Kia Carnival / Sedona (2006 year). Manual — part 2

GENERAL INFORMATION

GI-3

WELDING PROCEDURES

Observe the following tips when welding.
1.

Wear appropriate eye protection.

2.

Carefully follow the manufacturers operating
instructions for the welding machine you are using.

3.

Do not weld, smoke or allow open flames around
volatile chemicals, cleaners or solvents or in any area
where they have just been used.

BODY FRAME STRAIGHTENER

When using a frame straightener, do not enter the area
where the body is being straightened by the chain.

ELECTRICAL PROCEDURES

1.

Disconnect the negative battery terminal.

2.

Do not pull on wires when disconnecting electrical
connectors. Be careful to hold the connector itself when
disconnecting it.

3.

Insert the connector until it "licks" when connecting
the connector.

4.

Handle all electrical components with care.

BVQGI6004

GI-4

GENERAL INFORMATION

FOR BEST RESULTS

DISASSEMBLY

Measuring dimensions before beginning
Measure the dimensions of the damaged area according to the body dimension drawings before disassembling and repairing.
Adjust dimensions with body frame adjuster if deformed.

Selecting cutting area
Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding.
Select an area that would allow the new part to overlap repair area by 1.2~2.0 in (30~50 mm).

Protecting body from damage
Secure the body with clamps and jacks to prevent damage to the body when working on it.

BVQGI6005

GENERAL INFORMATION

GI-5

Disassembling related parts
Use caution when removing body molding and trim from
the area to be worked.
Apply masking tape where needed to prevent damage to
the part being removed or to the vehicle body.
Before starting repairs, check if pipes, hoses or electrical
components are present near damaged area.

BVQGI6006

Wire harness

Repair work area

Cutting area

GI-6

GENERAL INFORMATION

Machining holes for plug welding
Drill a hole of approximately 0.2~0.24 in (5~6 mm) in
diameter in those areas which are not suitable for spot
welding.

BVQGI6008

PREPARATION OF ASSEMBLY

Applying spot sealer
Remove paint from the surface of new parts and body to be spot welded, and apply spot sealer for rustproofing.

Selecting a welding method
If the thickness of the area to be welded with the panels overlapped is greater than 0.1 in (3 mm), do plug welding using a
carbon arc welding machine.

Protecting body from damage
Secure the body with clamps and jacks to prevent damage to the body when working on it.

Adjusting a new part
The new part should be cut larger than the repair area,
overlapping the repair area by 1.2~2.0 in (30~50 mm).

BVQGI6009

1.2~2.0 in

(30~50 mm)

Overlap

1.2~2.0 in

(30~50 mm)

Overlap

body side to modify

new part to modify

BVQGI6007

Thicker than
0.1 in (3mm)