Kia Carnival / Sedona (2006 year). Instruction — part 18

BP-26

BODY PANEL REPAIR PROCEDURE

6.

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

7.

Cut through the front pillar outer at cutline.

8.

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

9.

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

NOTE

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

10. Drill out all the spotwelds to separate side outer panel

from side inner panel (82points).

11. Cut the side outer reinforcement as shown in the

illustration.

BVQBP6090

BVQBP6091

BVQBP6092

Roof side outer

reinforcement

Front pillar outer lower

reinforcement

Front pillar

outer panel

Side inner panel

BVQBP6093

BVQBP6094

BVQBP6095

BODY PANEL REPAIR PROCEDURE

BP-27

12. Cut the side sill inner panel vertical cutting line and

remove the front pillar.

13. Straighten all flanges as necessary, prepare all surfaces

to be welded.

14. Clean all welds with a disc grinder.

NOTE

•

Be careful not to grind welded portions too much.

•

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

15. Apply the two-part epoxy primer to the interior of the

front side member

BVQBP6093

BVQBP6097

BVQBP6098

BVQBP6099

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.

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 new 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.

8.

Temporarily install front pillar outer panel in place.

9.

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

10. If necessary, make temporary welds, and then check

to confirm that the closing and fit for windshield glass,
door and fender are correct.

BVQBP6100

BVQBP6101

BVQBP6102

BVQBP6103

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.

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.

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

front pillar.

17. Clean all welds with a disc grinder.

NOTE

•

Be careful not to grind welded portions too much.

•

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

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.

BVQBP6104

Front pillar outer

panel section

100mm

BVQBP6105

BVQBP6106

BVQBP6107