manual reparatii kia sportage

Sportage

This body service manual illustrates body struc-tures and service procedures of Sportage madefor those who are engaged in servicingvehicles(body parts) built by Kia.

This manual illustrates replacements of majorbody panels, sealing treatment, plastic parts, bodydimensions etc. in a systematic manner which arenecessary for repairing the body.Firstly, you are encouraged to get familiar withhow to read this manual and understand eachsection, then you will get to know the proper ser-vice procedures. Keep this manual at a conve-nient place so that you can access easily at anytime to provide safer and more reliable service.

All contents such as specifications, data andsketches etc. included in this manual are madebased on those vehicles built at the time when thismanual is issued. Also, specifications or struc-tures are subject to change without prior notice byKia Motors. Therefore, there may be area wherecontents may not same as vehicles built todayonward, and in this case, body service manual tobe issued later shall be referred.

Kia Motors CorporationService Technical Dept.

1993, Kia Motors Corporation412A-EOZ-9312

Preface

Reference:Sportage service manual

212A-EOZ-9312Sportage electrical wiring diagram

512A-EOZ-9311

Sportage

BODY REPAIR MANUAL

You may find the Notes, Notices and Warnings inthe contents of this manual; the Notes for helpfulinformation during the service, the Notices foravoiding possible mistakes in advance which maydamage the vehicle during the service, and thewarnings for preventing possible carelessnesswhich may cause injury. Read carefully and doyour job safely.

Followings are the general safety tips you shouldobserve during the work:

Leave the ignit ion switch to OFF unless necessary.Use a safety stand for under body works.Wear protection glasses to protect your eyes.If you need the engine running do it in a well ventilated area to prevent danger which may be caused by the emission such as carbon monoxide etc.When the engine is running keep your hands or clothes away from the moving parts such as fan or belts.Be careful not to get burned when you are working on hot metal parts such as radiator, manifold, or catalytic converter etc.Do not smoke in a service area.

For your

Safety

Sportage

BODY REPAIR MANUAL

General Description 0000

Body Structure 1111

Replacing Body Panels 2121

Body Dimension 3131

Waterproof and Rustproof 4141

Body Modification Tools 5151

Wheel Alignment 6161

Plastic Parts 7171

Contents

GENERAL A

Notice During Works . . . . . . . . . . . . . . . . . 00- 3

Vehicle Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3

Safe works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3

Welding works . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3

Body Frame Straightener . . . . . . . . . . . . . . . . . 00- 4

Electrical Works. . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 4

For Efficient and Precise works . . . . . . . 00- 5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 5

Preparation of Assembly . . . . . . . . . . . . . . . . . . 00- 6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 7

Rustproof Treatment after Assembly. . . . . . . 00- 8

Support Points . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9

Support Points for Jackup

and Safety Stand . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9

Support points for Auto Lift(2 Post Lift) . . . . 00-10

Tow and Vin Number Stamping Location. . . . . . . . . . . . . . . . . . . . . . . 00-10

Tow Hooks for Tow Rope. . . . . . . . . . . . . . . . . . 00-10

Engine Number Stamping Location. . . . . . . . 00-10

Vin Number Stamping Location. . . . . . . . . . . . 00-11

Body Colors and Major Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12

Body Colors and Codes . . . . . . . . . . . . . . . . . . . 00-12

Major Specifications . . . . . . . . . . . . . . . . . . . . . . 00-12

00

00005

NOTICE DURING WORKS

Vehicle care

1. Cover the seats before doing the works to keep them fromgetting dirty.

2. Cover the glasses, seats and mats with heat resistant coverwhen doing welding works.

3. Also protect moldings, garnishes and ornaments.

Safe works

1. Wear safety cap and safety shoes at all times, and weargloves, safety glasses, ear protectors, face shield etc.depending on the works.

2. When you do welding works or other works using fires nearthe fuel tank,disconnect the tank and pipe and cap the pipeto prevent fuel leakage.

Welding works

Observe the following tips when doing welding works:1. Check if gas is leaking2. Handle equipment with care and check3. Use ignitor to ignite oxigen welding machine

00001

00002

00003

00004

Ear protectors

Gloves

Safety shoes

Safety glasses

Face shield

Mask

00-3NOTICE DURING WORKS GENERAL DESCRIPTION

Body frame straightener

Do not enter an area where the body is straightened by thechain when doing the body works using the frame straightener.

Electrical works

1. Disconnect the negative terminal of the battery.2. Do not pull the cable when disconnecting the connector.3. Insert the connector until it clicks when connecting the

connector.4. Handle the sensors and relays with care.

00006

00007

00-4 GENERAL DESCRIPTION NOTICE DURING WORKS

00009

FOR EFFICIENT AND PRECISEWORKS

Disassembly

Measuring dimensions before works Measure the dimensions of the damaged areaaccording to the body dimemsion drawings beforedoing disassembly and repair works, and adjustdimensions with body frame adjuster if deformed.

Selecting cutting areaSelect cut area of a panel where you have less dis-tortion when doing welding works and where you cando the works easily.

Protecting body from deformationSecure the body with clamps and jacks to preventdeformation of the body when doing disassembly orcorrection works.

Disassembling related parts

When the related parts such as moldings or ornaments are dis-assembled, apply protection tapes on the Preparation forassembly tools so that the body and parts being disassembledare not damaged.

Adjusting damaged panel

Before starting repair works, check if pipes, hoses, wire harnessetc. are present behind it, and start repair works allowing anoverlap as much as 30 50mm at the cutting area.

00008

Wire harness

Cutting areaRepair work area

00-5FOR EFFICIENT AND PRECISE WORKS GENERAL GENERAL DESCRIPTION

00012

PREPARATION OF ASSEMBLY

Applying spot sealer

Remove paints from all surfaces of new parts andbody to be spot welded, and apply spot sealer forrustproof.

Selecting a welding method

If the thickness of the area to be welded with the pan-els overlapped is greater than 3mm, do the plugwelding using a carbon arc welding machine.

Machining holes for plug welding

Machine a hole of 5~6mm dia using a drill for those area whichis not suitable for a spot welding.

Adjusting a new part

Adjust a new part allowing an overlap with a body part as muchas 30~50mm at the cutting area.

00011

00010

30 50mmoverlap

body side to modifynew part to modify

30 50mmoverlap

00-6 GENERAL DESCRIPTION FOR EFFICIENT AND PRECISE WORKS

ASSEMBLY

Measuring dimemisions before welding

When assembling a new part, assemble it correctlyaccording to the body dimension drawing, and startwelding after checking the gaps with nearby parts.

Notice when welding

The number of welding points shall be determinedbased on the criteria as below:

More than 1.3X of weldingpoints for a new part

Repair part

Pitch: less than 35mm

New part

Pitch: 50mm

Spot welding

Repair part

More than 1.3X of weldingpoints for a new part

More than 3mm

Plug welding

Notice when spot welding

The tip of a chip of the spot welding machine shallbe maintained correctly as it affects weldingstrength greatly.In principle, the spot welding shall be done onthose spots avoiding the existing spot weldedpoints.

Before and after the spot welding, weld a testpiece (test pin) of the same material as the bodypanel and check the welding strength.

00013

Using a test piece(test pin)Using a hammer and a chisel

Existing welded sports

New welded spots

Nuggit diameter to be4/5 of chip diameter

3mm

Center diameter3mm

00-7GENERAL DESCRIPTIONFOR EFFICIENT AND PRECISE WORKS

00014

RUSTPROOF TREATMENT AFTERASSEMBLY

Body sealing

Apply body sealer on the body where necessary.(Refer to P41-3~9).

Applying rustproof material

Apply rustproof material(wax, oil etc.) behind weldedarea.

Applying undercoat

Apply undercoat on the body where necessary. (Refer to P41-10).

00015

00016

00-8 GENERAL DESCRIPTION FOR EFFICIENT AND PRECISE WORKS

SUPPORT POINTS

Support points for Jackup and safety stand

FrontJackup point : cross member

Safety stand : body frame

RearJackup point : Differential center

Safety stand : body frame

00017

00018

00019

00020

00-9GENERAL DESCRIPTIONSUPPORT POINTS

Support points for auto lift(2 post lift)

FrontRight and left frame.

RearRight and left frame.

TOW AND VIN NUMBER STAMPINGLOCATION

Tow hooks for tow rope

frontLink a rope through tow hooks assembled in the side member.

Rear

Engine number stamping location

Gasoline engine (FE)

Do not turn sharply when towing.

Do not use rear suspension as a towing hook.

Use a right hook as rear left hook is close to the silencer

and it might be touched when turning.

Notice

00021

00022

00023

00024

00-10 GENERAL DESCRIPTION TOW AND VIN NUMBER STAMPING LOCATION

00025

00027

Diesel engine (Magma)

VIN number stamping location00026

00-11GENERAL DESCRIPTIONTOW AND VIN NUMBER STAMPING LOCATION

BODY COLORS AND MAJOR SPECIFICATIONS

Body colors and codes

Major specifications

Turquiose blue L2 2.5B 3.5/9

Whisper green 5L 7.10B 1.18 / 1.27

Hot red R7 5R 2.5 / 8

Dove gray V2 N 4.77

Brave blue II B4 2.59 B 1.5 / 2

Name Color Code Munsel No.

Interior color code :JB3 (BLUE)

Length (mm) 4.045

Width (mm) 1.735

Height (mm) 1.655

Wheel base (mm) 2.650

Tread (mm) Front 1.440

Rear 1.440

Min. ground clearance (mm) 200

Curb weight (kg) 1.400 1.420 1.390

Total weight (kg) 1.675 1.695 1.665

Displacement (cc) 1.998 2.184

Max. speed (km/h) 156 170 130

Gradability (tan ) 1.087 1.200 1.111

Highway fuel consumption (km/ ) 15.2 15.5 21.0

Engine Type 4 Door

Item FE SOHC FE DOHC MAGMA

00-12 GENERAL DESCRIPTION BODY COLORS AND MAJOR SPECIFICATIONS

BODY STRUCTURE B

Body Composition. . . . . . . . . . . . . . . . . . . . 11- 3

Body Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3

Body Service Holes . . . . . . . . . . . . . . . . . . . . . . . 11- 3

High Tension Steel Sheet Used Area . . . . . . 11- 4

Plated Steel Sheet Used Area. . . . . . . . . . . . . 11- 6

Steel cold plate used area . . . . . . . . . . . . . . . . 11- 8

11

BODY COMPOSITION

Body shell

Body consists of frames, body, members etc. assembled thus providing safety, durability, noise protection, rustproofand vibrationproof.

11001

Body service holes

Body service holes are provided in the under panel to improve serviceability of the body.

11-3BODY STRUCTUREBODY COMPOSITION

11002

High tension steel sheet used area

Roof panel

Cowl grille

Bonnet Roof reinforcement

Rear header

Front header

Side sill inner

Cowl panel

Cowl panel rear

Cowl panel front

Dash lower panel

Front wheel house

Side inner rail

Side outer rail

Front fender panel

Front wheel house assemblyd

Shroud member upper No.1



Shroud center stay Shroud lower panel

Shroud sidepanel

Shroudsidepanel

Side sill inner

Front floor panel


11-4 BODY STRUCTURE BODY COMPOSITION

11003

Rear end plate

Rear cross memberRear end panel

Rear floor side member

Service box

Rear floorcross member

Frame assembly

Rear rain rail

Rear side panel inner

Rear inner rail

Center pillar

A pillar inner

A pillar outer

Sill side panel

Rear side pannel

Rear door

Gusset sidepanel

Rear lamphouse

Rear drainpanel

Rear wheelhouse inner

Front door

Back door

Rear endplate

Rear floorside member



11004

Plated steel sheat used area

Roof panel

Cowl grille

Bonnet Roof reinforcement

Rear header

Front header

Side sill inner

Cowl panel

Cowl panel rear

Cowl panel front

Dash lower panel

Front wheel house

Side inner rail

Side outer rail

Front fender panel

Front wheel house assemblyd




Shroud center stay Shroud lower panel

Shroud sidepanel

Shroudsidepanel

Side sill inner

Front floor panel



11005

11006

Rear end plate



Service box


Frame assembly

Rear rain rail


Rear inner rail

Center pillar

A pillar inner

A pillar outer

Sill side panel

Rear side pannel

Rear door

Gusset sidepanel

Rear lamphouse

Rear drainpanel


Front door

Back door

Rear endplate




11008

Steel cold plate used area

Rear end plate



Service box


Frame assembly

Rear rain rail


Rear inner rail

Center pillar

A pillar inner

A pillar outer

Sill side panel

Rear side pannel

Rear door

Gusset sidepanel

Rear lamphouse

Rear drainpanel


Front door

Back door

Rear endplate


Steel cold plate used area


REPLACING BODY PANELS C

Replacing Body Panels......................................21- 3Welding Codes for Disassembling and Assembling Body Panels............................................21- 3Descriptions on each Part

when Disassembling Body Parts...........................21- 3Descriptions on each Part

when Disassembling Body Parts...........................21- 4Notes when Welding Body................................21- 5

Disassembling Body Frame .......................................21- 5Disassembling Spot Welding Area.............................21- 5Using a Spot Cutter Drill .............................................21- 6Assembling a new Body Frame.................................21- 7Determining a welding Method...................................21- 7Spot Welding...............................................................21- 7CO2 gas Arc Welding..................................................21- 8Replacing a Body Panel Efficiently ............................21- 9

Replacing a Body Panel.....................................21- 16Shroud upper plate ....................................................21- 16Shroud lower panel ....................................................21- 18Shroud panel ..............................................................21- 20Side rail outer panel ...................................................21- 22Side rail inner panel ...................................................21- 24Wheel house ..............................................................21- 26Front pillar ...................................................................21- 28Center pillar ................................................................21- 30Front side sill panel ....................................................21- 32Rear side sill panel .....................................................21- 34Rear fander panel and lamp housing ........................21- 36Rear end panel ...........................................................21- 38Roof panel ..................................................................21- 40

21

REPLACING PANELS

Welding codes for disassembling and assembling body panels

Descriptions on each part when disassembling body parts

front pillar

name of area disassembled location of area disassembled

. . . . . . spot welding . . . . . . Continuous CO2 gas arc welding

. . . . . . CO2 gas arc welding (plug welding) . . . . . . lower union welding

. . . . . . CO2 gas union welding . . . . . . repair

21052

Disassembly

Drill the area marked with with care so that a hole is not made as plug welding work shall be done toassemble a new part.Do a repair work 20~30 mm inside of cut area as shown.Repairing the front pillar outer shall be done on the upper side (roof side) than the front pillar inner.

Notes and Notice

FRONT

Outer panel

Inner panel

14 points

14 points

5 points

14 points

13 points

4 points

4 points

1 point

2 points

3 points

3 points

3 points

3 points

4 points

3 points

20~30mm

20~30mm

20~30mm

21-3REPLACING BODY PANELSREPLACING PANELS

Descriptions on each part when assembling body parts

When assembling a new part, assemble a new part correctly, measure dimensions of each part according tothe body dimension drawings and set to the reference dimensions.After assembling a new part, check status of assembly with related parts (hood, front fender etc.).Weld the section (A), and wipe on the surface after applying the sealant.

Assembly

Notes and Notice21002

FRONT

Section (A)

18 Points

3 Points

3 Points

18 Points3Points

3Points

2 Points1 Point

17 Points

18 Points

3 Points

7 Points

4 Points

4 Points

4 Points

21-4 REPLACING BODY PANELS REPLACING PANELS

NOTES WHEN WELDING BODY

Disassembling body frame

Most body parts are spot welded. Therefore, in order to disassemble the damaged area it is best todisassemble spot welded area from the body frame using a spot cutter and a drill.

Disassembling spot welded area

In order to disassemble spot welded area drill a hole only at an area to be disassembled. Note that a holeshould not made in the opposite side. A hole may be made although you are trying to avoid it, but a drill with ataper edge should not be used.

1. Spot cutter 1. Drill (Candle type edge) 1. Drill (taper edge)

2.

3. 3. 3.

2. 2.

21-5REPLACING BODY PANELSNOTES WHEN WELDING BODY

21003

Using a spot cutter drill

Punch in the middle of a spot welded area(nugget) to prevent adrilling by the spot cutter drill.

21004

It is important to punch in the middle Otherwise,

of a spot welded area(nugget).

Spot welded area are coming off the body frame. Spot welded area will not come off the body

frame.

This part will notbe cut.

This part willbe cut.

21-6 REPLACING BODY PANELS NOTES WHEN WELDING BODY

21005

Spot welding

1. A commercial spot welding machine used for repair does nothave as good performance as those for manufacturers.Therefore, welding shall be done on more points thanmanufacturers.

2. Especially, in order to provide sufficient strength theimportant parts and edges of a body shall be welded.

3. Set a flange to weld correctly and spot weld in the middle ofeach flange joint.(1) It is important to spot weld in the middle of each flange

joint.

(2) Spot welding on the edge of the flange joint wil l deteriorate welding strength.

Good

No good

21006

21007

Assembling a new body frame

The efficiency of the transmission and load distribution are determined by many complicated factors (such asthickness of plate, shape and size of a cross section, deformation of parts, variance of joints, welding method,welding locations). Therefore, a new part shall be fitted on to the body frame in a proper procedure in order notto deteriorate strength of a new body.

Determining a welding method

A welding method of a new part to a body frame is determined by the reliability, job efficiency, quality of finishedparts. Especially, welding method providing high reliability shall be selected for a body frame of a high strenthsteel.

spot welding the most reliable welding method(provides high efficiency of work and quality of assembled part.)

CO2 gas arc welding use when spot welding cannot be done or spot welding is notnecessary.

oxygen-acetylene welding X not used

welding reliabililty details

21-7REPLACING BODY PANELSNOTES WHEN WELDING BODY

21008

CO2 gas arc welding

In case it is not possible to do a spot welding do a plug weldingusing a CO2 gas arc welding.1. Weld 50% more than those spots welded at the factory.2. Set the flange correctly to minimize tolerance. A tolerance

greater than 1mm will deteriorate strength of the weldedarea.

3. Weld in the middle of the flange joint as same as the way

(1) Drill a hole of 5~6mm on one side only of the flange and weld from the next of it.

(2) Do not weld on the edge as shown in figure.

Minimize tolerance

21009

21010

21011

21-8 REPLACING BODY PANELS NOTES WHEN WELDING BODY

REPLACING BODY PANEL EFFICIENTLY

1. Body measurement

1) Before disassembling or cutting a rough area check and measure the damaged area according to the dimensions on the drawing, and if deformation is present then use a frame made for modifying a rough area.

2) When disassembling a panel fix a clamp to prevent deformation of each part, and support the lower end of a frame to prevent deformation during the work.

2. Cut and welding point selection

Cutting, if necessary, shall be done on an area apart fromreinforcements as much as possible, and select an areawhere deformation after welding is minimized.

3. Cutting rough area of replacement part

Cutting shall be done according to the following steps tomake disassembly easy:1) Cut an area close to a pipe or wiring harness with care

considering possible damage caused by heat when welding and working condition.

2) Cut an area leaving 30~50mm of tolerance considering welding work.

3) Determine a cutting method of an area to cut.

4. Removing paint from an area to spot weldUsing a torch and wire brush remove paint completely forwelding work on those area.

Disassembly

Clamp

Cut area

Reinforcement

Reinforcement

Wiring harness

Wire brush

Cutting torch

21012

21013

21014

21015

Tracking gage

21-9REPLACING BODY PANELSREPLACING BODY PANEL EFFICIENTLY

21016

5. Cutting a spot welded area

Make a scar in the middle of spot welded area with a punch,disassemble welded area using a spot welding cutter andremove using a chisel.

6. Removing brazed area

Disassemble using a torch and wire brush and remove witha chisel.

7. Removing arc welded area

Remove arc welded area using a disk grinder anddisassemble with a chisel.

Punch

Spot weldingcutter

21017

Torch

Wire brush

21018

Chisel

21019

21-10 REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY

1. Weld mark finish

Use a disk grinder or similar tool to finish spot weld mark,brazed mark smoothly. Grind with care not to grind morethan enough.

2. Drilling hole finish

When ready finish a drilling hole using an (even) grinder anda welding torch.

3. Panel preparation

Repair an area where welding is removed (not even area) ora bent area with a hammer to improve assembly of a newpart.

4. Cutting a rough area of a new part

Cut an area to cut or to weld using a hand saw or electricsaw leaving 30~50mm of tolerance.

5. Preparation for spot welding

Remove paint on spot welded area and on an areaoverlapped with a new part using a belt sander or similartool.

Preparation for assembly

Welding torch

Belt sander

21020

21021

21022

21023

21-11REPLACING BODY PANELSREPLACING BODY PANEL EFFICIENTLY

21024

6. Drilling a hole for plug welding

Drill a hole of 5~6mm dia(new part or side body) using ahand punch or a drill where it is not possible to spot weld.

7. Determining a welding method

If the thickness of a welding area is greater than 3mm, drill ahole using a 7mm dia drill for welding.

8. Cutting and cutting an welded area

Weld a new part temporarily on an area to be cut or welded. Check eveness and clearance and cut an area using a handsaw or air saw.

Do not weld where thickness is thicker than3mm(because of poor welding strength).

Notice

21025

21026

Cut and assembly area

Cut andassembly area

21027

3mm or less

3mm or less

Sport

Plug welding


1. Checking welding and fitting in advance

1) Set reference dimension to the body dimension drawing. Assemble a new part at its position.

2) Assemble a door, fix a rear door and other parts at their positions and check the clearance and surface if done correctly.

2. Selecting number of welding points

Select the number of welding points as follows:spot welding : initial number of welding points x 1.3 ormore plug welding : initial number of welding points ormore

3. Notice when spot welding

1) Do a preliminary welding before spot welding, and proceed welding if good.

2) Before spot welding check if welding debris, oil or paint are not present on area where surfaces meet.

3) The tip shall be maintained as welding strength is affected by the shape of a spot welding tip. Also take a cooling time after welding 5 or 6 times to minimize problems caused by excessive heat.

Assembly

Plug welding works shall be done using a CO2 gas arc

spatter protection device.

Welding a hard panel shall be done on designated

locations only.

Notice

Welding after repairPitch: 35mm

Initial weldingPitch: 50mm

Spot welding: initial number of welding x 1.3

Initial welding1.3mm or more

Welding after repair

Initial number of weldingpoints or more

Plug welding

Using a test pieceUsing a hammerand a chisel

Centerdiameter

Nugget diameter:4/5 of tip

3mm

Wet cloth

3mm

21028

21029

21030

21031

21-13REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY

21032

4) As same as general rules spot welding shall be done bigger than the existing welding points.

4. Checking temporary welding and fitting condition

Temporary fitting and welding necessary for an arc weldingor spot welding shall be checked along with fitness of relatedparts and measurement of prior to final welding.

5. Cutting and welding an assembled area

Welding a cut area and assembled area end to end maycause a problem at the welded area, therefore it is requiredto weld against a flange at the back and cut it if final weldingis done.

6. Finishing after welding

1) Check if welding is done properly.2) Grind the area pulg welded and welded end to end using

a disk grinder. Grind with care not to grind more than enough as it degrades welding strength.

7. Finishing area where welded end to end

Heat the welded area and make the surface even using aflexible file or sander.

Existing spot welding

New spot welding

21033

21034

Steel panel

21035

Welded area

Flexible file

21036


21037

8. Applying agent and body sealer on surfaceAfter the coating of agent on the surface is done, apply bodysealer where necessary.

9. Antirust treatmentApply antirust coating on the other side of the welded area.At this time utilize a hole or a gap on the side.

Apply body sealer before assembly otherwise it will bedifficult to do that.

Notice

Coating areabefore assembly

Bodysealer

21038

21039

21-15REPLACING BODY PANELS REPLACING BODY PANEL EFFICIENTLY

REPLACING A BODY PANELShroud upper panel

21040

Disassembly

Right view only as the left is opposite to the right.

7 points

9 points

3 points

21-16 REPLACING BODY PANELS REPLACING A BODY PANEL

21041

Assembly

When assembling a new part measure dimensions of each part according to the body dimension drawings

and set to the reference dimensions.

9 points

12 points

4 points

21-17REPLACING BODY PANELS REPLACING A BODY PANEL

Shroud lower panel

Disassembly

Section (A) indicates a drilling work inside the engine room.Right view only as the left is opposite to the right.

21042

3 points

11 points

9 points

7 points

Section A


Assembly

21043

When assembling a new part measure dimensions of each part according to the body dimension drawings and set to the reference dimensions.Section (A) requires a plug welding work inside the engine room.When doing a plug welding on section (B), spot weld shroud panel and front side frame first and weld it with a plate for assembly.

3 points

14 points

9 points

9 points

Section B

Section A

21-19REPLACING BODY PANELSREPLACING A BODY PANEL

Shroud panel

Disassembly

21044

Right view only as the left is opposite to the right.

Section indicates a drilling work inside the engine room.

3 points

Section A

8 points

9 points

5 points


3 points

7 points

9 points

10 points

Assembly

21045

When assembling a new part measure dimensions of each port according to the body dimension drawings


Set to the reference dimensions and check status of assembly with related parts.

(shroud upper plate, radiator etc.)

REPLACING BODY PANELS 21-21REPLACING A BODY PANEL

Side rail outer panel

Disassembly

21046

Replace parts with care so that other parts are not damaged.

12 points

12 points

4 points


16 points

16 points

4 points



After setting to the reference dimensions, check status of assembly with related parts (hood, front fender

etc.)

Assembly

21047


Side rail inner panel

Replace parts with care so that other parts are not damaged.

Section indicates a drilling work inside the engine room.

Disassembly

21048

3 points

19 points

1 point

6 points

Section A

4 points


Assembly

21049

Assemble a wheel apron panel correctly, measure dimensions of each part according to the body dimension

drawings and set to the reference dimensions.

After setting to the reference dimensions, check status of assembly with related parts (hood, front fender etc.)

Weld the section (A), and wipe on the surface after applying the sealant.

4 points

3 points

2 points

24 points6 points

Section A


Wheel house

Disassembly

Replace part with care so that other parts are not damaged.

Drilling work on the area marked with requires making a hole to allow plug welding when assembly.

21050

19 points

3 points

4 points

4 points

6 points

5 points

13 points


Assembly



After setting to the reference dimensions, check status of assembly with related parts (bonnet, front fender

etc.)

21051

24 points

3 points

4 points

8 points

13 points

4 points

6 points


Front pillar

Drill the area marked with with care so that a hole is not made as plug welding work shall be done to

assemble a new part.

Do a repair work 20~30mm inside of cut area as shown.

Repairing the front pillar outer shall be done on the upper side (roof side) than the front pillar inner.

Disassembly

21052

20~30mm

20~30mm

20~30mm

Outer panel

Inner panel

FRONT

14 points

14 points

14 points

5 points

3 points

3 points

3 points4 points2 points

4 points

1 point

2 points

3 points

13 points

3 points

4 points


Assembly

21053

When assembling a new part, assemble a new part correctly, measure dimensions of each part according to

the body dimension drawings and set to the reference dimensions.

After assembling a new part, check status of assembly with related parts (bonnet, front fender etc.)

Weld the section (A), and wipe on the surface after applying the sealant.

FRONT

18 points

3 points

3 points

18 pointsSection (A)

18 points

1 point2 points

4 points

3 points

3 points

3 points

4 points

14 points

4 points

7 points


Center pillar

Disassembly

Do a drilling work on the area marked with with care so that holes are not made through considering plug

welding works required to assemble a new part.

Do a repair work at 20 30mm inside of the cut area.

Select a cut area on a side sill area away from a hole as shown.

21054

FRONT

30 points

3 points

4 points 4 points

6 points

5 points

5 points

6 points

5 points

2 points

6 points

9 points

32 points


Assembly

21055

When cutting a new and existing parts, assemble a new part correctly, measure dimensions of each part

according to the body dimension drawings and set to the reference dimensions.

After assembling a new part, check status of assembly with related parts (front door).

FRONT

39 points42 points

12 points

5 points

4 points

5 points7 points5 points

8 points

6 points

7 points

2 points

6 points


Front side sill panel

Disassembly

Select a cut and assembly area away from a hole as shown.

Do a repair work at 20~30mm inside of the cut area.

FRONT


Rough cut area

12 points

20~30mm 20~30mm

13 points

Cut or assemble within this range

21056


Assembly

21057

FRONT


17 points

15 points

Cut or assemble within this range

After assembling a new part, check status of assembly with related parts (esp. front door).


Rear side sill panel

Select a cut area on a side sill area away from a hole as shown.


21058

Disassembly

FRONT


9 points

20~30mm

20~30mm

12 points

6 points

2 points

Rough cut area


Assembly

21059

After assembling a new part, check status of assembly with related parts (esp. rear door).

FRONT

16 points

8 points

2 points12 points



Rear fender panel and lamp housing

Disassembly

21060

Select a cut area of the pillar approximately 50mm away from the roof and rear fender assembled area as

shown, and cut with care so that the reinforcement is not damaged.


FRONT 9 points

3 points

2 points

19 points

3 points

2 points

3 points

1 point2 points

3 points 2 points

22 points11 points

6 points

6 points

20~30mm

20~30mm


FRONT

approx. 50mm

approx. 50mm 8 points 8 points

29 points

14 points

12 points

4 points

4 points4 points

2 points

2 points3 points

1 point

2 points

2 points

25 points

Assembly

21061

Before assembling a new part, apply sealer on the tire attachment area.

When cutting a new and existing parts, assemble a new part correctly, measure dimensions of each part

according to the body dimension drawings and set to the reference dimensions.

After assembling a new part, check status of assembly with related parts(rear door, back door, rear

combination lamp, rear bumper etc.)


Rear and panel

Disassembly

21062

3 points

3 points

21 points

19 points

3 points

3 points


Assembly

21063

When assembling a new part correctly, measure dimensions of each part according to the body dimension

drawings and set to the reference dimensions.

After assembling a new part, check status of assembly with related parts(trunk lid, rear bumper etc.).

25 points

27 points

4 points

3 points

4 points

3 points


Roof panel

Disassembly

21064

Grind the lower area assembled with the rear fender to disassemble.

FRONT

25 points

18 points

8 points

5 points5 points

23 points

18 points

8 points


Assembly

21065

Before assembling the roof panel, apply body sealer on the gap between the roof panel and reinforcements.

FRONT

33 points

23 points23 points

8 points

6 points

30 points

6 points

8 points


BODY DIMENSION D

Body Dimension Indication ..............................31- 3

Plane Dimension .......................................................31- 3

Actual Measured Dimension

(Straight Line Dimension) .....................................31- 3

Straight Line Dimension(Front Body).............31- 4

Straight Line Dimension(Side Frame).............31- 6

Straight Line Dimension(Interior A) ................31- 7

Straight Line Dimension(Interior B) ................31- 8

Straight Line Dimension(Rear Body) ..............31- 10

Plane Dimension(Frame) ..................................31- 11

Straight Line Dimension(Frame)......................31- 13

31

BODY DIMENSION INDICATION

Plane dimensionThe plane dimension indicates a dimension projected on a plane from a reference point of a body(Height etc. maybe different in some cases.)

Actual measured dimension(straight line dimension)The actual measured dimension indicates a straight line dimension between the measurement reference points.

Assembly nut of front fender

Straight line dimension

Plane dimension

31001

Straightline line dimension(front body dimension)

Front fender mounting nut M10

Front suspension mounting block assembly hole 8

Front fender mounting nut M10

Shroud member upper No.2 mounting nut M10

Shroud side panel reference hole 9

Shroud member door reference hole 8

Dash panel reference hole 7

Description Size of hole and nut(mm)Measurement

A-A'

B-B'

C-C'

D-D'

E-E'

F-F'

H

31-3BODY DIMENSIONBODY DIMENSION INDICATION

STRAIGHT LINE DIMENSION (FRONT BODY)

31002

AA'

DD' EE' FF'

BB' CC'

Dimension (mm)

Dimension (mm)

Measurement point

Measurement point

31-4 BODY DIMENSION STRAIGHT LINE DIMENSION (FRONT BODY)

Unit : mm

28

8

3

6

9

1012

11 13

7

5 4 2

1

HA'

C'

D'

E'

F'

F

B'D

E B

C

A

31003

31-5BODY DIMENSIONSTRAIGHT LINE DIMENSION (FRONT BODY)

STRAIGHT LINE DIMENSION (SIDE FRAME)

31004

10

5

1

2

3

4

9

8

7

13 15

1412

11

6

C D

E

FH

G

A

B

Dimension (mm)

Dimension (mm)

Measurement point

Measurement point

31-6 BODY DIMENSION STRAIGHT LINE DIMENSION (SIDE FRAME)

STRAIGHT LINE DIMENSION (INTERIOR A)

31005

1 109

8

76

54

3

C'

B'

2

A'

H'

H

F

JG

ED

A

G'

E'

D'

F'

B

C

J'

Dimension (mm)

Dimension (mm)

Measurement point

Measurement point

31-7BODY DIMENSIONSTRAIGHT LINE DIMENSION (INTERIOR A)

STRAIGHT LINE DIMENSION (INTERIOR B)

31006

2

3

9

104

56

7

8

1

A'

B'

B

D'

E'

C'

C

D

F

E

A

Dimension (mm)

Dimension (mm)

Measurement point

Measurement point

31-8 BODY DIMENSION STRAIGHT LINE DIMENSION (INTERIOR B)

31007

4

A

B

D'

D

H

C

E

G

F

J

I

3

2

10

1

8

9

5

6

7

Dimension (mm)

Dimension (mm)

Measurement point

Measurement point

31-9BODY DIMENSIONSTRAIGHT LINE DIMENSION (INTERIOR B)

STRAIGHT LINE DIMENSION (REAR BODY)

31008

Dimension (mm)

Dimension (mm)

Measurement point

Measurement point

1

5

2

7

8

3

9

6 11

B'

A'

C'

D

C

B

A

10 44

31-10 BODY DIMENSION STRAIGHT LINE DIMENSION (REAR BODY)

PLANE DIMENSION (FRAME)

A Body mounting bracket hole No.1 28

B Suspension mounting hole 65.6

C Body mounting bracket hole No.2 28

D Body mounting bracket hole No.3 28

E Lower arm bracket mounting hole 13

F Rear spring bracket hole 13

G Rear shock absorber bracket hole 19

H Body mounting bracket hole No.4

Description Size of hole (mm)Measurement point

A

B

C

D

E

F

G

H28 : LH

28 32 (SLOT) : RH

31-11BODY DIMENSIONPLANE DIMENSION (FRAME)

PLANE DIMENSION (FRAME)

Unit : mm

31009

31-12 BODY DIMENSION PLANE DIMENSION (FRAME)

STRAIGHT LINE DIMENSION (FRAME)

Body mounting bracket hole No.1 28

Suspension mounting hole 65



Rear spring bracket hole 19

Body mounting bracket hole No.4

Measurement point

A

B

C

D

E

F

Description Size of hole(mm)

28 : LH28 32 (SLOT) : RH

31-13BODY DIMENSIONSTRAIGHT LINE DIMENSION (FRAME)

STRAIGHT LINE DIMENSION (FRAME)

Unit : mm

31010

31-14 BODY DIMENSION STRAIGHT LINE DIMENSION (FRAME)

WATERPROOF AND RUSTPROOF E

Body sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3

Bonnet, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3

Body Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 4

Under Coating . . . . . . . . . . . . . . . . . . . . . . . . . 41-10

Applying urethane . . . . . . . . . . . . . . . . . . . . . 41- 11

Applying Antirust Agent . . . . . . . . . . . . . . . 41-12 41

BODY SEALING

Apply sealer on assembled area of the body panel and on the hemming area in (contact with the body) such asdoors(inner, outer), bonnet(inner, outer) for waterproof and rustproof.

Bonnet and door

* Trim each edge

sec A - A'

sec C - C'

C

C'

D

D'

sec D - D'

sec B - B' HINGE

HINGE

HINGE

30

30

30

50

30

30

30 30

30 30

30

20 20

50

30

30

2020

60

20

20

20

20

20

20

30 30

30

30

30

30

30

3030

A B

B'A'

BONNET

REAR DOORFRONT DOOR

BACK DOOR

41-3WATERPROOF AND RUSTPROOFBODY SEALING

41001

Body parts

sec A - A'

A

A'

41002

41-4 WATERPROOF AND RUSTPROOF BODY SEALING

A

sec. A-A'

A'

41003


A

A'

sec A - A'

41004


sec A - A'

A'C C'A

B

B'

sec B - B'

sec C - C'

41005


sec E - E'

E

C

D

D'

B

B'A

A'

C'

E'

sec A - A' sec B - B' sec D - D'

sec C - C'

41006


41007


UNDER COATING

Apply coating on the underbody for soundproof and rustproof.

sec D - D'

D

D'C

C'

AA'

B'

B

sec E - E'

sec C - C'

sec A - A'

sec B - B'E

E'

41008

41-10 WATERPROOF AND RUSTPROOF UNDER COATING

APPLYING URETHANE

41009

A

A'1800mm

sec A - A'

160mm

100mm

41-11WATERPROOF AND RUSTPROOFAPPLYING URETHANE

APPLYING ANTIRUST AGENT

41010

sec B - B'

B D

D'B'

A

A'

C

C'

sec A - A'sec C - C'

sec D - D'

41-12 WATERPROOF AND RUSTPROOF APPLYING ANTIRUST AGENT

41011

sec A - A'

200

sec B - B'

sec F - F'sec E - E'

sec D - D'

200

200

150

A

A'

E

E'

F

F'

100

300

C C'D

D'

B B'

sec C - C'

HINGE

HINGE

BONNET

FRONT DOOR REAR DOOR

BACK DOORHINGE

41-13WATERPROOF AND RUSTPROOFAPPLYING ANTIRUST AGENT

BODY MODIFICATION TOOLS F

Body Modification Tools. . . . . . . . . . . . . . 51- 3

Modification Tools. . . . . . . . . . . . . . . . . . . . . . . . . 51- 3

Cut and Disassembly Tools . . . . . . . . . . . . . . . 51- 4

Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 5

Measurement Tools . . . . . . . . . . . . . . . . . . . . . . . 51- 5

Welding Machine . . . . . . . . . . . . . . . . . . . . . . . . . 51- 6

Buffing and Grinding Tools . . . . . . . . . . . . . . . . 51- 7

Handheld Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 9

Repair Tool Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-10 51

BODY MODIFICATION TOOLS

Modification tools

Name Used for Figure

Frame straightener Modify twisted or bented body

Push out, stretch, pull indamaged area

Stretch damaged area

Port power

Body puller

51-3BODY MODIFICATION TOOLSBODY MODIFICATION TOOLS

Cut and disassembly tools


Air saw

Air diesel

Rotary cutter

Hand saw and metal scissors

Air drill

Spot cutter

Cut a panel

Cut or bend a panel, cut anddisassemble spot welded area

cut a panel

cut a panel

fix a spot cutter or drill to cut ordisassemble spot welding area,to finish a hole.

cut and disassemble spotwelded area

51-4 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS

Assembly tools


Vice pliers

Air bench

Quick bench

Flanging tool

Fix a panel or area to weld

Finish contact area of flangeand finish a hole for plugwelding

Finish a hole for plug welding

Finish contact area of flange


Centering gauge

Tracking gauge

Measure distortion of body andframe

Measure body and frame

Measurement tools



Gas weldingmachine

Spot weldingmachine

CO2 gas arc weldingmachine

Stud weldingmachine

Cut a panel

Weld a panel

Weld a panel

Stretch a panel, weld a stud boltto fix front window mold clip

Welding machine


Buffing and grinding tools


Disk grinder

Disk sander

Belt sander

Small sized grinder

Double actionsander

Orbital sander(short)

Buff

Buff

Buff paints

Buff paints or smooth finishing

Grind rough area of putteeassembled area

Grind rough area of putteeassembled area



Orbital sander(long)

Flexible file

Surform tool

Hand file

Used for puttee grinding of widearea

Grind touch up area, uneven area of a panel

Buff rough area of puttee area

Grind body puttee, pulley, finishputtee


Handheld tools


Body hammer anddolly

Center punch

Plane chisel

Weight hammer

Bowl pin hammer

Spoon

Punch a hole in the middle of aspot welding area

Cut and disassemble a panel

Used when greater force isrequired

Used when smaller force isrequired

Used for an area where notreached by hand



Body chisel

Wire brush

Bend rough body line damagedor sheet metal etc.

Remove paints, rust, slag onwelded area which are hard torecognize

Repair tool set


Window tool set

Repair tool set forplastics

Repair window collar

Repair plastic parts


WHELL ALIGNMENT G

Checks and Adjustments for Wheel Alighment. . . . . . . . . . . . . . . 61- 3

Preparation before Checking . . . . . . . . . . . . . . 61- 3

Checks and Adjustment . . . . . . . . . . . . . . . . . . . 61- 3

Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 4

Major Specifications . . . . . . . . . . . . . . . . . . . . . . 61- 4

61

CHECKS AND ADJUSTMENTS FOR WHEELALIGNMENT

Preparation before checking

1. Empty the vehicle and park at a leveled area with the wheelsfacing straight forward.

2. Set the tire pressure to the rated pressure, and set move-ment of the tires and disk wheels correctly.

3. Adjust the front and rear suspensions correctly.

4. Check if the shock absorbers work properly by pushing thebody.

5. Check if the height of the vehicle is 1,665 mm.

6. Check if the wheelbase is 2,650 mm.

Checks and adjustment

Checks and adjsutment should also be done on the front andrear according to the service manual released together.

Cutters should not be present on the wheel bearing,lower arm ball joint, rubber bush, pillow ball etc.

Notice

Notice

The difference between the right and the left of the dis-tance from the wheel center and the fender arch(A, B)as shown should be less than 10mm.If the difference is greater than 10mm, check if the sus-pensions are assembled correctly and if the status of thesprings are good, and adjust them correctly if notacceptable.

Notice

The difference between the wheelbase of the left andthe right should be less than 10mm.

61001

61002

Wheel base

61-3WHEEL ALIGNMENTCHECKS AND ADJUSTMENTS FOR WHEEL ALIGNMENT

Tire pressure

Major Specifications

Air pressure kPa (kg/cm2, psi)

Front Rear

P205 / 75R15 177 (1.8, 26)

Tire size

Item Specifications

Suspension type Double wishborne coil spring

Toe-in No passenger load 2.5 2.5mm (0.09 0.09 in)

2 passenger load 0 2.5 mm (0 0.090 in)

Camber No passenger load 0.44 0.5

2 passenger load 0 0.5

Caster No passenger load 3.58 0.5

2 passenger load 3.85 0.5

Front shock absorber type Double - acting, oil filed

Stabilizer type Torsion bar

Suspension type 4 Link coil spring

Toe-in (mm, in) 0

Camber 0

Rear shock absorber type Double - acting, oil filed

WheelalignmentFront

RearWheelalignment

61-4 WHEEL ALIGNMENT CHECKS AND ADJUSTMENTS FOR WHEEL ALIGNMENT

PLASTIC PARTS H

Heat Deformation Temperatures Table of Plastic Parts . . . . . . . . . . . . . . 71- 3

Name of Plastics and Materials. . . . . . . . 71- 4

Range of Repairability of Polyprophylene(PP) Bumper . . . . 71- 5

Repair Procedure of PP Bumper . . . . . . 71- 6

Repair Method of PP Bumper . . . . . . . . . . 71- 7

71

HEAT DEFORMATION TEMPERATURES TABLE OF PLASTIC PARTS

The heat deformation temperature indicates the temperature at which deformation may occur during the

Polyprophylene PP P-PR 60

ABS ABS P-AB 90

Nylon PA P-AM 70

Chlorovinyl PVC P-VC 60

Thermoplastic elastomer TPE P-TE 60

Acetal POM P-AC 110

Polybutylene tereftalate PBT P-BT 120

Acryl PMMA P-MA 80

Phenol PF P-PF 120

Polyethylene PE P-ET 50

Polycarbonate PC P-CT 120

Polyphenylene oxide PPO P-PC 115

PlasticAbbreviation

KS KES(Kia's code)

Heat deformationtemperature( )

71-3PLASTIC PARTSHEAT DEFORMATION TEMPERATURES TABLE OF PLASTIC PARTS

works.NAME OF PLASTICS AND MATERIALS

Instrument panel(ABS + Urethane foam)

Head lampLens : PCHousing : BMC Cowl grille (PPO)

Radiator grille (ABS)

Front bumper (PP)

Back glass molding (PVC)

Front combination lampLens : PMMAHousing : ABS

Rear combination lampLens : PMMAHousing : ABS

Rear bumper (PP)

Side protactingmolding (PVC)

Rear flap (TPE)

Front flap (TPE)

Side protector (PVC)

Front windshield molding (PVC)

Out side mirror(ABS)

Quarter Glass molding (PVC)

71001

71-4 PLASTIC PARTS NAME OF PLASTICS AND MATERIALS

RANGE OF REPAIRABILITY OF POLYPROPHYLENE(PP) BUMPER

Three types of bumpers damaged as shown below may be repaired. Bumpers damaged more than that may beable to be repaired but replacing is encouraged. Because repair may degrade beauty or quality of a bumperdue to degradation of adhesiveness. Also, such repair may cause more cost.

Bumper heightCrack on section

71002

71003

71004

1. If a hole on a bumper is less than 50mm.

2. If a crack on a bumper is less than 100mm.

3. If a crack on a bumper section is less than 100mm(lessthan half of bumper height) bumper height crack on section

71-5PLASTIC PARTSRANGE OF REPAIRABILITY OF POLYPROPHYLENE (PP) BUMPER

REPAIR PROCEDURE OF PP BUMPER

Replace damaged bumper with

a new bumper.

Apply primer for polyprophylene

over a bumper surface.

Surface ofbumper is notvisible.

Surface of bumper isvisible.

Remove paint

Make damaged area smooth.

Apply aluminum tape on the rearside of bumper.

Weld damaged area.

Grind damaged area with a rough sandpaper.

Remove oil from a damaged area(use TCE de-oil material).

Apply primer for polyprophylene over damaged area.

Apply solvent over damaged area to dry it.

Spray primer surface over a bumper and dry it.

Grind surface of a bumper with a sandpaper.

Remove oil with TCE de-oil material.

Wipe the surface of a bumper quickly with a clean cloth.

Paint the bumper with a paint of the same color and dry it.

71-6 PLASTIC PARTS REPAIR PROCEDURE OF PP BUMPER

REPAIR METHOD OF PP BUMPER

If a scar on a PP bumper reached the surface of polyprophylene, it cannot be recovered by painting.

1. If there is a scar made by a knife, make the area smooth, cut a rough area and grind the damaged area at45 with a sander.

Hole Crack Scar

Section A-A'Section B-B'Section C-C'

Section D-D'

Upper layer(coating) Primer surface layerPrimer layer Polyprophylene layer

Cut with a knife . A-A'Section B-B'

C-C'

Surface of polyprophlene

Section D-D'Cut with a knife.

Make an angle with a sander.Make an angle with a sander.

Angle of 45 is required for accumulation of welding rod of polyprophylene.

71-7PLASTIC PARTSREPAIR METHOD OF PP BUMPER

2. Welding damaged area1) To repair cracked area, melt the area using a heater gun and attachment.

2) To repair a hole, remove oil from the damaged area, apply aluminum tape on the rear side and remove oil on the rear side of the bumper.

3. Melt polyprophylene welding rod using a heater gun and fill it in a cracked area.

Heater gun

Apply on surface.

Surface of polyprophylene

Melt the surface using a heater gun.

Section view after melt

Remove oil.Section A-A'

Apply aluminum tape on the rear side of the damaged area.

Polyprophylene welding rod

A-A'Section B-B'

C-C'


Melt here.

Melt here.


Tape

Section A-A'

Plane view


Surface ofpolyprophylene

Note

1) Heat and melt the area indicated.2) Melt the welding rod with care so that it is not overmelted. If the welding rod is overmelted like a jelly,

then the welding strength is deteriorated.3) Use a heater gun 10~20mm away from the repair area to be welded.4) Welding rod should not move until the welded area is cooled.

71-8 PLASTIC PARTS REPAIR METHOD OF PP BUMPER

4. Grind polyprophylene surface little by little. Because it easily melts due to the frictioin heat. If melted,remove that area. Also, grind an area where solvent is applied.

5. Apply polyprophylene primer evenly with a brush over the area wider than the area to repair. Dry it at 20for more than 10 minutes.

6. Mix main solvent and hardener at a ratio depending on paint specifications. Mix solvent and apply over thedamaged area.

Solvent consists of two types of epoxy.When the solvent is hardened, you will have desirable finish having flexibility like polyprophylene.Solvent for polyprophylene bumper consists of main solvent and hardener. However, as this is different from solvent for urethane bumper you will not have desirous adhesive if different type of solvent is used.

Do not grind continuously. Paint

Area to apply solvent

Grind area painted and roughsurface.

Apply primer wider than the area to repair.

Polyprophylene primer

Do not have bubbles created

Surface of polyprophylene

Solvent

Weld

Note

1) Mix main solvent and hardener such that bubbles are not made.2) Work immediately after mixing solvent as the solvent gets hardened fast (in about 5 minutes).3) Dry it at 20 for about 30 minutes before grinding.


7. Grind the damaged area with sand paper of #180~#240.

8. Remove oil on the painted surface.

9. Mix polyprophylene primer and hardener at a ratio depending on paint specifications.Apply polyprophylene primer using a brush and a spray on the surface of the damaged area and the bumper.

Use a primer within 16 hours after it is mixed.

10. Apply polyprophylene primer.

Note

1) The surface will not be even if excessive force is applied during grinding.2) If there are fuzz in the damaged area, heat it a little bit with a heater gun and melt it.

Polyprophylene primer Primer hardener

Note

Use water only to clean after applying polyprophylene primer. Solvent if used will melt the primer.

71-10 PLASTIC PARTS REPAIR METHOD OF PP BUMPER

11. Grind slightly the sprayed area using a primer surfacer, and finish the surface of the bumper with a sandpaper(#400~#600). And the polyprophylene surface should not be disposed. (either wet sanding or dry sanding is all right.)

12. Use agent(TCE(Tri Chloro Ethane) de-oil material) to remove the oil, and wipe the finished surface of thebumper quickly with a clean cloth.

13. Do a painting work suitable for polyprophylene bumper.

14. Dry in the air at 20 for about 8 hours, and positive dry in 60 for about 2 hours.(However, drying time varies paint by paint).

Note

The painting method for the polyprophylene bumper to repair is same as that for the urethanebumper.Therefore, use urethane primer only for urethane bumper and use polyprophylene primer forpolyprophylene bumper for painting.Flexible polyprophylene bumper is suitable for painting the bumper to repair.If hard type bumper is used in place of the polyprophylene bumper, the paint film may be crackedor peeled off by a small deformation or impact.To repair polyprophylene bumper, do a positive drying or air drying type painting forpolyprophylene. (This can also be done on the urethane bumper. This is called urethanepainting.)

Note

Do a drying in the air if possible. Positive drying may create air bubble on the top layer.


Applying urethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 11Applying antirust agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 12

Body color and major specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 12Body colors and codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 12Major specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 12

Body composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3Body shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3Body service holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3High tension steel sheet used area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4Plated steel sheet used area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 6Steel cold plate used area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8

Body dimension indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 3Plane dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 3Actual measured dimension(straight line dimension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 3

Body sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3Bonnet, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 3Body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 4

Body modification tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 3Modification tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 3Cut and disassembly tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 4Assembly tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 5Measurement tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 5Welding machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 6Buffing and grinding tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 7Handheld tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 9Repair tools set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51- 10

INDEX

A

B

Check and adjustments for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 3Preparation before checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 3Checks and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 3Tire pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 4Major specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61- 4

For efficient and precise works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 5Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 5Body and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 6Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 7Rustproof treatment after assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 8

Heat deformation temperatures table of plastic parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 3

Notice during works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Vehicle care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Safe works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Welding works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 3Body frame straightener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 4Electrical works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 4

Notes when welding body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 5Disassembling body frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 5Disassembling spot welded area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 5Using a spot cutter drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 6Assembling a new body frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 7Determining a welding method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 7Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 7CO2 gas arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 8Replacing body panel efficiently . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 9

Name of plastics and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 4

C

N

F

H

Plane dimension(Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 11

Range of repairability of polyprophylene (PP) bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 5Repair procedure of pp bumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 6Repair method of pp bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71- 7

Replacing body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3Welding codes for disassembling and assembling body panels . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3Descriptions on each part when disassembling body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3Descriptions on each part when assembling body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 4

Replacing a body panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 16Shroud upper plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 16Shroud lower panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 18Shroud panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 20Side rail outer panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 22Side rail inner panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 24Wheel house. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 26Front pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 28Center pillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 30Front side sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 32Rear side sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 34Rear fander panel and lamp housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 36Rear end panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 38Roof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 40

Straight line dimension(front body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 4Straight line dimension(side frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 6Straight line dimension(interior A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 7Straight line dimension(interior B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 8Straight line dimension(rear body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 10Straight line dimension(under body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31- 13

Support point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9Support point for jack up and safety stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 9Support point for auto lift(2 post lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10

P

R

S

Tow and VIN number stamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10Tow hooks for tow rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10Engine number stamping location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10VIN number stamping location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 11

Under coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41- 10

T

U

manual reparatii kia sportage

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