Kia Carnival / Sedona (2006 year). Instruction — part 21

BP-38

BODY PANEL REPAIR PROCEDURE

REAR FLOOR SIDE MEMBER

REMOVAL

NOTE

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.

NOTE

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.

2.

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

3.

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

4.

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

5.

Prepare all surfaces to be welded.

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15 mm

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BODY PANEL REPAIR PROCEDURE

BP-39

6.

Clean MIG welds with a disc grinder.

7.

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

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BP-40

BODY PANEL REPAIR PROCEDURE

INSTALLATION

1.

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

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.

3.

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

4.

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

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.

8.

Apply conversion coating and water rinse.

9.

Apply the two-part epoxy primer.

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BODY PANEL REPAIR PROCEDURE

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10. Apply the correct seam sealer to all joints.

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

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.

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