Kia Carnival / Sedona (2006 year). Manual — part 19

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.

22. Apply an anti-corrosion agent to the welded parts and

inside of front pillar (Refer to the CORROSION
PROTECTION).

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.

27. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

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

BVQBP6108

BVQBP6109

BVQBP6110

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.

2.

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

3.

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

4.

Drill out all spotwelds and cut all laser welds attaching
the center outer pillar to the body to remove center
outer pillar.

5.

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

NOTE

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

6.

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

BVQBP6111

150mm

50mm
50mm

BVQBP6112

100mm

80mm

BVQBP6113

BVQBP6114

BVQBP6115

BVQBP6116

BP-32

BODY PANEL REPAIR PROCEDURE

7.

Remove the center pillar.

NOTE

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

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.

9.

Straighten all flanges as necessary.

10. Prepare all surfaces to be welded.

BVQBP6117

Side outer

reinforcement

Center pillar

outer panel

Side inner panel

BVQBP6118

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.

2.

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

3.

Cut and chamfer butt end to improve weld surface.

4.

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

5.

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

6.

Clean MIG welds with a disc grinder.

7.

Apply the epoxy primer to the side inner reinforcement.

8.

Temporarily 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.

BVQBP6119

BVQBP6120

BVQBP6121

BVQBP6122

BVQBP6123

BVQBP6113