Kia Carnival / Sedona (2006 year). Instruction — part 14

BP-10

BODY PANEL REPAIR PROCEDURE

INSTALLATION

1.

Checking welding and fitting in advance
a)

When installing a new par t, 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.

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

NOTE

•

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.

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.

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3mm

3mm

Spot welding:initial number of welds x1.3

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

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

Initial welding

pitch:50 mm

Welding after repair

pitch:35 mm

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Center

diameter

3 mm

Using a test piece

Using a hammer

and a chisel

Nugget
diameter:
4/5 of tip

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.

4.

Cutting and welding an removed area
To align a roof panel and a center pillar together for 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.

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.

b)

Finish areas that have been brazed by applying
body filler then smooth the area with a flexible file
and sander.

6.

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

NOTE

Apply body sealer before assembly.

7.

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

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3mm(0.2 in)

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BP-12

BODY PANEL REPAIR PROCEDURE

RADIATOR SUPPORT PANEL

ASSEMBLY

NOTE

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).

NOTE

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

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BODY PANEL REPAIR PROCEDURE

BP-13

2.

Drill out all the spotwelds to separate radiator support
panel from front side member(7 points).

3.

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

4.

Clean MIG welds with a disc grinder.

5.

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

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