Kia Optima Bodyshop Manual
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Kia Optima Bodyshop Manual

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See also: Owner's Manual , Manual
Body Shop Manual
FOREWORD
This Body Shop Manual illustrates body structures and
service procedures for the OPTIMA/MAGENTIS.
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 OPTIMA/MAGENTIS Service Manual.
Information regarding electrical harness routing/
connections, etc. can be found in the OPTIMA/MAGENTIS
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.
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.
Copyright c 2005, Kia Motors Corporation
Printed in Korea, September 2005
Pub. No. : A2GB-EG58A (English)
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.
Kia Motors Corporation
SEOUL, KOREA
CONTENTS
Title
General Information
Body Construction
Body Dimensions
Body Panel Repair Procedure
Body Sealing Locations
Corrosion Protection
Body Modification Tools
Plastic Parts
Group
GI
BC
BD
BP
BS
CP
BT
PP

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Summary of Contents for Kia Optima

  • Page 1 Printed in Korea, September 2005 Pub. No. : A2GB-EG58A (English) 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.
  • Page 2 IMPORTANT SAFETY NOTICE 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.

  • Page 3: Table Of Contents

    General Information 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 ..........

  • Page 4: Fundamental Procedures Vehicle Protection

    GI-2 GENERAL INFORMATION FUNDAMENTAL PROCEDURES A WORD ABOUT SAFETY Wear the appropriate safety equipment that is VEHICLE PROTECTION necessary for the procedure being performed. Cover the seats before performing any procedure to keep them from getting dirty. Safety glasses Cover all glasses, seats and mats with a heat resistant Ear protectors Mask cover when welding.

  • Page 5: Welding Procedures

    GENERAL INFORMATION GI-3 WELDING PROCEDURES Observe the following tips when welding. Wear appropriate eye protection. Carefully follow the manufacturers operating instructions for the welding machine you are using. Do not weld, smoke or allow open flames around volatile chemicals, cleaners or solvents or in any area where they have just been used.

  • Page 6: For Best Results Disassembly

    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).
  • Page 7 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.

  • Page 8: Preparation Of Assembly

    GI-6 GENERAL INFORMATION 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.

  • Page 9: Assembly

    GENERAL INFORMATION GI-7 ASSEMBLY Measuring dimensions before welding When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after checking the gaps with nearby parts. Caution when welding The number of welding points should be determined based on the criteria below: Spot welding Plug welding Increase the number of...

  • Page 10: Rustproof Treatment After Assembly

    GI-8 GENERAL INFORMATION RUSTPROOF TREATMENT AFTER ASSEMBLY Body sealing Apply body sealer where necessary. Applying rustproof material Apply rustproofing material(wax, oil, etc.) behind welded area. BMGGI6012 Applying undercoat Apply undercoat on the body where necessary.

  • Page 11: Vehicle Lift (2-Support Type) And Safety Stand Positions

    GENERAL INFORMATION GI-9 VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS Place the lift blocks under the support points as shown in the illustration Raise the hoist a few inches and rock the vehicle to be sure it is firmly supported. Raise the hoist to full height to inspect the lift points for secure support.

  • Page 12: Jack Support Positions

    GI-10 GENERAL INFORMATION JACK SUPPORT POSITIONS BMGGI6013...
  • Page 13 Body Construction BODY COMPONENTS ......... BC - 2 ZINC-GALVANIZED STEEL PANELS ..BC - 4 HIGH STRENGTH STEEL PANELS ..BC - 6...
  • Page 14 BC-2 BODY CONSTRUCTION BODY COMPONENTS Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destination. BMGBC6001...
  • Page 15 BODY CONSTRUCTION BC-3 1. Radiator support lower member 55. Rear package tray side front panel 2. Radiator support upper member 56. Rear package tray side rear panel 3. Radiator support center member 57. Cowl top upper reinforcement 4. Fender panel 58.
  • Page 16 BC-4 BODY CONSTRUCTION ZINC-GALVANIZED STEEL PANELS Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency below. BMGBC6002...
  • Page 17 BODY CONSTRUCTION BC-5 1. Radiator support lower member 55. Rear package tray side front panel 2. Radiator support upper member 56. Rear package tray side rear panel 3. Radiator support center member 57. Cowl top upper reinforcement 4. Fender panel 58.
  • Page 18 BC-6 BODY CONSTRUCTION HIGH STRENGTH STEEL PANELS Because high strength steel panel has excellent resistance, it is used in areas which have a high posibility of painting deficiency below. BMGBC6003...
  • Page 19 BODY CONSTRUCTION BC-7 1. Radiator support lower member 55. Rear package tray side front panel 2. Radiator support upper member 56. Rear package tray side rear panel 3. Radiator support center member 57. Cowl top upper reinforcement 4. Fender panel 58.
  • Page 20 Body Dimensions GENERAL ............BD - 2 MEASUREMENT METHOD ....... BD - 2 PROJECTED DIMENSIONS ......BD - 2 ACTUAL-MEASUREMENT DIMENSIONS ..BD - 3 MEASUREMENT POINT ........BD - 3 FRONT BODY ..........BD - 4 SIDE BODY ............BD - 6 INTERIOR A .............

  • Page 21: General

    BD-2 BODY DIMENSIONS GENERAL MEASUREMENT METHOD PROJECTED DIMENSIONS Basically, all measurements in this manual are taken with a tracking gauge. These are the dimensions measured when the measurement points are projected into the reference When a measuring tape is used, check to be sure there plane, and are the reference dimensions used for body is no elongation, twisting or bending.

  • Page 22: Actual-Measurement Dimensions

    BODY DIMENSIONS BD-3 ACTUAL-MEASUREMENT DIMENSIONS MEASUREMENT POINT These dimensions indicate the actual linear distance Measurements should be taken at the hole center. between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement. Measure by first adjusting both probes to the same length (A=A') CAUTION...

  • Page 23: Front Body

    BD-4 BODY DIMENSIONS FRONT BODY BMGBD6001 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol A-A' A-B' B-B' C-C' D-D' D-E' Length(mm) 1416 1660 1585 1178 1054 Point symbol D'-E' D'-E E-E' F-F' G-G' G-H' H-H' Length(mm) 1054 1505 1476...
  • Page 24 BODY DIMENSIONS BD-5 A,A' C,C' B,B' BMGBD6002 BMGBD6003 BMGBD6004 Front end module mounting hole Hood hinge mounting hole (ø11) Tooling hole (ø11) (ø9) E,E' BMGBD6005 BMGBD6006 BMGBD6007 Engine bracket mounting hole Transaxle bracket mounting hole Wiring mounting hole (S7x12) (ø15) (ø15) H,H' G,G'...

  • Page 25: Side Body

    BD-6 BODY DIMENSIONS SIDE BODY BMGBD6101 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol Length(mm) 1217 1164 1117 Point symbol Length(mm) 1103 1128 1174 1082 1196 Point symbol Length(mm)
  • Page 26 BODY DIMENSIONS BD-7 BMGBD6102 BMGBD6103 BMGBD6104 Tooling hole (ø10) Wiring mounting hole (S7x12) Front door upper hinge mounting hole (ø13) BMGBD6105 BMGBD6105A BMGBD6106 Front door lower hinge mounting Fender mounting hole (ø10) Rear door upper hinge mounting hole (ø13) hole (ø13) BMGBD6107 BMGBD6108...

  • Page 27: Interior A

    BD-8 BODY DIMENSIONS INTERIOR A BMGBD6201 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-H' Length(mm) 1222 1389 1450 1235 1429 1423 1205 1456 Point symbol K-K' Length(mm) 1457...
  • Page 28 BODY DIMENSIONS BD-9 B,B' C,C' A,A' BMGBD6202 BMGBD6203 BMGBD6204 Front trim mounting hole (ø8.5) Front cab mounting hole (ø6.6) Front cowl side trim mounting hole (ø8.5) F,F' E,E' D,D' BMGBD6205 BMGBD6206 BMGBD6207 Front seatbelt mounting hole Center pillar lower trim mounting Front seatbelt retractor mounting (ø16) hole...

  • Page 29: Interior B

    BD-10 BODY DIMENSIONS INTERIOR B M M' BMGBD6301 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol M-A' M-B' M-C' M-D' M-E' M-F' M-G' M-H' Length(mm) 1111 1147 1021 1144 1565 1393 Point symbol M-K' Length(mm) 1244...
  • Page 30 BODY DIMENSIONS BD-11 B,B' C,C' A,A' BMGBD6202 BMGBD6203 BMGBD6204 Front trim mounting hole (ø8.5) Front cab mounting hole (ø6.6) Front cowl side trim mounting hole (ø8.5) F,F' E,E' D,D' BMGBD6205 BMGBD6206 BMGBD6207 Front seatbelt mounting hole Center pillar lower trim mounting Front seatbelt retractor mounting (ø16) hole...

  • Page 31: Interior C

    BD-12 BODY DIMENSIONS INTERIOR C BMGBD6401 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol N-A' N-B' N-C' N-D' N-E' N-F' N-G' N-H' Length(mm) 1380 1560 1557 1074 1142 Point symbol N-K' Length(mm)
  • Page 32 BODY DIMENSIONS BD-13 B,B' C,C' A,A' BMGBD6202 BMGBD6203 BMGBD6204 Front trim mounting hole (ø8.5) Front cab mounting hole (ø6.6) Front cowl side trim mounting hole (ø8.5) F,F' E,E' D,D' BMGBD6205 BMGBD6206 BMGBD6207 Front seatbelt mounting hole Center pillar lower trim mounting Front seatbelt retractor mounting (ø16) hole...

  • Page 33: Rear Body

    BD-14 BODY DIMENSIONS REAR BODY BMGBD6501 * These dimensions indicated in this figure are projected dimensions. Point symbol A-A' A-B' B-B' B-G' C-C' D-D' D-G' Length(mm) 1085 1303 1206 1243 Point symbol E-E' E-F' Length(mm) 1119 1227...
  • Page 34 BODY DIMENSIONS BD-15 A,A' B,B' BMGBD6502 BMGBD6503 BMGBD6504 Rear roof edge C Pillar edge Tooling hole (ø7) E,E' D,D' BMGBD6505 BMGBD6506 BMGBD6507 Tooling hole (ø7) Trunk hinge mounting hole (ø9) Rear bumper mounting hole ( 8.5x8.5) F,F' G,G' BMGBD6508 BMGBD6509 Tooling hole (ø16) Trim mounting hole...

  • Page 35: Under Body

    BD-16 BODY DIMENSIONS UNDER BODY ( PROJECTED DIMENSIONS ) BMGBD6600 * These dimensions indicated in this figure are projected dimensions. Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-H' Length(mm) 1004 1012 1130 1023 Point symbol K-K' M-M' N-N' Length(mm) 1089.5 1028...
  • Page 36 BODY DIMENSIONS BD-17 A,A' B,B' C,C' BMGBD6601 BMGBD6601A BMGBD6602 Tooling hole (ø25) Sub frame front mounting hole Sub frame rear pipe nut (ø16) (ø25) F,F' D,D' E,E' BMGBD6602A BMGBD6603 BMGBD6603A Passage stay mounting hole Tooling hole (ø10) Tooling hole (ø10) (ø13) K,K' H,H'...
  • Page 37 BD-18 BODY DIMENSIONS UNDER BODY ( ACTUAL MEASUREMENT DIMENSIONS ) BMGBD6701 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol A-A' A-B' A'-D B-D' B'-E C-C' D'-E D-F' Length(mm) 1004 1028.5 1439 1321.7 2048 1223.5 1510.5 Point symbol D'-G E'-F E-G'...
  • Page 38 BODY DIMENSIONS BD-19 A,A' B,B' C,C' BMGBD6601 BMGBD6601A BMGBD6602 Tooling hole (ø25) Sub frame front mounting hole Sub frame rear pipe nut (ø16) (ø25) F,F' D,D' E,E' BMGBD6602A BMGBD6603 BMGBD6603A Passage stay mounting hole Tooling hole (ø10) Tooling hole (ø10) (ø13) K,K' H,H'...
  • Page 39 Body Panel Repair Procedure REPLACING BODY PANELS CODES FOR REMOVING AND INSTALLING BODY PANELS ......BP - 2 NOTES WHEN WELDING BODY REMOVING SPOT WELDED AREA ....BP - 3 INSTALLING A NEW BODY FRAME ....BP - 5 DETERMINING A WELDING METHOD ... BP - 5 SPOT WELDING ..........

  • Page 40: Replacing Body Panels Codes For Removing And Installing Body Panels

    BP-2 BODY PANEL REPAIR PROCEDURE REPLACING BODY PANELS CODES FOR REMOVING AND INSTALLING BODY PANELS 0.8~1.2 in. (20~30 mm) 0.8~1.2 in. (20~30 mm) Location for cut and assembly Rough cutting location BVQBP6001...

  • Page 41: Notes When Welding Body Removing Spot Welded Area

    BODY PANEL REPAIR PROCEDURE BP-3 NOTES WHEN WELDING BODY REMOVING SPOT WELDED AREA Most body parts are spot welded. In order to remove the damaged area, it is best to remove the spot welded area from the body frame using a spot cutter or candle type edge drill bit. Do not use a drill bit with a tapered edge.
  • Page 42 BP-4 BODY PANEL REPAIR PROCEDURE Center punch the middle(nugget) of the spot weld. Otherwise, This part will not be cut. This part will be cut. Spot welded area can be removed from the body frame. Spot welded area cannot be removed from the body frame.

  • Page 43: Installing A New Body Frame

    BODY PANEL REPAIR PROCEDURE BP-5 INSTALLING A NEW BODY FRAME The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness of plate, shape and size of a cross section, damage of parts, variance of joints, welding method, and/or welding locations. Therefore, a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the body.

  • Page 44: Carbon Arc Welding

    BP-6 BODY PANEL REPAIR PROCEDURE CARBON ARC WELDING Do not weld on the edge of the flange joint. In areas where spot welding is not suitable, do plug welding using a carbon are welding machine. Clamp the parts to be welded together tightly. Do not exceed 1 mm of space between parts.

  • Page 45: Replacing Body Panel Removal

    BODY PANEL REPAIR PROCEDURE BP-7 REPLACING BODY PANEL Cutting rough area for replacement part Cutting should be done according to the following steps REMOVAL to make removal easy: Use care when cutting an area close to a pipe or Body measurement wiring harness.
  • Page 46 BP-8 BODY PANEL REPAIR PROCEDURE Determine a cutting method Cutting a spot welded area Make a hole in the middle of spot welded area with a punch, remove welded area using a spot cutter and remove using a chisel. BVQBP6014 Removing brazed area Remove using a torch and wire brush, and chisel.

  • Page 47: Preparation For Installation

    BODY PANEL REPAIR PROCEDURE BP-9 PREPARATION FOR INSTALLATION Preparation for spot welding Remove paint on spot welded area and on the area Spot weld finish overlapped by the new part using a belt sander or Use a disk grinder or similar tool to finish spot weld similar tool.

  • Page 48: Installation

    BP-10 BODY PANEL REPAIR PROCEDURE INSTALLATION 2. Selecting number of welding points Spot welding : Multiply the original number of Checking welding and fitting in advance factory welds by 1.3 times When installing a new par t, measure the Plug welding : Same number as original number dimensions of each part according to the body of factory welds dimensions given in Section 31, and set part to...
  • Page 49 BODY PANEL REPAIR PROCEDURE BP-11 The tip of the spot welding machine should be Finish areas that have been brazed by applying maintained to a minimum tolerance of 3 mm. Also body filler then smooth the area with a flexible file let area cool after 5 or 6 welds to minimize and sander.

  • Page 50: Front Side Member Removal

    BP-12 BODY PANEL REPAIR PROCEDURE FRONT SIDE MEMBER Drill out all the spotwelds to separate front side member outer front extension from front side member. REMOVAL NOTE NOTE When spotwelded portions are not apparent, remove This procedure is to be used only for repair of minor damage paint with a rotary wire brush.

  • Page 51: Installation

    BODY PANEL REPAIR PROCEDURE BP-13 INSTALLATION NOTE Take care not to cut through front side member inner Transcribe the front side member inner and outer cutline reinforcement. to the new front side member, cut to length and chamfer butt end to improve weld surface. 3.
  • Page 52 BP-14 BODY PANEL REPAIR PROCEDURE Measure each measurement point ( Refer to the BODY Apply an anti-corrosion agent as required(Refer to the DIMENSIONS) and correct the installation position. CORROSION PROTECTION). Prepare the exterior surfaces for priming using wax and grease remover. 10.

  • Page 53: Fender Apron Inner Front Panel

    BODY PANEL REPAIR PROCEDURE BP-15 FENDER APRON INNER FRONT PANEL Remove the fender apron inner front panel. AND FENDER APRON UPPER MEMBER Before removing the fender apron upper member, remove fender apron inner front panel assembly previously. BMGBP6103 Measure and mark the vertical cutlines on fender apron upper member hole edge.

  • Page 54: Installation

    BP-16 BODY PANEL REPAIR PROCEDURE INSTALLATION Cut through the fender apron upper member inner and outer at cutlines. Transcribe the fender apron upper member inner and outer cutline to the new fender apron upper member, cut to length and chamfer butt end to improve weld surface.
  • Page 55 BODY PANEL REPAIR PROCEDURE BP-17 MIG butt weld all seams. Fit and clamp the fender apron inner front panel inner and outer in place. Prepare all surfaces to be welded. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. BMGBP6103B Clean MIG welds with a disc grinder.
  • Page 56 BP-18 BODY PANEL REPAIR PROCEDURE 13. Apply an anti-corrosion agent as required (Refer to the 20. After completing body repairs, carefully apply under CORROSION PROTECTION). coating to the fender apron complete panel assembly (Refer to the CORROSION PROTECTION). 14. Prepare the exterior surfaces for priming using wax and grease remover.

  • Page 57: Side Sill Panel Removal

    BODY PANEL REPAIR PROCEDURE BP-19 SIDE SILL PANEL Cut through the side sill outer panel at cutlines. REMOVAL Measure and mark vertical cutting line from the rear door step trim mounting hole on the side sill outer panel. 110 mm BMGBP6201D Drill out the spotwelds, attaching to the side sill outer panel to side sill reinforcement.
  • Page 58 BP-20 BODY PANEL REPAIR PROCEDURE INSTLLATION After removing, apply the welding primer. Transcribe cutline dimension to side sill outer panel, adding 30mm overlap to rear end and cut to length. Using service panel for replacement of side sill outer panel, drill 8mm holes in overlap areas and along upper and lower flanges.
  • Page 59 BODY PANEL REPAIR PROCEDURE BP-21 Clean and prepare all welds and remove all residue. Apply an anti-corrosion agent to welded parts and interior of the side sill (Refer to the CORROSION PROTECTION). Prepare the exterior surfaces for priming, using wax and grease remover.

  • Page 60: Front Pillar Removal

    BP-22 BODY PANEL REPAIR PROCEDURE FRONT PILLAR To remove the front pillar, grind away and drill out all welds attaching the cowl side upper outer panel as REMOVAL shown in the illustration. Measure and mark the each cutline on the front outer NOTE pillar at 140mm from side outer panel angular point as If it is possible that the cowl side upper other panel is...
  • Page 61 BODY PANEL REPAIR PROCEDURE BP-23 Before cutting front pillar, be sure to support roof panel. 10. Cut the side outer reinforcement as shown in the illustration. 11. Cut the side sill inner panel vertical cutting line end remove the front pillar. BMGBP6302 Cut front pillar through each cutline, tasking care not to damage the other panel as illustration.

  • Page 62: Installation

    BP-24 BODY PANEL REPAIR PROCEDURE INSTALLATION Transcribe the cutline to new side inner panel, adding 30mm overlap to end and cut to length. Transcribe the cutline to the new side inner panel, cut to length and chamfer butt end to improve weld surface. Drill 6mm holes in the side inner panel for MIG welding.
  • Page 63 BODY PANEL REPAIR PROCEDURE BP-25 11. MIG butt weld front pillar outer panel and side sill outer reinforcement seams. 12. Reattach the cut away front pillar outer panel section, then MIG butt weld. 100 mm Front pillar outer panel section BMGBP6304A 13.

  • Page 64: Center Pillar Removal

    BP-26 BODY PANEL REPAIR PROCEDURE CENTER PILLAR Before cutting center pillar, be sure to support roof panel. REMOVAL Measure and mark the horizontal cutting line on center pillar outer panel as indicated in the illustration. 100 mm 70 mm 70 mm BMGBP6408A Drill out all spotwelds attaching the center outer pillar to the body to remove center outer pillar.
  • Page 65 BODY PANEL REPAIR PROCEDURE BP-27 Cut through center outer pillar and side sill outer panel After cutting side outer panel (center pillar outer & side at cutlines. sill), cut the center pillar outer reinforcement and center pillar inner panel. NOTE When cutting side sill outer panel take care not to cut through mating flanges or side outer reinforcement.
  • Page 66 BP-28 BODY PANEL REPAIR PROCEDURE INSTLLATION Determine if the side outer reinforcement is damaged and needs to be replaced. If replacing is necessary, In order to install center inner pillar drill out all spotwelds mark out the damaged portion of the reinforcement. attaching the roof side outer rail to center inner pillar to Cut at cutlines and remove damaged portion.
  • Page 67 BODY PANEL REPAIR PROCEDURE BP-29 MIG butt weld all seams in center inner pillar and sill Transcribe the cutting line dimensions to the new side side outer reinforcement as shown in the illustration. sill outer reinforcement, adding 30mm overlap to each end and cut to length.
  • Page 68 BP-30 BODY PANEL REPAIR PROCEDURE 12. Check the fit of the front and rear doors. 20. Apply metal conditioner and water rinse. 13. Reinstall center outer pillar and screw in place. 21. Apply conversion coating and water rinse. 14. MIG plug weld all holes and MIG butt weld all seams. 22.

  • Page 69: Quarter Panel Removal

    BODY PANEL REPAIR PROCEDURE BP-31 QUARTER PANEL Drill out all attaching spotwelds on the quarter outer panel, including the seam around the door lip opening. REMOVAL Depending on the extend of damage, measure and mark cutlines on the quarter outer panel as indicated in the illustration.
  • Page 70 BP-32 BODY PANEL REPAIR PROCEDURE INSTLLATION Cut the quarter outer panel at cutlines and remove the quarter outer panel as illustration. Transcribe the cutline to the new quarter outer panel, adding 30mm for overlap at the old joint. NOTE When cutting the quarter outer panel, be careful not to Drill out 6mm holes in overlap areas and along upper cut side inner panel.
  • Page 71 BODY PANEL REPAIR PROCEDURE BP-33 Apply body filler to the welded seam. Sand and finish. 12. Apply the correct seam sealers to all joints. Apply the two-part epoxy primer to the interior of the quarter outer panel. 13. Reprime over the seam sealer to complete the repair. PRO-1250 PRO-1270 Apply an anti-corrosion agent to the welded parts and...

  • Page 72: Installation

    BP-34 BODY PANEL REPAIR PROCEDURE INSTALLATION REAR SIDE MEMBER Transcribe the cutline to the new rear floor side member. REMOVAL Cut at line and drill out the spotwelds attaching the Depending on the extent of damage, if the right side reinforcement and separate it.
  • Page 73 BODY PANEL REPAIR PROCEDURE BP-35 Apply an anti-corrosion to the interior of the rear floor 13. After completing body repairs, carefully apply under side member coating to the under body (Refer to the CORROSION (Refer to the CORROSION PROTECTION). PROTECTION). Prepare exterior surfaces for priming, using wax and 14.
  • Page 74 Body Sealing Locations FLOOR .............. BS - 2 UNDER BODY ..........BS - 4 SIDE BODY ............BS - 5 DOOR .............. BS - 7 HOOD .............. BS - 11 TRUNK LID ............BS - 12...

  • Page 75: Floor

    BS-2 BODY SEALING LOCATIONS FLOOR < Views > BMGBS600A BMGBS6001 BMGBS6002 BMGBS6003 BMGBS6004...
  • Page 76 BODY SEALING LOCATIONS BS-3 BMGBS6005 BMGBS6006 BMGBS6007 BMGBS6008 BMGBS6009 BMGBS6010 BMGBS6011...

  • Page 77: Under Body

    BS-4 BODY SEALING LOCATIONS UNDER BODY < Views > BMGBS600B BMGBS6012 BMGBS6013 BMGBS6014 BMGBS6015...

  • Page 78: Side Body

    BODY SEALING LOCATIONS BS-5 SIDE BODY < Views > BMGBS6100 BMGBS6101 BMGBS6102...
  • Page 79 BS-6 BODY SEALING LOCATIONS BMGBS6103 BMGBS6104 BMGBS6105 BMGBS6106 BMGBS6107 BMGBS6108 BMGBS6109...

  • Page 80: Door

    BODY SEALING LOCATIONS BS-7 DOOR < Views > BMGBS6200 Front door Front door frame assembly frame assembly Front door outer panel Front door inner panel BMGBS6201 BMGBS6202 Front door frame assembly Front door Front door frame assembly inner panel Front door outer panel BMGBS6203 BMGBS6204...
  • Page 81 BS-8 BODY SEALING LOCATIONS Rear door frame assembly Rear door frame assembly Rear door outer panel Rear door inner panel BMGBS6205 BMGBS6206 Rear door frame assembly Rear door frame assembly Rear door inner panel Rear door outer panel BMGBS6207 BMGBS6208 BMGBS6209...
  • Page 82 BODY SEALING LOCATIONS BS-9 < Section > BMGBS6210 A - A' B - B' BMGBS6211 BMGBS6212 C - C' D - D' BMGBS6213 BMGBS6214...
  • Page 83 BS-10 BODY SEALING LOCATIONS E - E' BMGBS6215...

  • Page 84: Hood

    BODY SEALING LOCATIONS BS-11 HOOD < Section > BMGBS6300 Hood outer panel Hood rail Hood inner panel A - A' BMGBS6301 B - B' C - C' BMGBS6303 BMGBS6302...

  • Page 85: Trunk Lid

    BS-12 BODY SEALING LOCATIONS TRUNK LID < Section > BMGBS6400 5 mm Trunk lid outer panel assembly Trunk lid Trunk lid outer panel assembly inner panel B - B' Trunk lid inner panel BMGBS6402 Trunk lid outer panel Trunk lid inner panel A - A' C - C'...
  • Page 86 Corrosion Protection ZINC-GALVANIZED STEEL PANELS ..CP - 2 ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER ... CP - 4 ANTIVIBRATION PADS-LOCATION & SECTION ............CP - 5 UNDER BODY COAT ........CP - 8 CAVITY WAX INJECTION ......CP - 11 ANTI-CORROSION AGENT ......

  • Page 87: Zinc-Galvanized Steel Panels

    CP-2 CORROSION PROTECTION ZINC-GALVANIZED STEEL PANELS Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency below. BMGBC6002...
  • Page 88 CORROSION PROTECTION CP-3 1. Radiator support lower member 55. Rear package tray side front panel 2. Radiator support upper member 56. Rear package tray side rear panel 3. Radiator support center member 57. Cowl top upper reinforcement 4. Fender panel 58.

  • Page 89: Zinc-Phosphate Coat & Cationic Electrodeposition Primer

    CP-4 CORROSION PROTECTION ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER In order to improve the adhesion of the paint coat on the steel panel, and also to improve the corrosion resistance, the entire body is coated with a film of Zinc-phosphate and a cationic electrodeposition primer. Cationic electrodeposition primer Zinc-phosphate film Body steel panel...

  • Page 90: Antivibration Pads-Location & Section

    CORROSION PROTECTION CP-5 ANTIVIBRATION PADS-LOCATION & SECTION 84123-2G000 84125-2G000 84161-2G000 84172-2G000 84172-2G400 84128-2G000 (LHD) 84128-2G900 (RHD) 84113-2G000 84115-2G000 84151-2G000 84171-2G000 84171-2G000 [ LPI ] BMGCP6100 Dash panel 84113/23-2G000 84113/23-2G000 Dash panel A - A B - B BMGCP6101 BMGCP6102 BVQCP6400 Center floor panel Center floor panel 29mm...
  • Page 91 CP-6 CORROSION PROTECTION Front seat mounting member Rear seat inner mounting bracket 84113/23-2G000 84115/25-2G000 15mm 20mm 84115/25-2G000 Center floor panel Center floor side member E - E F - F BMGCP6105 BMGCP6106 Cowl top upper reinforcement Cowl top panel 84151/61-2G000 22mm Cowl top lower reinforcement...
  • Page 92 CORROSION PROTECTION CP-7 ATTACHMENT OF ANTIVIBRATION PADS Antivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat. If these antivibration pads are peeled off in the course of replacement or repair of a welded panel, cut and attach replacement material (in the shape shown in the figure).

  • Page 93: Under Body Coat

    CP-8 CORROSION PROTECTION UNDER BODY COAT In order to provide corrosion, stone chipping and vibration resistance, under body coat is applied to the under sides of the floor and wheel house. Therefore, when such panel is replaced or repaired, apply under body coat to that part. FLOOR Because parts are to be mounted in these locations, mask the location, before applying the under body coat.
  • Page 94 CORROSION PROTECTION CP-9 SIDE BODY Because parts are to be mounted in these locations, mask the location, before applying the under body coat. Under body coating ( Thickness : 1.0 mm , : 1.5 mm ) BMGCP6300 Feder apron upper inner panel Shock absorber housing lower panel...
  • Page 95 CP-10 CORROSION PROTECTION Rear suspension Wheel house mounting bracket inner panel VIEW "W" VIEW "Z" BMGCP6305 BMGCP6306...

  • Page 96: Cavity Wax Injection

    CORROSION PROTECTION CP-11 CAVITY WAX INJECTION In order to provide greater corrosion resistance, cavity wax injection has been performed for the lower areas of the vehicle, such as the sidemember, the side sill and the inside of other panels which are a hollow construction. When replacing these parts, be such to apply cavity wax to the appropriate areas of the new parts.
  • Page 97 CP-12 CORROSION PROTECTION Wax injection Wax injection holes (2places) holes (2places) Wax injection holes (2places) Wax injection holes (2places) Wax injection must be done through access holess marked. Cavity wax injection (Thickness 40 - 50 ) Wax injection holes (2places) BMGCP6500 Trunk lid outer panel assembly...
  • Page 98 CORROSION PROTECTION CP-13 Wax injection holes (6places) Wax injection must be done through access holess marked. Cavity wax injection (Thickness 40 - 50 ) BMGCP6505 A - A, A' - A' V, V BMGCP6506 BMGCP6507...

  • Page 99: Anti-Corrosion Agent

    CP-14 CORROSION PROTECTION UNDER BODY ANTI-CORROSION AGENT The undersides of the floor and wheel house are undercoated to provide greater corrosion resistance. Therefore, when such panel is replaced or repaired, apply under body anti-corrosion agent to that part. NOTE Do not apply the under body anti-corrosion agent to come in contact with tires, muffler and exhaust pipe. BMGCP6600 150 mm Side sill module...
  • Page 100 Body Modification Tools MODIFICATION TOOLS ......BT - 2 CUT AND DISASSEMBLY TOOLS ..BT - 3 ASSEMBLY TOOLS ........BT - 4 MEASUREMENT TOOLS ......BT - 4 WELDING MACHINE ........BT - 5 BUFFING AND GRINDING TOOLS ..BT - 6 HANDHELD TOOLS ........

  • Page 101: Modification Tools

    BT-2 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS MODIFICATION TOOLS Name Used for Figure A3EB3501 Frame straightener Modify twisted or bent body A3EB3502 A3EB3503 Port power Push out, stretch, pull in damaged area A3EB3504 Body puller Stretch damaged area A3EB3505...

  • Page 102: Cut And Disassembly Tools

    BODY MODIFICATION TOOLS BT-3 CUT AND DISASSEMBLY TOOLS Name Used for Figure Air saw Cut a panel A3EB3506 Cut or bend a panel, cut and Air chisel disassemble spot welded area A3EB3507 Rotary cutter Cut a panel A3EB3508 Hand saw and Cut a panel metal scissors A3EB3509...

  • Page 103: Assembly Tools

    BT-4 BODY MODIFICATION TOOLS ASSEMBLY TOOLS Name Used for Figure Vice pliers Fix a panel or area to weld A3EB3512 Finish contact area of flange and finish Air bench a hole for plug welding A3EB3513 Finish a hole for plug welding Quick bench A3EB3514 Flanging tool...

  • Page 104: Welding Machine

    BODY MODIFICATION TOOLS BT-5 WELDING MACHINE Name Used for Figure Gas welding machine Cut a panel A3EB3518 Spot welding machine Weld a panel A3EB3519 Carbon arc welding Weld a panel machine A3EB3520 Stretch a panel, weld a stud bolt to fix Stud welding machine front window mold clip A3EB3521...

  • Page 105: Buffing And Grinding Tools

    BT-6 BODY MODIFICATION TOOLS BUFFING AND GRINDING TOOLS Name Used for Figure Disk grinder Buff A3EB3522 Disk sander Buff A3EB3523 Belt sander Buff paints A3EB3524 Small sized grinder Buff paints or smooth finishing A3EB3525 Grind rough area of puttee assembled Double action sander area A3EB3526...
  • Page 106 BODY MODIFICATION TOOLS BT-7 Name Used for Figure Orbital sander(long) Used for puttee grinding of wide area A3EB3528 Grind touch up area, uneven area of a Flexible file panel A3EB3529 Surform tool Buff rough area of puttee area A3EB3506 A3EB3530 Hand file Grind body puttee, pulley, finish puttee A3EB3531...

  • Page 107: Handheld Tools

    BT-8 BODY MODIFICATION TOOLS HANDHELD TOOLS Name Used for Figure Body hammer and dolly A3EB3532 Punch a hole in the middle of a spot Center punch welding area A3EB3533 Plane chisel Cut and disassemble a panel A3EB3534 Weight hammer Used when greater force is required A3EB3535 Bowl pin hammer Used when smaller force is required...

  • Page 108: Repair Tools Set

    BODY MODIFICATION TOOLS BT-9 Name Used for Figure Bend rough body line damaged or sheet Body chisel metal etc. A3EB3538 Remove paints, rust, slag on welded Wire brush area which are hard to recognize A3EB3539 REPAIR TOOLS SET Name Used for Figure Window tool set Repair window collar...
  • Page 109 Plastic Parts POLYPROPYLENE(PP) BUMPER REPAIRABILITY ..........PP - 2 BUMPER REPAIR PROCEDURE ....PP - 3 REPAIR METHOD FOR PP BUMPER ..... PP - 4...
  • Page 110 PP-2 PLASTIC PARTS POLYPROPYLENE(PP) BUMPER REPAIRABILITY The three types of damaged bumpers shown below can be repaired. Because of cost and quality considerations, bumpers with more damage may be repaired, but replacing the bumper is encouraged. If a hole on a bumper is less than 2 in.(50 mm). A3EB3601 If a crack on a bumper is less than 4 in.(100 mm).
  • Page 111 PLASTIC PARTS PP-3 BUMPER REPAIR PROCEDURE Surface of Surface of Remove paint. bumper is not bumper is visible. visible. Sand damaged area smooth. Apply aluminum tape on the rear side of bumper. Replace damaged bumper with a new bumper. Apply primer for polypropylene over bumper surface.
  • Page 112 PP-4 PLASTIC PARTS REPAIR METHOD FOR PP BUMPER Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Use the repair methods shown below to repair damage that reaches the surface of the polypropylene. Hole Crack Scar...
  • Page 113 PLASTIC PARTS PP-5 Welding damaged area To repair cracked area, melt the area using a heat gun and attachment. Heat gun Melt the surface using a heat gun. Apply on surface Surface of polypropylene Section view after melt VQPP004 To repair a hole, remove oil from the damaged area and apply aluminum tape to the rear side of the damaged area. Section A-A’...
  • Page 114 PP-6 PLASTIC PARTS Grind polypropylene surface carefully. It melts easily due to the heat generated by friction. If melted, remove that area. Also, grind the area where solvent is to be applied. Area to apply solvent Do not grind continuously. Paint Grind painted area and rough surface.
  • Page 115 PLASTIC PARTS PP-7 Sand the damaged area with sandpaper using #180~#240 grit paper. Sand the damaged area with sandpaper using #180~#240 grit paper. NOTE NOTE • • The surface will not be even if excessive force is applied during sanding. The surface will not be even if excessive force is applied during sanding.

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