Kia Carnival / Sedona (2006 year). Manual — part 1

General Information

Body Construction

Body Dimensions

Body Panel Repair Procedure

Body Sealing Locations

Corrosion Protection

Body Modification Tools

Plastic Parts

Body Shop Manual

FOREWORD

This Body Shop Manual illustrates body structures and
service procedures for the CARNIVAL/SEDONA.

This manual illustrates the replacement of major body
panels, plastic parts, body dimensions, sealing treatment
etc., in a systematic manner which is necessary for effective
and lasting body repairs.
You are encouraged to become familiar with this manual
and understand each section in order to perform proper
repair procedures. Keep this manual in a convenient
location so that it is readily available.

All information in this manual including specifications,
data and illustrations is made based on the vehicles built at
the time the manual was printed.

Information regarding the removal/replacement of
components not specifically covered in this manual can be
found in the CARNIVAL/SEDONA Service Manual.
Information regarding electrical harness routing/
connections, etc. can be found in the CARNIVAL/SEDONA
Electrical Troubleshooting Manual.

The descriptions and specifications contained in this manual
were in effect at the time this manual was approved for
printing. Kia Motors Corporation reserves the right to
discontinue models at any time, or change specifications
or design without notice and without incurring obligation.

Kia Motors Corporation

SEOUL, KOREA

All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted in
any form or by any means without the prior written permission of Kia Motors Corporation.

CAUTION :
Severe engine and transaxle damage may result
from the use of poor quality fuels and lubricants
that do not meet Kia specifications. You must
always use high quality fuels and lubricants that
meet the specifications described on the
specification section in the relevant group of the
Workshop Manual.

CONTENTS

Title

Group

GI

BC

BD

BP

BS

CP

BT

PP

Copyright c 2005, Kia Motors Corporation
Printed in Korea, September 2005
Pub. No. : A4DB-EG56A (English)

IN THIS MANUAL

Proper service methods and repair procedures are essential for safe, reliable operation of all
motor vehicles as well as personal safety of the operator. The service procedures and
descriptions in this shop manual provide general directions for a service and repair.

Procedure, techniques, tools, and parts for service including the skill of the technician vary.
It is impossible to provide advice or caution as to each case in this manual.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is
not recommended by the vehicle manufacturer, must first assure thoroughly that neither their
personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement
part, service procedure, or tool they select.

The following list contains some general WARNINGS that you should follow while working on a
vehicle.

Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Make sure that the ignition switch is always in the OFF position, unless otherwise required by
the procedure.
Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in
park unless instructed otherwise for a specific operation
Place supporters against the front and rear surfaces of the tires to help prevent the vehicle
from moving
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide
poisoning.
Keep yourself and your clothing away from moving parts when the engine is running,
especially the drive belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
Do not smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing
before beginning to work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the
radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even
though the ignition switch is in the OFF position. For this reason care should be taken to
ensure that the radiator fan electric motor is completely disconnected when working under the
hood and the engine is not running.

Remind you to be especially careful in those areas where carelessness can
cause personal injury.
To prevent you from making errors that could damage the vehicle as well as
personal injury.

Gives you added information that will help you complete a particular procedure.

WARNING :

CAUTION :

NOTE :

IMPORTANT SAFETY NOTICE

General

Information

GI

FUNDAMENTAL PROCEDURES

VEHICLE PROTECTION . . . . . . . . .. GI - 2
A WORD ABOUT SAFETY . . . . . . . ... GI - 2
WELDING PROCEDURES . . . . . . . .. GI - 3
BODY FRAME STRAIGHTENER . . . . . . GI - 3
ELECTRICAL PROCEDURES . . . . . . GI - 3

FOR BEST RESULTS

DISASSEMBLY . . . . . . . . . . . . . GI - 4
PREPARATION OF ASSEMBLY . . . . . ... GI - 6
ASSEMBLY . . . . . . . . . . . . . ... GI - 7
RUSTPROOF TREATMENT AFTER
ASSEMBLY . . . . . . . . . . . . . ... GI - 8

VEHICLE LIFT (2-SUPPORT TYPE) AND
SAFETY STAND POSITIONS

. . . . ... GI - 9

JACK SUPPORT POSITIONS

. . . . .. GI - 10

BODY COLORS AND MAJOR
SPECIFICATIONS

. . . . . . . . . . .. GI - 11

GI-2

GENERAL INFORMATION

FUNDAMENTAL PROCEDURES

VEHICLE PROTECTION

1.

Cover the seats before performing any procedure to
keep them from getting dirty.

2.

Cover all glasses, seats and mats with a heat resistant
cover when welding.

3.

Protect moldings, garnishes and ornaments.

BVQGI6001

A WORD ABOUT SAFETY

1.

Wear the appropriate safety equipment that is
necessary for the procedure being performed.

2.

When welding or performing other procedures that
require the use of an open flame near the fuel tank,
disconnect and remove the tank and fuel pipe, and
cap the pipe to prevent fuel leakage.

BVQGI6002

Safety glasses

Ear protectors

Gloves

Face shield

Mask

Safety shoes

BVQGI6003