For efficient and precise works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 5Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 5Body and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 6Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 7Rustproof treatment after assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 8
Heat deformation temperatures table of plastic parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 3
Notice during works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Vehicle care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Safe works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Welding works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Body frame straightener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 4Electrical works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 4
Notes when welding body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 5Disassembling body frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 5Disassembling spot welded area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 5Using a spot cutter drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 6Assembling a new body frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 7Determining a welding method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 7Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 7CO2 gas arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 8Replacing body panel efficiently . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 9
Name of plastics and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 4
C
N
F
H
Plane dimension(Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 11
Range of repairability of polyprophylene (PP) bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 5Repair procedure of pp bumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 6Repair method of pp bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 7
Replacing body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3Welding codes for disassembling and assembling body panels . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3Descriptions on each part when disassembling body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3Descriptions on each part when assembling body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 4
Replacing a body panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 16Shroud upper plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 16Shroud lower panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 18Shroud panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 20Side rail outer panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 22Side rail inner panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 24Wheel house. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 26Front pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 28Center pillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 30Front side sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 32Rear side sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 34Rear fander panel and lamp housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 36Rear end panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 38Roof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 40
Straight line dimension(front body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 4Straight line dimension(side frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 6Straight line dimension(interior A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 7Straight line dimension(interior B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 8Straight line dimension(rear body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 10Straight line dimension(under body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 13
Support point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9Support point for jack up and safety stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9Support point for auto lift(2 post lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10
P
R
S
Tow and VIN number stamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10Tow hooks for tow rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10Engine number stamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10VIN number stamping location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 11
Under coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 10
T
U