Kia Sportage Body Workshop Manual

Kia Sportage Body Workshop Manual
Body shop Manual
FOREWORD
This Body Shop Manual illustrates body structures and
service procedures for the SPORTAGE.
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 SPORTAGE Service Manual. Information
regarding electrical harness routing/ connections, etc.
can be found in the SPORTAGE Electrical Troubleshooting
Manual.
CONTENTS
Title
Group
GENERAL INFORMATION
00
BODY STRUCTURE
11
REPLACING BODY PANELS
21
BODY DIMENSIONS
31
WATERPROOFING AND
RUSTPROOFING
41
BODY MODIFICATION TOOLS
51
PLASTIC PARTS
61
The descriptions and specifications contained in this
manual were in effect at the time this manual was
approved for printing. Kia Motors Corporation reserves
the right to discontinue models at any time, or change
specifications or design without notice and without
incurring obligation.
Kia Motors Corporation
SEOUL, KOREA
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
2004, Kia Motors Corporation
Printed in Korea, August 2004
Pub. No. : A1FB-EG48A (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.
21-18 Replacing body panels
A
E
B
C
D
C
D
E
B
A
6 Points
5 Points
BMKM030
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 body shop manual provide general directions for a service and repair.
Procedure, techniques, tools, and parts for service including the skill of the technician vary.
It is impossible to provide advice or caution as to each case in this manual.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is
not recommended by the vehicle manufacturer, must first assure thoroughly that neither their
personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement
part, service procedure, or tool they select.
IN THIS MANUAL
WARNING : Remind you to be especially careful in those areas where carelessness can
cause personal injury.
CAUTION : To prevent you from making errors that could damage the vehicle as well as
personal injury.
NOTE : Gives you added information that will help you complete a particular procedure.
The following list contains some general WARNINGS that you should follow while working on a
vehicle.
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Make sure that the ignition switch is always in the OFF position, unless otherwise required by
the procedure.
Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in
park unless instructed otherwise for a specific operation
Place supporters against the front and rear surfaces of the tires to help prevent the vehicle
from moving
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide
poisoning.
Keep yourself and your clothing away from moving parts when the engine is running,
especially the drive belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
Do not smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing
before beginning to work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the
radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even
though the ignition switch is in the OFF position. For this reason care should be taken to
ensure that the radiator fan electric motor is completely disconnected when working under the
hood and the engine is not running.
General information
General information
Fundamental procedures
Vehicle protection ........................................................................................ 00A word about safety ..................................................................................... 00Welding procedures .................................................................................... 00Body frame straightener ............................................................................. 00Electrical procedures .................................................................................. 00-
1
1
1
2
2
For best results
Disassembly .................................................................................................. 00Preparation of assembly ............................................................................ 00Assembly ........................................................................................................ 0000Rustproof treatment after assembly
3
5
6
7
Vehicle lift (2-Support type) & safety stand positions .................. 00- 8
Jack and safety stand positions ............................................................. 00- 8
Towing ..................................................................................................................00- 9
Body colors and major specifications
Kia color codes ............................................................................................ 00- 10
Paint manufacture codes ............................................................................00- 10
00
General information
00-1
2. When welding or performing other procedures that
require the use of an open flame near the fuel tank,
disconnect and remove the tank and fuel pipe, and
cap the pipe to prevent fuel leakage.
Fundamental procedures
Vehicle protection
1. Cover the seats before performing any procedure to
keep them from getting dirty.
2. Cover all glasses, seats and mats with a heat
resistant cover when welding.
ASD1BM003
Welding procedures
AFJ3B3001
3. Protect moldings, garnishes and ornaments.
A word about safety
1. Wear the appropriate safety equipment that is
necessary for the procedure being performed.
Safety
glasses
Mask
Face shield
Ear
protectors
Gloves
Safety
shoes
00003
Observe the following tips when welding.
1. Wear appropriate eye protection.
2. Carefully follow the manufacturers operating
instructions for the welding machine you are using.
3. Do not weld, smoke or allow open flames around
volatile chemicals, cleaners or solvents or in any
area where they have just been used.
00-2 General information
Body frame straightener
When using a frame straightener, do not enter the area
where the body is being straightened by the chain.
Electrical procedures
1. Disconnect the negative battery terminal.
2. Do not pull on wires when disconnecting electrical
connectors. Be careful to hold the connector itself
when disconnecting it.
3. Insert the connector until it “clicks” when connecting
the connector.
4. Handle all electrical components with care.
ba2c015f
General information
00-3
For best results
Disassembly
Measuring dimensions before beginning
Measure the dimensions of the damaged area according to the body dimension drawings before disassembling
and repairing. Adjust dimensions with body frame adjuster if deformed.
Selecting cutting area
Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding.
Select an area that would allow the new part to overlap repair area by 1.2~2.0 in (30~50 mm).
Protecting body from damage
Secure the body with clamps and jacks to prevent damage to the body when working on it.
BMKM100
00-4 General information
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.
Wire harness
Repair work area
Cutting area
1SD1BM005
General information
00-5
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.
Thicker than
0.1 in (3mm)
BMKM101
Machining holes for plug welding
Drill a hole of approximately 0.2~0.24 in (5~6 mm) in
diameter in those areas which are not suitable for spot
welding.
Adjusting a new part
The new part should be cut larger than the repair area,
overlapping the repair area by 1.2~2.0 in (30~50 mm).
1.2~2.0 in
(30~50 mm)
Overlap
1.2~2.0 in
(30~50 mm)
Overlap
body side to modify
new part to modify
00012
ASD1BM007
00-6 General information
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:
Old part
Pitch:
1.4 in (35 mm)
Repair part
Pitch: 2.0 in (50 mm)
Increase the
number of spot
welds by 30%.
Spot welding
Repair part
more than
0.1 in (3 mm)
Plug welding
A
Pitch:
Same number of
welds as original
part.
9
BMKM102
Caution when spot welding
The tip of the spot welding machine should be maintained to a minimum of 0.1 in (3 mm) because it greatly
affects welding strength. When possible, spot welding should be done between the existing spot welded points.
Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the
welding strength.
Using a test piece(test pin)
Using a hammer and a chisel
Good
No good
Existing welded spots
New welded spots
0.1 in
(3 mm)
0.1 in
(3 mm)
Center
diameter
Nugget diameter
to be 4/5 of chip
diameter
ASD1BM010
General information
00-7
Rustproof treatment after assembly
Body sealing
Apply body sealer where necessary.
Applying rustproof material
Apply rustproofing material(wax, oil, etc.) behind welded area.
BMKM103
Applying undercoat
Apply undercoat on the body where necessary.
00-8 General information
Vehicle Lift (2-Support Type) And Safety Stand Positions
1. Place the lift blocks under the support points as shown in the illustration
2. Raise the hoist a few inches and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
Lift Block
[Rear]
Lift Block
[Front]
AAIE010A
Jack Support Positions
AAIE010B
General information
00-9
Towing
[2WD]
[4WD]
[Wheel lift]
[Flat - bed]
AAIE010C
If emergency towing is necessary, we recommend having it done by an authorized KIA dealer or a commercial towtruck service.
Profer lifting and towing procedures are necessary to prevent damage to the vehicle.
The use of wheel dollies or flatbed is recommended.
On 2WD vehicles, it is accptable to tow truck and wheel dollies are nou used, the front of the vehicle should always
be lifted, not the rear.
On 4WD vehicles, your vehicle must be towed with a wheel lift and dollies or flatbed equipment with all the wheels off
the ground.
When being towed by a commercial tow truck and wheel dollies are not used, the front of the vehicle should always
be lifted, not the rear.
00-10 General information
Body colors and major specifications
Kia color codes
Kia code
Paint color
6D
Smoky Brown
9P
Black Cherry
3P
Volcanic Red
K6
Smart Blue
1L
Vert Jade Pearl
9L
Natural Olive
Y3
Greenish Gold
S6
Satin Silver
S4
Grayish Silver
UD
Clear White
Paint manufacture codes
Kia code
Color name
Dupont
Spies
Hecker
Standox
BASF
6D
Smoky Brown
X1950
755710
6D
6D
KIA9816
6D
9P
Black Cherry
X1951
755711
9P
9P
KIA9410
9P
3P
Volcanic Red
X1952
755712
3P
3P
KIA9320
3P
K6
Smart Blue
X1953
755713
K6
K6
KIA9540
K6
1L
Vert Jade Pearl
X1954
755714
1L
1L
KIA9525
1L
9L
Natural Olive
X1955
755715
9L
9L
KIA9626
9L
Y3
Greenish Gold
X1956
755716
Y3
Y3
KIA9815
Y3
S6
Satin Silver
X1957
755717
S6
S6
KIA9739
S6
S4
Grayish Silver
X1958
755718
S4
S4
KIA9738
S4
UD
Clear White
F2756
755719
UD
UD
KIA4004
UD
Akzo
Nobel
PPG
Body structure
Body structure
Body composition
Body shell ..................................................................................................... 11- 1
Body service holes ..................................................................................... 11- 1
High tension steel sheet used area
Radiator support panel ................................................................................ 11- 2
Fender apron panel ....................................................................................... 11- 3
Cowl & Dash panel ....................................................................................... 11- 4
Side body panel ............................................................................................. 11- 5
Center floor panel .......................................................................................... 11- 6
Rear floor panel ............................................................................................. 11- 7
Roof panel(Without sunroof) .................................................
........................................... 11- 8
Roof panel (With sunroof) ........................................................................... 11- 9
Fender panel & Hood panel & Tail gate panel ........................................ 11-10
Door panel ....................................................................................................... 11-11
Zine-galvanized steel sheet used area
Radiator support panel ................................................................................ 11-12
Fender apron panel ....................................................................................... 11-13
Cowl & Dash panel ....................................................................................... 11-14
Side body panel ............................................................................................. 11-15
Center floor panel .......................................................................................... 11-16
Rear floor panel ............................................................................................. 11-17
Roof panel(Without sunroof) .................................................................... 11-18
Roof panel (With sunroof) ........................................................................... 11-19
Fender panel & Hood panel & Tail gate panel ........................................ 11-20
Door panel ....................................................................................................... 11-21
11
Body structure
11-1
Body composition
Body shell
The body consists of the body shell, frame and cross members, etc, welded together. This provides safety, durability,
noise protection, rustproofing and vibration proofing of the vehicle.
BMKM001
Body service holes
Body service holes are provided in the inner panel to improve serviceability of the body.
BMKM002
11-2 Body structure
High tension steel sheet used area
Radiator support panel
1
HIGH TENSION STEEL SHEET USED AREA
(1) Radiator support panel complete
BMKM003
Body structure
11-3
Fender apron panel
1
2
BMKM004
HIGH TENSION STEEL SHEET USED AREA
(1) Fender apron panel assembly
(2) Front side outer member assembly
11-4 Body structure
Cowl panel & Dash panel
2
1
2
3
HIGH TENSION STEEL SHEET USED AREA
(1) Cowl panel complete
(2) Cowl side outer panel
BMKM005
(3) Dash panel complete
Body structure
11-5
Side body panel
2
1
3
4
5
6
7
HIGH TENSION STEEL SHEET USED AREA
(1)
(2)
(3)
(4)
Front inner pillar assembly
Quarter inner panel assembly
Side outer rear extension assembly
Quarter outer panel assembly
BMKM 006
(5) Center outer pillar assembly
(6) Pillar outer panel assembly
(7) Side assembly outer panel
11-6 Body Structure
Center floor panel
3
4
7
2
6
5
7
1
1
4
5
3
8
10
9
HIGH TENSION STEEL SHEET USED AREA
BMKM 007
(1)
(2)
(3)
(4)
(5)
Front seat cross rear member assembly
Center floor panel
Side sill inner panel assembly
Center floor side outer member assembly
Center floor side inner member assembly
(6) Propeller shaft mounting bracket
(7) Skid plate mounting gusset
(8) Parking brake lever reinforcement assembly
(9) Front seat cross front member assembly
(10) Center support bracket
Body structure
11-7
Rear floor panel
7
2
1
2
3
4
5
6
HIGH TENSION STEEL SHEET USED AREA
(1)
(2)
(3)
(4)
Rear floor panel
Rear floor side member assembly
Rear floor upper cross member assembly
Rear floor lower No.3 cross member assembly
BMKM008
(5) Rear floor lower No.2 cross member assembly
(6) Rear floor lower No.1 cross member assembly
(7) Rear end cross member assembly
11-8 Body Structure
Roof panel (Without sunroof)
3
2
1
6
5
4
BMKM009
HIGH TENSION STEEL SHEET USED AREA
(1) Roof front rail assembly
(2) Roof rear rail assembly
(3) Roof panel
(4) Roof center No.1 rail
(5) Roof center No.2 rail
(6) Roof center No.3 rail
Body structure
11-9
Roof panel (With sunroof)
3
2
1
5
4
BMKM010
HIGH TENSION STEEL SHEET USED AREA
(1) Roof front rail assembly
(2) Roof rear rail assembly
(3) Roof panel
(4) Sunroof reinforcement
(5) Roof center No.3 rail
11-10 Body Structure
Fender panel & Hood panel & Tail gate panel
2
1
3
5
4
5
BMKM011
HIGH TENSION STEEL SHEET USED AREA
(1) Hood panel assembly
(2) Hood hinge assembly
(3) Fender panel
(4) Tail gate panel assembly
(5) Tail gate hinge assembly
Body structure
11-11
Door panel
1
3
2
7
4
BMKM012
HIGH TENSION STEEL SHEET USED AREA
(1) Front door panel assembly
(2) Rear door panel assembly
(3) Front door hinge assembly
(4) Rear door hinge assembly
11-12 Body structure
Zinc-galvanized steel sheet used area
Radiator support panel
1
ZINC-GALVANIZED STEEL SHEET USED AREA
(1) Radiator support panel complete
BMKM013
Body structure
11-13
Fender apron panel
1
2
BMKM014
ZINC-GALVANIZED STEEL SHEET USED AREA
(1) Fender apron panel assembly
(2) Front side outer member assembly
11-14 Body structure
Cowl panel & Dash panel
2
1
2
3
ZINC-GALVANIZED STEEL SHEET USED AREA
(1) Cowl panel complete
(2) Cowl side outer panel
BMKM015
(3) Dash panel complete
Body structure
11-15
Side body panel
2
1
3
4
5
6
7
ZINC-GALVANIZED STEEL SHEET USED AREA
(1)
(2)
(3)
(4)
Front inner pillar assembly
Quarter inner panel assembly
Side outer rear extension assembly
Quarter outer panel assembly
BMKM016
(5) Center outer pillar assembly
(6) Pillar outer panel assembly
(7) Side assembly outer panel
11-16 Body Structure
Center floor panel
3
4
7
2
6
5
7
1
1
4
5
3
8
10
9
ZINC-GALVANIZED STEEL SHEET USED AREA
BMKM017
(1)
(2)
(3)
(4)
(5)
Front seat cross rear member assembly
Center floor panel
Side sill inner panel assembly
Center floor side outer member assembly
Center floor side inner member assembly
(6) Propeller shaft mounting bracket
(7) Skid plate mounting gusset
(8) Parking brake lever reinforcement assembly
(9) Front seat cross front member assembly
(10) Center support bracket
Body structure
11-17
Rear floor panel
7
2
1
2
3
4
5
6
ZINC-GALVANIZED STEEL SHEET USED AREA
(1)
(2)
(3)
(4)
Rear floor panel
Rear floor side member assembly
Rear floor upper cross member assembly
Rear floor lower No.3 cross member assembly
BMKM018
(5) Rear floor lower No.2 cross member assembly
(6) Rear floor lower No.1 cross member assembly.
(7) Rear end cross member assembly
11-18 Body Structure
Roof panel (Without sunroof)
3
2
1
6
5
4
BMKM019
ZINC-GALVANIZEDw STEEL SHEET USED AREA
(1) Roof front rail assembly
(2) Roof rear rail assembly
(3) Roof panel
(4) Roof center No.1 rail
(5) Roof center No.2 rail
(6) Roof center No.3 rail
Body structure
11-19
Roof panel (With sunroof)
3
2
1
5
4
BMKM020
ZINC-GALVANIZED STEEL SHEET USED AREA
(1) Roof front rail assembly
(2) Roof rear rail assembly
(3) Roof panel
(4) Sunroof reinforcement
(5) Roof center No.3 rail
11-20 Body Structure
Fender panel & Hood panel & Tail gate panel
2
1
3
5
4
5
BMKM021
ZINC-GALVANIZED STEEL SHEET USED AREA
(1) Hood panel assembly
(2) Hood hinge assembly
(3) Fender panel
(4) Tail gate panel assembly
(5) Tail gate hinge assembly
Body structure
11-21
Door panel
1
3
2
7
4
BMKM022
ZINC-GALVANIZED STEEL SHEET USED AREA
(1) Front door panel assembly
(2) Rear door panel assembly
(3) Front door hinge assembly
(4) Rear door hinge assembly
Replacing body panels
Replacing body panels
Replacing body panels
Codes for disassembling and assembling body panels .................... 21- 1
Notes when welding body
Disassembling spot welded area ............................................................. 21Assembling a new body frame ................................................................. 21Determining a welding method ................................................................. 21Spot welding .................................................................................................. 21Carbon arc welding ..................................................................................... 21Replacing body panel ................................................................................. 21-
2
4
4
4
5
6
Fender apron panel assembly .................................................................. 21-11
Cowl panel assembly ................................................................................. 21-17
Dash panel assembly ................................................................................... 21-22
Center floor panel assembly ..................................................................... 21-26
Rear floor panel assembly ......................................................................... 21-29
Side panel assembly ................................................................................... 21-32
Roof panel assembly ................................................................................... 21-38
Back panel assembly ................................................................................... 21-43
Quarter outer rear panel assembly ........................................................ 21-45
Side sill panel assembly ............................................................................ 21-46
Wheel house panel assembly ................................................................... 21-47
21
Replacing body panels
21-1
Replacing body panels
Codes for disassembling and assembling body panels
See Notice and Cautions for disassembly
0.8~1.2 in.
(20~30 mm)
0.8~1.2 in.
(20~30 mm)
Rough cutting location
Location for cut and assembly
ARS1BD040A
21-2 Replacing body panels
Notes when welding body
Disassembling spot welded area
Most body parts are spot welded. In order to disassemble the damaged area, it is best to disassemble 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. Center punch middle of spot weld to insure the entire spot weld will be removed.
1. Spot cutter
1. Drill(candle type edge)
1. Drill(taper edge)
2.
2.
2.
3.
3.
3.
Correct
Correct
Not correct
A3EB3251
Replacing body panels
Center punch the middle(nugget) of the spot weld.
Otherwise,
This part will not be cut.
Spot welded area can be removed from the body frame.
21-3
This part will be cut.
Spot welded area cannot be removed from the body
frame.
A3EB3252
21-4 Replacing body panels
Assembling 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.
Determining a welding method
It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the
body be used when making repairs, Try to use either spot welding or carbon arc(plug) welding, Do not braze any body
components other than the ones brazed at the factory. Do not use an oxy-acetylene torch for welding.
Welding
Symbol
Details
The most reliable welding method
Spot welding
(provides high efficiency and quality of assembled part.)
Carbon arc welding
Use when spot welding cannot be done or spot welding is
(Plug welding)
not necessary.
Oxygen-acetylene welding
Not used
Spot welding
2. When spot welding, weld in the middle of the joint.
1. Commercial spot welding machines do not perform
as well as the machines used in the manufacturing
process. When spot welding, increase the number
of spot welds by 30%(1.3 times the original number
of welds).
or carbon arc(plug) welding. Do not braze any body
Good
A3EB3254
Spot welding on the edge of the joint will reduce
welding strength.
A3EB3253
No good
A3EB3255
Replacing body panels
21-5
b) Do not weld on the edge of the flange joint.
Carbon arc welding
In areas where spot welding is not suitable, do plug
welding using a carbon arc welding machine.
1. Clamp the parts to be welded together tightly. Do not
exceed 1 mm of space between parts. A tolerance
greater than 1 mm will reduce the strength of the
welded area.
No good
A3EB3257
1mm
Maximum tolerance
A3EB3256
2. Weld in the middle of the flange joint.
a) Drill a hole 5~6 mm on one side of the flange only,
and weld within the hole.
Good
A3EB3254
21-6 Replacing body panels
Replacing body panel
Disassembly
1. Body measurement
a) Before disassembling, measure the damaged area
according to the dimensions supplied in Body
Dimension, Section 31. If deformation is present,
use a frame straightener to adjust.
b) When disassembling a panel, apply clamps to
prevent damage of each part, and support the
lower end of the frame to prevent deformation
during the procedure.
2. Cut and welding point selection
Cutting, if necessary, should not be done in a
reinforcement area. Select an area which will result in
the least amount of deformation after welding.
Cut area
Reinforcement
Reinforcement
Tracking gauge
A3EB3258
3. Cutting rough area for replacement part
Cutting should be done according to the following steps
to make disassembly easy:
a) Use care when cutting an area close to a pipe or
wiring harness.
b) Cut an area leaving 30~50 mm of tolerance.
a
A3EB3261
ASD1BM005
4. Removing paint from an area to be spot welded
Using a torch and wire brush, remove paint completely
before beginning welding.
Replacing body panels
5. Determine a cutting method
a) Cutting a spot welded area
Make a hole in the middle of spot welded area with
a punch, disassemble welded area using a spot
cutter and remove using a chisel.
1SD1BM015
b) Removing brazed area
Disassemble using a torch and wire brush, and
remove with a chisel.
21-7
Preparation for assembly
1. Spot weld finish
Use a disk grinder or similar tool to finish spot weld
mark. Do not grind more than is necessary to smooth
surface.
1SD1BM018
2. Panel preparation
Repair any bent or uneven areas with a hammer to
improve the assembly process.
1SD1BM019
1SD1BM016
c) Removing arc welded area
Remove plug welded area using a disk grinder and
disassemble with a chisel.
3. Cutting a rough area for a new part
When rough cutting an area for a new part, leave a
tolerance of 30~50 mm.
1SD1BM020
1SD1BM017
21-8 Replacing body panels
4. Preparation for spot welding
Remove paint on spot welded area and on the area
overlapped by the new part using a belt sander or
similar tool.
1SD1BM021
5. Drilling a hole for plug welding
If the thickness of the part to be welded is less than 3
mm, drill a 5~6 mm diameter hole. If the thickness of
the part to be welded is greater than 3 mm, drill a hole
using a 7 mm diameter drill.
Notice
Do not spot weld where thickness is greater than
3 mm.
1SD1BM022
Replacing body panels
Assembly
1. Checking welding and fitting in advance
a) When assembling a new par t, measure the
dimensions of each part according to the body
dimensions given in Section 31, and set part to the
reference dimensions.
21-9
2. Selecting number of welding points
Spot welding : Multiply the original number of
factory welds by 1.3 times
Plug welding : Same number as original number of
factory welds
Notice
Plug welding should be done using a carbon arc
welding machine.
Brazing should be done only on areas that were
originally brazed at the factory.
Welding after repair
pitch:35 mm
Initial welding
pitch:50 mm
Spot welding:initial number of welds x1.3
Welding points-same number as original number of factory welds.
1SD1BM02004
3mm Plug welding-used when
spot welding is not
feasible or material is
thicker than 3 mm
b) Prior to final welding, check the fit of all related parts.
A3EB3259
3. Caution when spot welding
a) Do a test welding on a piece of material of the
same type and thickness as the part to be welded
and proceed if test weld is good.
b) Before spot welding, check if welding debris, oil or
paint is present on the area where surfaces meet.
Clean or sand as necessary.
Using a hammer
and a chisel
1SD1BM023
Center
diameter
3 mm
Using a test piece
Nugget
diameter:
4/5 of tip
A3EB3260
21-10 Replacing body panels
c) The tip of the spot welding machine should be
maintained to a minimum tolerance of 3 mm. Also
let area cool after 5 or 6 welds to minimize
problems caused by excessive heat.
b) Finish areas that have been brazed by applying
body filler then smooth the area with a flexible file
and sander.
3mm(0.2 in)
3mm(0.12in)
1SD1BM026
1SD1BM029
4. Cutting and welding an assembled area
To align a roof panel and a center pillar together for
butt welding, temporarily fasten a steel flange to the
roof panel and then apply the new center pillar panel.
Remove the flange when final welding is done.
6. Applying anti-rust agent and body sealer
After coating the surface with anti-rust agent, apply
body sealer where necessary.
Notice
Apply body sealer before assembly.
1SD1BM027
5. Finishing after welding
a) Grind any areas that were plug welded or butt
welded using a disk grinder. Grind carefully to avoid
removing too much material. This degrades the
strength of the weld.
1SD1BM028
1SD1BM030
7. Anti-rust treatment
Apply anti-rust agent to inside of doors and sills by
spraying through access holes provided.
A3EB3261
Replacing body panels
21-11
Fender apron panel assembly
Welding part
D
C
E
A
9 Points
E
13 Points
B
25 Points
D
B
C
A
26 Points
BMKM023
21-12 Replacing body panels
4 Points
5 Points
8 Points
7 Points
20 Points
8 Points
10 Points
20 Points
4 Points
9 Points
BMKM024
Replacing body panels
21-13
10 Points
12 Points
7 Points
16 Points
BMKM025
21-14 Replacing body panels
Setion
Engine stay
mounting bracket
Fender apron
upper inner panel
Fender apron
upper outer panel
Front side complete
member assembly
Fender apron
inner front panel
Air duct mounting bracket
Fender apron inner
front reinforcement
assembly
Fender apron
inner front panel
Fender mounting
front bracket assembly
SECTION B-B
Fender bolt mounting tape
Front side complete
member assembly
SECTION A-A
SECTION E-E
Fender apron
upper outer panel
Fender apron
upper outer panel
Fender apron
inner panel
Fender apron
inner panel
Fender apron
inner front panel
Front side complete
member assembly
SECTION C-C
Front side complete
member assembly
SECTION D-D
BMKM026
Replacing body panels
B
21-15
A
E
B
E
D
D
C
C
A
Fender apron
complete panel
Fender apron
complete panel
Dash panel
Dash panel
SECTION A-A
SECTION B-B
BMKM027
21-16 Replacing body panels
Dash panel
Dash panel
Fender apron
complete panel
SECTION C-C
SECTION D-D
Fender apron
complete panel
Dash panel
SECTION E-E
BMKM028
Replacing body panels
21-17
Cowl panel assembly
Welding part
74 Points
8 Points
8 Points
21 Points
32 Points
7 Points
BMKM029
21-18 Replacing body panels
A
E
B
C
D
C
D
E
B
A
6 Points
5 Points
BMKM030
Replacing body panels
21-19
Section
Cowl top outer
reinforcement
assembly
Cowl top
outer panel
Brake bar
mounting bracket
Cowl side inner
lower extension
Cowl inner lower
panel assembly
SECTION A-A
Cowl top outer panel
Cowl top outer
reinforcement
assembly
Plenum chamber
guide panel
Cowl inner lower panel
SECTION B-B
BMKM031
21-20 Replacing body panels
Cowl top outer panel
Cowl top outer panel
Cowl top outer
reinforcement
assembly
Cowl top outer
reinforcement
assembly
Cowl inner
lower panel
Cowl inner lower panel
SECTION C-C
SECTION D-D
Cowl top outer panel
Cowl top outer
reinforcement
assembly
Cowl side
hinge panel
Cowl inner
lower panel
SECTION E-E
BMKM032
Replacing body panels
F
21-21
G
F
G
Cowl top outer panel
Cowl top outer
reinforcement assembly
Steering column
mounting bracket
assembly
Cowl inner
lower panel
SECTION G-G
Cowl top outer panel
Cowl top outer reinforcement assembly
Cowl inner
lower panel
Brake bar mounting
brake assembly
SECTION F-F
BMKM033
21-22 Replacing body panels
Dash panel assembly
Welding part
58 Points
E
D
A
B
D
C
58 Points
C
F
A
F
B
E
33 Points
5 Points
3 Points
56 Points
21 Points
BMKM034
Replacing body panels
21-23
Section
Dash side
member assembly
Dash panel
Dash reinforcement
assembly
Dash panel
Foot rest bracket
SECTION A-A
SECTION B-B
Dash panel
Dash side
member assembly
Dash side
member assembly
Dash center support
member assembly
SECTION F-F
BMKM035
21-24 Replacing body panels
Dash reinforcement
assembly
Dash panel
Dash panel
Dash side
member
assembly
Dash reinforcement
assembly
Dash center support
member assembly
SECTION C-C
Dash panel
SECTION D-D
Dash reinforcement assembly
SECTION E-E
BMKM036
Replacing body panels
21-25
G
G
H
H
Dash panel
Foot rest
bracket
assembly
Dash reinforcement assembly
Dash panel
Dash lower
member assembly
SECTION G-G
SECTION H-H
BMKM037
21-26 Replacing body panels
Center floor panel assembly
Welding part
33 Points
35 Points
F
7 Points
E
D
D
10 Points
E
B
C
A
C
B
A
12 Points
F
28 Points
BMKM038
Replacing body panels
21-27
Section
Side sill inner
panel assembly
Center floor side
inner member
assembly
Center support
bracket assembly
Center floor
side outer
member assembly
Center floor panel
Front seat cross
front member
assembly
Center floor side
inner member assembly
Center floor panel
Center floor side
inner member
assembly
SECTION A-A
SECTION B-B
Center floor panel
Parking brake
lever reinforcement
assembly
Center floor side inner
member assembly
Center floor side
inner member assembly
SECTION C-C
BMKM039
21-28 Replacing body panels
Center floor side
outer member
assembly
Side sill inner panel
Skid plate
mounting gusset
Front seat cross
rear member
assembly
Center floor side
outer member
assembly
SECTION D-D
SECTION E-E
Parking brake lever
reinforcement assembly
Center floor panel
Center suppert
bracket assembly
Front seat cross front
member assembly
Front seat cross rear
member assembly
Center floor panel
Propeller shaft
mounting bracket
assembly
SECTION F-F
BMKM040
Replacing body panels
21-29
Rear floor panel assembly
Welding part
11 Points
C
D
C
17 Points
B
B
17 Points
A
A
43 Points
D
BMKM041
21-30 Replacing body panels
14 Points
62 Points
32 Points
60 Points
BMKM042
Replacing body panels
21-31
Section
Rear floor panel
SECTION A-A
Rear floor side complete member assembly
Rear floor panel
Rear floor side complete
member assembly
Rear floor panel
SECTION B-B
Rear floor side complete
member assembly
SECTION C-C
Rear floor panel
Rear floor side complete
member assembly
SECTION D-D
BMKM043
21-32 Replacing body panels
Side panel assembly
Welding part
100 Points
E
E
36 Points
H
C
H
J
C
G
A
G
A
K
K
J
D
B
F
B
D
F
95 Points
BMKM044
Replacing body panels
21-33
24 Points
4 Points
5 Points
24 Points
55 Points
22 Points
BMKM045
21-34 Replacing body panels
60 Points
10 Points
8 Points
BMKM046
Replacing body panels
21-35
Section
Side outer complete panel
Side outer complete panel
Side inner complete panel
Side inner complete panel
SECTION B-B
SECTION A-A
Side outer complete panel
Side outer
complete panel
Side inner complete panel
SECTION C-C
Side inner
complete panel
SECTION D-D
BMKM047
21-36 Replacing body panels
Side outer complete panel
Side inner complete panel
SECTION E-E
Side outer
complete panel
Side outer
complete panel
Side inner
complete panel
Side inner
complete panel
SECTION F-F
SECTION G-G
BMKM048
Replacing body panels
21-37
Side inner
complete panel
Side outer
complete panel
Quarter complete panel
SECTION H-H
Side outer
complete
panel
Wheel house
inner panel
Wheel house
outer panel
SECTION J-J
side outer complete panel
Side inner
complete panel
SECTION K-K
BMKM049
21-38 Replacing body panels
Roof panel assembly
welding part
34 Points
27 Points
22 Points
BMKM050
Replacing body panels
21-39
19 Points
F
E
F
E
C
D
C
D
B
B
A
A
1 Point
12 Points
BMKM051
21-40 Replacing body panels
Section
Roof panel
Front rack mounting
front No.1
Roof rack mounting
front No.2 bracket
Roof center No.1 rail
SECTION B-B
Front roof garnish
mounting No.1 bracket
Roof panel
SECTION A-A
Roof rack mounting
center No.2 bracket
Roof center No.2 rail
SECTION C-C
BMKM052
Replacing body panels
21-41
Roof panel
Roof center No.1, No.3 bracket
SECTION D-D
Roof panel
Roof center No.2 rail
SECTION E-E
Roof rack mounting
rear No.1 bracket
assembly
Roof panel
SECTION F-F
BMKM052
21-42 Replacing body panels
K
K
G
H
G
H
WITH SUNROOF
Roof panel
Roof panel
Sunroof reinforcement
ring assembly
Sunroof reinforcement
ring assembly
SECTION H-H
SECTION G-G
Roof panel
Sunroof reinforcement
ring assembly
SECTION K-K
BMKM054
Replacing body panels
21-43
Back panel assembly
Welding part
C
35 Points
C
A
23 Points
B
B
A
38 Points
BMKM055
21-44 Replacing body panels
Section
Complete
floor assembly
Complete floor
assembly
SECTION A-A
SECTION B-B
Washer
assembly
bolt
Complete floor assembly
SECTION C-C
BMKM056
Replacing body panels
21-45
Quarter outer rear panel assembly
Welding part
64 Points
BMKM057
21-46 Replacing body panels
Side sill panel assembly
Welding part
34 Points
5 Points
40 Points
6 Points
BMKM058
Replacing body panels
21-47
Wheel house panel assembly
Welding part
17 Points
D
D
A
34 Points
B
39 Points
B
C
C
A
BMKM059
21-48 Replacing body panels
Section
C pillar inner
reinforcement
Wheel house inner
complete panel
Quarter inner panel
Wheel house
inner complete panel
SECTION A-A
Deadening pad
Quarter inner panel
Wheel house inner
complete panel
SECTION B-B
Quarter inner panel
SECTION C-C
Wheel house inner
complete panel
Quarter inner panel
SECTION D-D
BMKM060
Body dimensions
Body dimensions
Body dimensions
Body dimension indications ..................................................................... 31- 1
Projected dimensions .....................................................................................31 - 1
Straight-line dimensions ............................................................................... 31- 1
Front body ....................................................................................................... 31- 2
Side frame panel ............................................................................................ 31- 4
Interior A .......................................................................................................... 31- 6
Interior B .......................................................................................................... 31- 8
Interior C .......................................................................................................... 31-10
Rear body ........................................................................................................ 31-12
Under body
Projected dimensions .....................................................................................31-14
Straight-line dimensions ............................................................................... 31-16
31
Body dimensions
31-1
Body dimensions
Body dimension indication
Projected dimensions
The projected dimension indicates a dimension from a reference point on the body. (Height may be different in some
cases)
Straight-line dimensions (Actual measured dimensions)
The straight-line dimension indicates a actual measured dimension between the measurement reference points.
Assembly front fender
Straight-line
dimensions
Projected dimensions
A3EB3351
31-2 Body dimensions
Front body straight - line dimensions
B,B'
A,A'
Hood hinge mounting hole
ø12
ø9
Radiator support mounting hole
D
C,C'
Front suspension mounting hole
ø11
Engine bracket mounting hole
ø14
E,E'
D'
Transmission bracket mounting hole
ø14
Radiator support guide mounting hole
30X28
BMKM061
Body dimensions
31-3
A
B
4
1
A'
5
C
5
2
3
4
B'
C'
D
6
E
D'
7
E'
BMKM062
Measurement point
Dimension (mm)
1
2
1526
1426
3
1079
4
5
6
7
570
1581
973
964
31-4 Body dimensions
Side frame straight - line dimensions
B
C
A
ø6
Fender mounting hole
Front door upper hinge mounting hole
ø12
Front door lower hinge mounting hole
ø12
F
D
E
Rear door upper hinge mounting hole
ø11
Rear door lower hinge mounting hole
ø11
Rear door switch mounting hole
ø17
G
I
H
Rear bumper mounting hole
8X8
Quarter glass mounting hole
5.2X10
Quarter glass mounting hole
ø5.2
BMKM063
Body dimensions
31-5
H
17
15
D
B
A
2
8
7
5
3
11
6
1 4
I
16
F
12
9
G
13
10
14
E
C
BMKM064
Measurement point
1
2
3
4
5
6
7
8
9
Dimension (mm)
890
889
1913
1965
404
1083
1109
1179
1038
Measurement point
10
11
12
13
14
15
16
17
Dimension (mm)
461
867
956
1495
1531
1165
1548
588
31-6 Body dimensions
Interior A straight - line dimensions
B,B'
A,A'
C,C'
A pillar trim mounting hole
ø8.5
Cowl crossbar mounting hole
ø9
A pillar lower trim mounting hole
ø8.5
D,D'
F,F'
E,E'
Front seatbelt upper mounting hole
ø15
Front seatbelt lower mounting hole
ø15
Rear seatbelt mounting hole
ø15
I,I'
G,G'
H,H'
Quarter lower trim mounting hole
ø12
D pillar trim mounting hole
J,J'
ø8.5
I : Side trim mounting hole
J : Side trim mounting hole
ø8
ø8.5
BMKM065
Body dimensions
31-7
A'
A
D'
1
4
D
H
F'
6
F
I'
9
I
B
H'
8
B'
2
10
J
J'
G
7
G'
E
5
E'
C
3
C'
BMKM066
Measurement point
Dimension (mm)
Measurement point
Dimension (mm)
1
2
3
4
5
6
7
8
9
1186
1262
1408
1248
1388
1271
1427
1003
1076
10
1194
31-8 Body dimensions
Interior B straight - line dimensions
B,B'
A,A'
C,C'
A pillar trim mounting hole
ø8.5
Cowl crossbar mounting hole
ø9
A pillar lower trim mounting hole
ø8.5
D,D'
F,F'
E,E'
Front seatbelt upper mounting hole
ø15
Front seatbelt lower mounting hole
ø15
Rear seatbelt mounting hole
ø15
H,H'
G,G'
Quarter lower trim mounting hole
ø12
Parking cable bracket mounting hole
ø9
BMKM067
Body dimensions
31-9
A'
A
D'
1
D
F'
F
6
6
4
B'
B
4
2
2
1
E
5
G
G'
7
7
H
3
3
5
E'
H'
C
C'
BMKM068
Measurement point
Dimension (mm)
1
2
3
4
5
6
7
1327
1270
1190
1232
721
1575
1082
31-10 Body dimensions
Interior C straight - line dimensions
A,A'
B,B'
Front seatbelt upper mounting hole
ø15
Front seatbelt lower mounting hole
C,C'
ø15
D,D'
Rear seatbelt mounting hole
ø15
F,F'
E,E'
Quarter lower trim mounting hole
ø12
D pillar trim mounting hole
ø8.5
side trim mounting hole
ø8
G,G'
H,H'
Side trim mounting hole
ø8.5
Seatbelt mounting hole
ø18
BMKM069
Body dimensions
A'
E'
E
A
C
9
2
5
31-11
C'
10
F
F'
6
1
11 G
12
13
D
7
3
B
G'
14
8
4
D'
B'
BMKM070
Measurement point
Dimension (mm)
Measurement point
Dimension (mm)
1
1364
10
1150
2
1250
11
1271
3
4
5
6
7
8
9
1151
998
1139
997
839
603
1249
12
13
14
1166
1228
1107
31-12 Body dimensions
Rear body straight - line dimensions
A,A'
B,B'
Tail gate hinge mounting hole
ø12
Roof rack molding mounting hole
8.5X8.5
C,C'
D,D'
Combination lamp rear mounting hole
8.5X8.5
Sunroof drain hole
ø15.3
E,E'
Tail gate striker mounting hole
ø16
BMKM071
Body dimensions
A
A'
1
B
31-13
B'
2
7
7
5
5
8
8
10
10
C
C'
3
9
9
6
6
4
D
D'
E E'
BMKM072
Measurement point
1
2
3
4
5
6
7
8
9
Dimension (mm)
710
994
1230
1460
535
474
1229
1536
1421
Measurement point
10
Dimension (mm)
1050
31-14 Body dimensions
Under body dimensions
Projected dimensions
Measurement point
Description
Hole size
A
Front side inner member hole
ø25
B
Front side inner member hole
ø25
C
Center side member hole
ø20
D
Rear floor side member trailing arm mounting hole
ø16
E
2WD cross bar mounting hole
ø17
F
Back beam mounting hole
ø17
-6.8
921
C
808
D
796
474.5
174.4
B
168.8
A
25.8
31.3
183
D'
F'
E'
A'
C'
B'
950
959
1137
806
805.6
992
C
B
F
E
A
D
Body dimensions
E
31-15
E
595.5
BMKM073.
31-16 Body dimensions
Straight-line dimensions
Measurement point
Description
Hole size
A
Front side inner member hole
ø25
B
Front side inner member hole
ø25
C
Center side member hole
ø20
D
Rear floor side member trailing arm mounting hole
ø16
E
2WD cross bar mounting hole
ø17
F
Back beam mounting hole
ø17
Body dimensions
31-17
A
A'
992
12
98
B
19
56
B'
11
C'
18
75
42
C
12
15
53
56
D'
D
11
59
E
15
02
E'
11
25
F'
F
950
BMKM074
Waterproofing and rustproofing
Waterproof and rustproof
Sealing
Body ...................................................................................................... 41- 1
Door ...................................................................................................... 41- 5
Hood ...................................................................................................... 41- 8
Tail gate ................................................................................................ 41-10
Under coating................................................................................. 41-11
Applying rustproofing material
Body ...................................................................................................... 41-15
Door ...................................................................................................... 41-18
Hood ...................................................................................................... 41-19
Tail gate ................................................................................................. 41-20
41
Waterproofing and rustproofing
41-1
Sealing
To waterproof and rustproof the vehicle, apply sealer on assembled area of the body panel and on any areas in
contact with the body, such as doors(inner/outer), hood(inner/outer), and tail gate(inner/outer).
Body (Floor)
B
FF
A
A
'Z'
'X'
B
C
C
'Y'
BMKM075
41-2 Waterproofing and rustproofing
View
E
E
'W'
VIEW 'X'
VIEW 'W'
VIEW 'Z'
VIEW 'Y'
BMKM076
Waterproofing and rustproofing
41-3
Section
Side sill
outer panel
Sub frame mounting nut
Front side rear
lower member
assembly
Side outer
reinforcement
Side sill
inner panel
Dash panel
Front seat
center member
assembly
Center floor side
outer member assembly
Center floor panel
Center floor panel
SECTION A-A
Center floor side
inner member assembly
SECTION B-B
Parking cable bracket
Front seat rear
center member
assembly
Rear floor lower No.2
cross member assembly
Rear end upper
cross member
assembly
Rear floor panel
Center floor panel
D
D
Rear floor lower No.3
cross member assembly
'V'
Propeller shaft
bracket assembly
Rear floor lower No.1
cross member assembly
Rear end outer
cross member
assembly
SECTION C-C
BMKM077
41-4 Waterproofing and rustproofing
Rear floor panel
Side sill inner rear panel
SECTION F-F
Rear floor panel
Rear floor side
member assembly
Side sill
inner panel
Rear floor lower No.1
cross member assembly
SECTION D-D
Fender apron
upper inner panel
Shockabsorber
housing cover
Cowl side upper outer panel
Fender panel
Shockabsorber
housing panel
Front side outer member assembly
Front side inner member assembly
SECTION E-E
BMKM078
Waterproofing and rustproofing
41-5
Door
B
A
B
A
W1
C
C
Z1
X1
Y1
X2
W2
Z2
Y2
W1
(INNER)
X1
(OUTER)
D
D
D
D
W2
(OUTER)
X2
(OUTER)
BMKM079
41-6 Waterproofing and rustproofing
View
Y1
(INNER)
Y2
(OUTER)
Z
Z1
(INNER)
Z2
(OUTER)
BMKM080
Waterproofing and rustproofing
41-7
Section
SECTION A-A
SECTION B-B
5mm
MIN
SECTION C-C
1.5m
mM
IN
SECTION D-D
BMKM081
41-8 Waterproofing and rustproofing
Hood
A
A
B
B
B
B
C
C
SECTION A-A
BMKM082
Waterproofing and rustproofing
41-9
Section
SECTION B-B
+2
-1
1.5 MAX
5
SECTION C-C
(mm)
BMKM083
41-10 Waterproofing and rustproofing
Tail gate
A
B
A
B
1.5MIN
5MIN
SECTION A-A
SECTION B-B
(mm)
BMKM084
Waterproofing and rustproofing
41-11
Under coating
C
D
X
B
B
D
C
H
H
U
Q
Q
A
F
Y
F
Z
E
W
A
E
BMKM085
41-12 Waterproofing and rustproofing
View
VIEW 'Y'
VIEW 'X'
VIEW 'Z'
VIEW 'W'
VIEW 'U'(4WD)
VIEW 'U'(2WD)
BMKM086
Waterproofing and rustproofing
41-13
Section
Fender apron
upper inner panel
Shockabsorber
housing cover
Fender panel
Shockabsorber
housing panel
Front side
outer member
assembly
Cowl side upper
outer panel
SECTION A-A
Front side
inner member
assembly
Dash panel
Sub frame mounting nut
Center floor panel
SECTION B-B
Rear floor lower No.3 cross
member assembly
Rear floor panel
Rear end upper
cross member
assembly
Rear end outer
cross member
assembly
SECTION H-H
(mm)
BMKM087
41-14 Waterproofing and rustproofing
Side outer panel
Rear floor panel
Center floor panel
Side outer reinforcement
Side sill inner panel
Skid plate
mounting gusset
Front seat front
cross member
assembly
Rear floor lower No. 1
cross member assembly
SECTION D-D
Rear floor lower No.1
cross member assembly
Center floor panel
Rear floor panel
Center floor side
outer member
assembly
Side sill inner
rear panel
Rear floor side
member assembly
Center floor side
inner member
assembly
SECTION E-E
SECTION C-C
Rear end upper
center member
assemlby
Rear spring house cover
Side outer panel
Rear end outer
cross member
assembly
Quater inner panel
Wheel house
inner panel
SECTION F-F
(mm)
Rear end lower
cross member
assembly
SECTION Q-Q
BMKM088
Waterproofing and rustproofing
41-15
Applying rustproofing material
Body
"X"
A
"Z"
"Y"
"Z1"
A
Wax injection holes
BMKM089
41-16 Waterproofing and rustproofing
View
B
B
Wax injection hole
( ø20)
VIEW "X"
VIEW "Z1"
VIEW "Y"
VIEW "Z"
Wax injection holes
( ø25)
BMKM090
Waterproofing and rustproofing
41-17
Section
Side outer reinforcement
side inner panel
Side outer panel
MIN 50
side sill inner panel
ole
ø20 H ction
inje
Wax
M IN 5 0
SECTION A-A
SECTION B-B
(mm)
BMKM091
41-18 Waterproofing and rustproofing
Door
V2
V
V3
V1
130
130
130
E
E
Wax injection holes
83 MIN
Wax injection holes
VIEW "V" "V1" "V2" "V3"
SECTION E-E
(mm)
BMKM092
Waterproofing and rustproofing
41-19
Hood
C
Wax injection holes
200
200
C
250
250
D
300
300
Wax injection holes
D
Wax injection holes
MIN 30
SECTION C-C
SECTION D-D
(mm)
BMKM093
41-20 Waterproofing and rustproofing
Tail gate
F
F
F
F
150
E
E
83MIN
5MIN
5MIN
SECTION E-E
(mm)
SECTION F-F
BMKM094
Body modification tools
Body modification tools
Body modification tools
Modification tools ......................................................................................... 51Cut and disassembly tools ........................................................................ 51Assembly tools ............................................................................................. 51Measurement tools ...................................................................................... 51Welding machine .......................................................................................... 51Buffing and grinding tools ......................................................................... 51Handheld tools .............................................................................................. 51Repair tools set ............................................................................................. 51-
1
2
3
3
4
5
7
8
51
Body modification tools
51-1
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
51-2 Body modification tools
Cut and disassembly tools
Name
Air saw
Used for
Figure
Cut a panel
A3EB3506
Air chisel
Cut or bend a panel, cut and disassemble
spot welded area
A3EB3507
Rotary cutter
Cut a panel
A3EB3508
Hand saw and
metal scissors
Cut a panel
A3EB3509
Fix a spot cutter or drill to cut or
Air drill
disassemble spot welding area, to finish a
hole.
A3EB3510
Spot cutter
Cut and disassemble spot welded area
A3EB3511
Body modification tools
51-3
Assembly tools
Name
Vice pliers
Used for
Figure
Fix a panel or area to weld
A3EB3512
Air bench
Finish contact area of flange and finish a
hole for plug welding
A3EB3513
Quick bench
Finish a hole for plug welding
A3EB3514
Flanging tool
Finish contact area of flange
A3EB3515
Measurement tools
Name
Centering gauge
Used for
Figure
Measure distortion of body and frame
A3EB3516
Tracking gauge
Measure body and frame
A3EB3517
51-4 Body modification tools
Welding machine
Name
Gas welding machine
Used for
Figure
Cut a panel
A3EB3518
Spot welding machine
Weld a panel
A3EB3519
Carbon arc welding
Weld a panel
machine
A3EB3520
Stud welding machine
Stretch a panel, weld a stud bolt to fix
front window mold clip
A3EB3521
Body modification tools
51-5
Buffing and grinding tools
Name
Disk grinder
Used for
Figure
Buff
A3EB3522
Disk sander
Buff
A3EB3523
Belt sander
Buff paints
A3EB3524
Small sized grinder
Buff paints or smooth finishing
A3EB3525
Double action sander
Grind rough area of puttee assembled
area
A3EB3526
Orbital sander(short)
Grind rough area of puttee assembled
area
A3EB3527
51-6 Body modification tools
Name
Orbital sander(long)
Used for
Figure
Used for puttee grinding of wide area
A3EB3528
Flexible file
Grind touch up area, uneven area of a
panel
A3EB3529
Surform tool
Buff rough area of puttee area
A3EB3530
Hand file
Grind body puttee, pulley, finish puttee
A3EB3531
Body modification tools
51-7
Handheld tools
Name
Used for
Figure
_
Body hammer and dolly
A3EB3532
Center punch
Punch a hole in the middle of a spot
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
A3EB3536
Spoon
Used for an area where not reached by
hand
A3EB3537
51-8 Body modification tools
Name
Body chisel
Used for
Figure
Bend rough body line damaged or sheet
metal etc.
A3EB3538
Wire brush
Remove paints, rust, slag on welded area
which are hard to recognize
A3EB3539
Repair tools set
Name
Window tool set
Used for
Figure
Repair window collar
A3EB3540
Repair tool set for plastics
Repair plastic parts
A3EB3541
Plastic parts
Plastic parts
Polypropylene (PP) bumper repairability ............................................ 61- 1
Bumper repair procedure .......................................................................... 61- 2
Repair method for PP bumper .................................................................. 61- 3
61
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.
1. If a hole on a bumper is less than 2 in.(50 mm).
A3EB3601
2. If a crack on a bumper is less than 4 in.(100 mm).
A3EB3602
3. If a crack on bumper section A is less than
4 in.(100 mm) (less than half of the bumper height).
Bumper height
Crack on section
A
A3EB3603
61-1
61-2 Plastic parts
Bumper repair procedure
Surface of
bumper is not
visible.
Surface of
bumper is
visible.
Remove paint.
Sand damaged area smooth.
Apply aluminum tape on the rear
side of bumper.
Weld damaged area.
Sand damaged area with a rough sandpaper.
Clean and degrease damaged area(use TCE de-oil material).
Apply primer for polypropylene over damaged area.
Apply solvent over damaged area.
Spray primer surface over bumper and let dry.
Sand surface of bumper with sandpaper.
Clean and degrease with TCE de-oil material.
Wipe the surface of bumper with a tack cloth.
Paint bumper with a paint of the same color and let dry.
Replace damaged bumper with a
new bumper.
Apply primer for polypropylene
over bumper surface.
Plastic parts
61-3
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
B
C
D
B'
C'
D'
A
A'
Section A-A'
1
Section B-B'
Section C-C'
Section D-D'
2
3
4
1 Upper layer(coating)
3 Primer layer
2 Primer surface layer
4 Polypropylene layer
1. Rough cut the damaged area 45 using a knife and then sand the angle smooth.
Cut with a knife.
Section
A-A'
B-B'
C-C'
Section D-D'
Cut with knife.
Surface of polypropylene
Make an angle with a sander.
Make an angle with a sander.
45
Angle of 45 is required for accumulation of polypropylene welding rod.
61-4 Plastic parts
2. Welding damaged area
a) 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
Section view after melt
Surface of polypropylene
b) 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’
Remove oil.
Apply aluminum tape on the rear side of the damaged area.
3. Melt polypropylene welding rod using a heat gun and fill in the cracked area.
A-A’
B-B’
C-C’
Section
Polypropylene
welding rod
Polypropylene welding rod
Melt here.
Melt here
Notice
• Heat and melt the area indicated.
• Melt the welding rod carefully so that it does not over-melt. If the welding rod over-melts like jelly, the
welding strength will deteriorate.
• Use the heat gun 0.4~0.8 in.(10~20 mm) away from the repair area to be welded.
• Welding rod should not move until the welded area is cooled.
Polypropylene welding rod
Section A-A’
Polypropylene welding rod
Surface of
polypropylene
Tape
Plane view
Plastic parts
61-5
4. 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
Paint
Do not grind continuously.
Grind painted area and rough surface.
5. Apply polypropylene primer evenly with a brush over an area wider than the area to be repaired.
Dry it at 20OC(68OF) for more than 10 minutes.
Apply primer wider than the area to repair.
Polypropylene primer
6. Mix main filler material and hardener at a ratio depending on paint specifications. Mix filler material and apply over
the damaged area.
Notice
• Mix main filler material and hardener so that no bubbles are made.
• Work immediately after mixing filler material because the filler material hardens quickly(in about 5 minutes).
• Dry it at 20 OC(68 OF) for about 30 minutes before sanding.
Do not allow bubbles to be created.
Filler material
Weld
Surface of polypropylene
• Filler material consists of two types of epoxy.
When the filler material hardens, you will have a desirable finish with flexibility like polypropylene.
• Use only filler material designed for use on polypropylene bumpers.
61-6 Plastic parts
7. Sand the damaged area with sandpaper using #180~#240 grit paper.
Notice
• The surface will not be even if excessive force is applied during sanding.
• If there is fuzz in the damaged area, heat it a little bit with a heater gun and melt it.
8. Degrease the painted surface.
9. Mix polypropylene primer and hardener at a ratio depending on paint specifications.
Spray polypropylene primer on the surface of the damaged area and the bumper.
Polypropylene primer
Primer hardener
Use the primer within 16 hours after it is mixed.
10. Apply polypropylene primer.
Notice
• Use only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.
Plastic parts
11. Lightly sand the sprayed area using a primer
surfacer, and finish the surface of the bumper with
a sandpaper(#400~#600).
The polypropylene surface should not be
exposed.(Either wet sanding or dry sanding is all
right.)
12. Use agent(TCE(Tri Chloro Ethane) degreasing
material) to remove any grease or oil, and wipe the
finished surface of the bumper quickly with a clean
cloth.
Notice
• The painting method for the polypropylene bumper
is the same used to paint the urethane bumper.
• Therefore, use urethane primer only on urethane
bumpers and polypropylene primer on
polypropylene bumpers.
14. Air dry at 20˚C(68˚F) for about 8 hours, or dry in
60˚C(140˚F) for about 2 hours.
(Since drying time varies according to the type of
paint used, follow paint manufacturers directions for
drying times.)
Notice
• Air dry if possible. Forced drying may create air
bubbles on the top layer.
61-7
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