Kia Carnival / Sedona (2006 year). Manual — part 17

BP-22

BODY PANEL REPAIR PROCEDURE

REMOVAL

NOTE

This procedure is to be used only for repair of minor damage
to the front side member and when it is impossible to
straighten the damaged side member.
The following procedure illustrates a repair for the front left
side member.
The procedure may also be applied to the front left side
member.

1.

Measure and mark the vertical cut lines on front side
member inner tooling hole outer side.

2.

Drill out the spotwelds to separate front side member
from engine mounting bracket.(6points)

3.

Drill out all the spotwelds to separate fender apron inner
panel from front side member.

NOTE

•

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

•

In order to perform cutting and separation of
spotwelded points use a spot weld cutter which is
larger than the size of the nugget to make a hole
only in the panels to be replaced.

BVQBP6074

BVQBP6075

BVQBP6076

BVQBP6077

BODY PANEL REPAIR PROCEDURE

BP-23

3.

Cut through the front side member inner and outer at
cutlines.

NOTE

Take care not to cut through front side member inner
reinforcement.

4.

Prepare all surfaces to be welded

INSTALLATION

1.

Transcribe the front side member inner and outer cut
line to the new front side member, cut to length and
chamfer butt end to improve weld surface.

2.

Drill 8mm holes in new front side member for MIG plug
welding.

3.

Fit and clamp the front side member inner and outer in
place.

4.

MIG plug weld all holes and MIG butt weld all seams.

5.

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

BVQBP6078

BVQBP6079

BVQBP6080

BVQBP6081

BP-24

BODY PANEL REPAIR PROCEDURE

6.

Clean and prepare all welds, remove all residue.

7.

MIG plug weld all holes.

8.

Clean MIG welds with a disc grinder.

9.

MIG plug weld engine mounting bracket from front side
member.

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

front side member.

11. Apply an anti-corrosion agent as required

(Refer to the CORROSION PROTECTION).

12. Prepare the exterior surfaces for priming using wax

and grease remover.

13. Apply metal conditioner and water rinse.

14. Apply conversion coating and water rinse.

15. Apply the two-part epoxy primer.

16. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

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

BVQBP6082

BVQBP6083

BVQBP6084

BVQBP6085

BODY PANEL REPAIR PROCEDURE

BP-25

FRONT PILLAR

REMOVAL

1.

Measure and mark the each cut line on the front outer
pillar at 130mm from the roof panel end line as indicated
in the illustration.

2.

Measure and mark the cut line on front side sill outer
panel as shown in the illustration.

3.

To remove the front pillar, grind away and drill out all
welds and cut all laser welds attaching the cowl side
upper outer panel as shown in the illustration.

NOTE

If it is possible that the cowl side upper outer panel is
reusable, be careful not to damage it while removing.

4.

Drill out all welds attaching the front pillar to cowl cross
member bracket.

5.

Remove spotwelds attaching cowl cross member
bracket to remove side inner pillar.

BVQBP6086

50mm

50mm

130mm

BVQBP6087

100mm

BVQBP6088

BVQBP6089