Kia Manual - I-CAR

Kia Manual - I-CAR
Module 1
Kia Body Repair Manuals
All Kia “Body Repair Manuals” (BRM) include a
good overview of the vehicle body structure
along with generic general information and
cautions for repairing Kia vehicles. Much of the
same information is included in all manuals
and applies to all current models in the Kia
fleet.
Modules 1 of this manual will cover the Kia
generic body repair information covering all
models included in those course. Module 2 will
look at model specific information for each of
the following vehicles:-
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Picanto (TA)
Rio (UB)
Soul l (PS) 2015
Cerato (YD) 2,4 & 5 door 2014
Pro-Ceed (JD) 2013
Optima (TF) 2014
Carens (RP) 2014
Sportage (SL)
Sorento (UM12)
Carnival (YD)
Light truck K2900 (PU)
be returned to pre-impact dimensions prior to
beginning the sectioning repair procedures.
The extent of damage that must be repaired
should then be evaluated to determine the
appropriate repair procedures. This manual
provides locations and procedures where
structural sectioning may be employed. It is
the responsibility of the repair technician,
based upon the extent of damage, to
determine which location and procedure is
suitable for the particular damaged vehicle.
During the repair of a collision damaged
automobile, it is impossible to fully duplicate
the methods used in the factory during the
vehicle manufacture. Therefore, auto body
repair techniques have been developed to
provide a repair that has strength properties
equivalent to those of the original design and
manufacture.
Safety Factors
When repairing Kia vehicles it is important to
follow the following recommendations.
1.
2.
3.
General Information
General Guide Lines and Precautions
This vehicle is a completely new design.
During its development, close attention has
been given to safety, stability, weight and
corrosion protection. Typical of unibody
design, the vehicle is designed so that the
front and rear compartments will absorb much
of the collision energy so that the passengers
are better protected. During collisions, these
front and rear energy absorbing systems may
be severely damaged. During repair, these
damaged areas must be returned to their
original strength and geometry. If this is not
properly done, the vehicle will not provide the
intended level of protection to its occupants in
the event of another collision.
The repairs described in this manual were
performed on the vehicle's body shells. In
some instances special fixtures were welded in
place to support the structure. During the
repair of an actual vehicle, the interior would
be fully disassembled and standard jack
screws or portable braces may be used for
temporary support. During the repair of an
accident involved vehicle, the vehicle must first
4.
5.
6.
7.
8.
Disconnect the negative (-) battery cable
before performing any work on the
vehicle.
Protect yourself by wearing goggles,
earplugs, respirators, gloves, safety
shoes, caps, etc. when working on a
vehicle.
Safely support the vehicle before any
work is done. Block the front or rear
wheels if the vehicle is not lifted off of the
ground
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
Ensure proper ventilation of your working
area. Some paint and sealant can
generate toxic gases when heated. Use
an air chisel or saw to remove damaged
panels instead of a gas torch.
Observe all local and national safety
regulations when performing any work.
Cover interior with heat-resistant cover to
ensure safety when welding.
Take care when using gas or cutting
torches so as not to burn body sealer or
interior. Extinguish immediately if they
should catch fire.
1
SRS Air-Bag
This vehicle is equipped with a Supplemental
Restraint System AIR-BAG to provide the
vehicle's driver and/or the front passenger with
additional protection than that offered by the
seat-belt system alone, in case of a frontal
impact of sufficient severity. When handling
airbag components (removal, installation or
inspection, etc.), always follow the directions
given in the repair manual for the relevant
model to prevent the occurrence of accidents
and airbag malfunction.
1.
2.
3.
4.
Work must be started after approximately
30 seconds or longer from the time the
ignition switch is turned to the LOCK
position and the negative (-) terminal
cable is disconnected from the battery.
(The airbag system is equipped with a
back-up power source so that if work is
started within 30 seconds of
disconnecting the negative (-) terminal
cable of the battery, the airbag may be
deployed.) When the negative (-) terminal
cable is disconnected from the battery,
memory of the clock and audio systems
will be cancelled. So before starting work,
make a record of the contents memorized
by the audio memory system. Then when
work is finished, reset the audio system
as before and adjust the clock.
When using electric welding, first
disconnect the air-bag connectors under
the steering column near the MULTIFUNCTION SWITCH and the passenger's
side crash pad before starting work.
Store the air-bag modules where the
ambient temperature remains below 93°C
(200F°), without high humidity and away
from electrical noise.
WARNING/CAUTION labels are attached
to the periphery of the air-bag
components. Refer to the SHOP
MANUAL.
Note; detailed illustrations showing where
airbag, sensors and components are shown
for each model. This should be checked before
removal of any interior trim panels.
The following examples show illustrations for
the Optima (TF) 2014 and the pressure sensor
of the UM12 2015 model.
Welding
All repairs in this manual require the use of a
Metal-Inert Gas (MIG) welder, Gas
(oxyacetylene) welding must not be used. Both
high strength steel and mild steel can be
welded using the MIG welder.
The I-CAR recommendations for welding
should be followed. The shielding gas should
be 75% Argon and 25% CO2. The
recommended welding wire size is 0.23" and
the wire should satisfy the American Welding
Society standard code AWSER70S-6. During
the repair process, plug welds are used to
duplicate original factory spot welds. All plug
welds should be done with the MIG welder. An
8mm (5/16") hole is placed in the top (welding
side) sheet metal. Then begin welding along
the edges and the spiral towards the centre
(see illustration). This is important so that weld
penetration between the two metal pieces
takes place along the circumference of the
circle.
Observe the following tips when welding.
1. Wear appropriate eye protection.
2. Carefully follow the manufacturer’s
operating instructions for the welding
machine you are using.
2
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.
Measuring Dimensions before Welding
When installing a new part, assemble it
according to the body dimensions given in
Section BD, 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:
Electronic Parts
Caution when Spot Welding
The tip of the spot welding machine should be
maintained to a minimum of 3mm (0.1 in)
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.
Vehicles today include many electronic parts
and components, and these are in general
very susceptible to adverse effects caused by
overcurrent, reverse current, electromagnetic
waves, high temperature, high humidity
impacts, etc. In particular such electronic
components can be damaged if there is a
large current flow during welding from the body
side.
Take the following precautions during body
repair to prevent damage to the CONTROL
MODULES (ECM, TCM, ABS CM, SRS CM,
etc.).
1. Before removing and inspecting the
electrical parts or before starting electric
welding operations, disconnect the
negative (-) terminal cable from the
battery.
2. Do not expose the CONTROL MODULES
to ambient temperatures above 80°C (176
°F). If it is possible the ambient
temperatures may reach 80°C (176°F) or
more, remove the CONTROL MODULES
from the vehicle before starting work.
3. Be careful not to drop the CONTROL
MODULES and not to apply physical
shocks to them.
3
Preparation of Panel
Installation
Adjusting a New Part
The new part should be cut larger than the
repair area, overlapping the repair area by
30~50mm (1.2~2.0 in).
Applying Spot Sealer
Remove paint from the surface of new parts
and body to spot weld, 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 3mm
(0.1 in), do plug welding using a carbon arc
welding machine.
Corrosion Protection and Sealing
Protecting Body from Damage
Secure the body with clamps and jacks to
prevent damage to the body when working on
it.
Machining Holes for Plug Welding
For areas where a spot welder cannot be used
use a puncher or drill to make hole for plug
welding.
Diameter of
Plug hole
Proper corrosion protection and sealing is an
important part of repair. When reviewing these
repair procedures, it is important to recognize
the need for corrosion restoration to provide
long term strength of the repaired member.
A two part epoxy primer was applied to the
metal surfaces during the latter part of the
repair. For closed sections, such as front and
rear rails, rocker panels and pillars, the primer
is applied without applying the metal
conditioner and the conversion coating. These
steps are omitted to ensure that no rinse water
is trapped in the closed sections. The primer
application followed by an application of an oil
or wax based rust proofing material. After the
corrosion restoration process for the closed
sections are completed, then the process can
be applied to all exterior sections. For exterior
surfaces, both metal conditioner and
conversion coating treatments are applied to
the exterior surface prior to application of the
epoxy primer. The procedure in applying the
corrosion restoration process is an important
order to ensure that moisture, due to the water
rinsing of the metal conditioner and conversion
coating is not inadvertently trapped inside any
closed section before the epoxy primer and
rust proofing materials have been applied.
Appropriate seam sealers are then applied to
all joints. Follow manufacturer's
recommendations for the appropriate type of
seam sealer to be used at each seam or joint.
4
Side Body Panels
The side body panel for this vehicle is
designed and stamped from a single piece of
sheet metal from the factory as shown in the
figure. While the entire side panel is not
available in New Zealand, the partial panels
shown are available.
The illustration below shows the panels
available for the Optima (TF)
Body Construction
Body Assembly
Kia now provides detailed information on the
different steels used for manufacturing almost
all the different models of the current fleet.
The following example shows the different
steels used for the Optima.
Vehicle Lift and Safety
Stand Positions
Kia repair manuals have illustrations that show
the correct support points for raising all of their
models.
This illustration shows the Optima.
5
Body Dimensions
Actual-Measurement Dimensions
Body Panel Repair
Procedure
These dimensions indicate the actual linear
distance between measurement points, and
are the reference dimensions for use if a
tracking gauge is used for measurement.
Codes for Removing and Installing
Body Panels
Measurement Point
Symbols
Measurements should be taken at the hole
centre.
Spot weld
Outside
Middle
Body Panel Gaps
Inside
Kia provides the panel gaps for fitting panels,
note that these are not all the same.
Cut
Mig plug weld
welding
6
Spot Welding
MIG butt weld
MIG lap weld
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 weld by 30% (1.3
times the original number of welds).
Caution; when spot welding, to achieve
maximum strength the welds should be done
in the middle of the joint.
Sealer
Adhesive
Installing a New Body Panel
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
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.
Carbon Arc (MIG steel) 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 1mm of space
between parts. A tolerance greater than
1mm will reduce the strength of the
welded area.
Panel joints
Partial replacement panel joints are shown as
Open Butt Welds in the BRM, the illustration
shows a front rail partial replacement joint.
2.
Weld in the middle of the flange joint.
a. Drill a hole 5~6mm on one side of the
flange only, and weld within the hole.
b. b. Do not weld on the edge of the
flange joint.
7
Replacing Body Panels
Preparation for Installation
Removal:
1. Measuring the Body is essential before
removing the damaged area according to
the dimensions supplied in Body
Dimension, section BD. If deformation is
present, use a frame straightener to
adjust. When removing 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. Caution; during ultra high strength panel
repair
a. A damaged ultra strength panel
should not be repaired by pulling it.
Replace the whole panel with new
one.
Spot weld finish. Use a disk grinder or similar
tool but do not grind more than is necessary
to smooth the surface.
Drilling a hole for plug welding
If the thickness of the part to be welded is less
than 3mm, drill a 5~6mm diameter hole. If the
thickness of the part to be welded is greater
than 3mm, drill a hole using a 7mm diameter
drill.
Caution;
Do not spot weld where the panel stack is
thicker than 3mm
Finishing after welding
b. A damaged ultra strength panel
should not be partially replaced
at random. Replace the whole
panel with new one.
c.
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.
When a damaged ultra strength
panel is replaced with new one,
spot-welding should be used, if
possible. If shown in the repair
method apply the epoxy adhesive
and then carry out spot-welding.
8
Applying anti-rust agent and body
sealer
After coating the surface with anti-rust agent,
apply body sealer where necessary.
Apply body sealer before assembly.
Module 2
Model Specific options
This module looks at the different models of
the current Kia fleet and shows the partial
replacement options available for each model.
Note; the introduction and general information
covering the Kia recommendations for welding
and panel replacement methods shown in
Module 1 of this manual should be used when
replacing any body panels not shown in
Module 2. Full panels being replaced should
only be fitted at OEM joints and not sectioned.
Anti-rust treatment
Apply anti-rust agent inside of doors and sills
by spraying through access holes provided.
The following partial replacement information
is taken from the Kia BRMs and was current at
the time of developing this programme. The
information included in this manual is a
condensed overview of the options available
and although in some cases this will be
sufficient to carry out a full repair for outer
panels the full repair method should be
obtained for more involved panel replacement
such as reinforcements.
Kia Picanto (TA)
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the Picanto.
9
Side panels available
Partial replacement options
The illustration below shows the partial side
panel sections available for the Picanto.
The Picanto has a good number of options
Front rail option
Carrier mounting bracket
Steels used for the Picanto body
The Body Repair Manual (BRM) has a very
detailed breakdown of the different grades of
steel used for the Picanto body and although it
shows Ultra High Strength Steel (UHSS) in the
key it does not show any panels made from
UHSS.
The following 2 illustrations show a large
amount of High Strength Steel (HSS) used for
the body panels.
Front rail partial
10
A Pillar option
The A Pillar outer and inner reinforcement can
be replaced, the cut out sections (windows)
shown in the illustration are for gaining access
if replacing the reinforcement.
11
B Pillar option
Rear quarter panel
The B Pillar has the option for joining through
the upper section of the Pillar without needing
to cut a window in the upper cant rail, get the
full method if replacing the reinforcement.
Rear quarter panel is a straight forward cut
and weld method with open butt welded joints.
Has a hemmed non welded edge around the
wheel arch.
12
Rear Dog-leg
Lower A Pillar
Handy option. The lower cut measurement is
the same as the rear quarter panel.
Handy option also, plus has a method for
partial replacement of the reinforcement.
Check full A Pillar for lower cut measurement.
Reinforcement
Reinforcement
35mm
13
Sill panel options
Rear panel cut option
The sill panel has many cut options.
Check the cut option that will best fit your
repair. The reinforcement can also be
sectioned so get full details for this method.
No measurement given, the illustrations show
the outer and inner panel option.
Rear Rail
The rear rail appears to have an OEM joint
that can be used for fitting the rail end.
14
Body sealing and corrosion protection
The BRM has full details on the joints to be
sealed and the location of access holes for
applying cavity wax.
Product names are not given so duplicate with
equivalent aftermarket product.
Kia Rio (UB)
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the Rio.
NVH Foam and Torque Settings
NVH foam and the torque settings are not
shown in the Picanto BRM manual.
Overview
The Picanto has some good repair options for
a small vehicle, but perhaps this will change
with a new model as the steels used for this
model allow for a great range of repair.
Side panels available
The illustration below shows the partial side
panel sections available for the Rio.
15
Steels used for the Rio body
Partial replacement options
HSS is used for the doors boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the B Pillar and cant rail
reinforcement with mild steel used for side
aperture panel.
The Rio has a good number of options.
Front rail option
Carrier mounting bracket
Front rail option
Panel gap and body measurements are
given
16
Front rail continued
A Pillar option
The A Pillar outer and inner reinforcement can
be replaced, the cut out sections (windows)
shown in the illustration are for gaining access
if replacing the reinforcement, you will require
the full procedure when replacing the
reinforcement.
17
B Pillar option
Reinforcement
The B Pillar outer requires a window cut in the
upper cant rail panel if fitting the
reinforcement. The reinforcement is made
from UHSS so must be fitted at OEM joints
and not sectioned, take care not to cut the
reinforcement if removing the outer panel. Get
the full method if replacing the reinforcement.
CAUTION
Always apply the spotweldable sealer
between the centre pillar outer panel and
centre pillar outer reinforcement, and also
between the centre pillar outer reinforcement
and centre pillar inner panel.
CAUTION Always apply the spotweldable
sealer between the centre pillar outer panel
and centre pillar outer reinforcement, and
also between the centre pillar outer
reinforcement and centre pillar inner panel
during installation.
18
Rear quarter panel
Hemmed wheel-arch
Rear quarter panel is a straight forward cut
and weld method with open butt welded joints.
Has a hemmed non welded edge around the
wheel arch.
Rear Dog-leg
Handy option. The lower cut measurement is
the same as the rear quarter panel.
19
Lower A Pillar
Sill panel options
Handy option. Also has method for partial
replacement of the reinforcement. Check full A
Pillar for lower cut measurement.
The Rio has limited options for the sill panel,
only the section in the front door opening is
available. It also has a partial replacement
option for the reinforcement (shown in the
bottom illustration).
Reinforcement
Reinforcement
20mm
Sill Reinforcement
Reinforcement
20
Rear panel cut option
Rear rail
The illustrations show the outer and inner
panel option.
The rear rail appears to have an OEM joint
that can be used for fitting the rail end.
NVH Foam and Torque Settings
NVH foam and the torque settings are not
shown in the Rio BRM manual.
Sealing and Corrosion protection
The Rio has a very detailed section on sealing
and corrosion protective wax installation.
Overview
The Rio has some good repair option.
Inner rear panel
21
Kia Soul (PS) 2015
SRS continued
SRS continued
SRS Air-Bag
The supplemental restraint system (SRS) is
designed to supplement the seat belt to help
reduce the risk or severity of injury to the driver
and passenger by activating and deploying the
driver, passenger, side airbag and belt
pretensioner in certain frontal or side
collisions.
The SRS (Airbag) consists of; a driver side
airbag module located in the centre of the
steering wheel, which contains the folded
cushion and an inflator unit; a passenger side
airbag module located in the passenger side
crash pad contains the folded cushion
assembled with inflator unit; side airbag
modules located in the front seat contain the
folded cushion and an inflator unit; curtain
airbag modules located inside of the headliner
which contains folded cushions and inflator
units.
WARNING/CAUTION labels are attached to
the periphery of the air-bag components. Refer
to the Shop Manual.
Side panels available
The illustration below shows the partial side
panel sections available for the Soul.
The illustration shows the different parts of the
SRS system; note the pressure sensors in the
front door cavity.
Tightening Torques
Torque settings are given for the Soul
mechanical. Below is an example for the Front
Suspension taken from the BRM.
Tightening torque (kgf.m)
Nm kgf.m lb-ft
Wheel Hub nuts 88.3 ~ 107.9 9.0 ~ 11.0 65.1
~ 79.6
Wheel speed sensor mounting bolt 6.8 ~ 10.7
0.7 ~ 1.1 5.0 ~ 7.9
Wheel speed sensor wiring bracket bolt 8.8 ~
13.7 0.9 ~ 1.4 6.5 ~ 10.1
22
Strut assembly upper mounting nut 44.1 ~
58.8 4.5 ~ 6.0 32.5 ~ 43.3
Strut assembly lower mounting bolt 137.3 ~
156.9 14.0 ~ 16.0 101.3 ~ 115.7
Partial replacement options
The Soul has a good number of options.
Panel gap and body measurements are
given in the BRM
Front rail options
Carrier mounting bracket
Steels used for the Soul body
HSS is used for the doors, boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the B Pillar reinforcement
and under floor rail with mild steel used for
side aperture panel.
Front rail full section option
23
Front rail partial
A Pillar option
The A Pillar outer and inner reinforcement can
be replaced, the cut out sections (windows)
shown in the illustration are for gaining access
if replacing the reinforcement, you will require
the full procedure when replacing the
reinforcement.
Reinforcement
Reinforcement
24
B Pillar option
Lower sill joint B
The B Pillar outer requires a window cut in the
upper cant rail panel if fitting the
reinforcement. The reinforcement is made
from UHSS so must be fitted at OEM joints
and not sectioned, take not to cut if removing
the outer panel. Get the full method if replacing
the reinforcement.
Lower sill joint C
Reinforcement panel
Reinforcement
25
Rear quarter panel
Rear Dog-leg
Rear quarter panel is a straight forward cut
and weld method with open butt welded joints.
Has a hemmed non welded edge around the
wheel arch.
Handy option. The lower cut measurement A
is the same as the rear quarter panel. B is cut
from the V shown in the illustration (no
measurement is given).
A
B
Inner dog-leg reinforcement option
Reinforcement
26
Sill panel options
The Soul has limited options for the sill panel,
only the section in the front door opening is
available. It also has a partial replacement
option for the reinforcement (shown in the
bottom illustration).
Lower A Pillar
Handy option, and also has method for partial
replacement of the reinforcement. Check full A
Pillar for lower cut measurement.
Reinforcement
Reinforcement
Reinforcement
Reinforcement
27
Rear panel cut option
The illustrations show a straight cut through
the rear panel with only one measurement.
Kia Cerato (YD)
4 and 5 door plus Koup 2014
The Koup manual is 308 pages and contains
all 3 models.
Rear rail
The rear rail appears to have an OEM joint
that can be used for fitting the rail end.
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the Cerato.
Overview
The Rio has some good repair options.
28
Side panels available
Steels used for the Soul body
The illustration below shows the partial side
panel sections available for the Cerato.
HSS is used for the doors, boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the B Pillar reinforcement
and under floor rail with mild steel used for
side aperture panel.
Tightening Torque
Torque settings are shown in the BRM for all
bolt on Items and are very detailed. The
following examples are for the Bonnet and
door hinge.
N.m Kgf.m lb-ft
Front and rear doors Door hinge to body 33.3
~ 41.2 3.4 ~ 4.2 24.6 ~ 30.4
Door hinge to door 21.6 ~ 26.5 2.2 ~ 2.7 15.9
~ 19.5
Door checker to door 3.9 ~ 5.9 0.4 ~ 0.6 2.9
~ 4.3
Door checker to body 19.6 ~ 29.4 2.0 ~ 3.0
14.5 ~ 21.7
The (YD) BRM has all measurements
for the 3 body structures
This also includes the body gaps.
29
Front rail option
Body gap measurements
Partial replacement options
The Cerato has a good number of options.
Front rail options
Carrier mounting bracket
30
Upper apron panel
A Pillar option
A good option for partial replacement.
No measurements are given so follow cut line
shown in the illustration.
The A Pillar outer and inner reinforcement can
be replaced. The cut out sections (windows)
shown in the illustration are for gaining access
if replacing the reinforcement, you will require
the full procedure when replacing the
reinforcement.
31
Reinforcement panel
B Pillar option
The B Pillar outer requires a window cut in the
upper cant rail panel if fitting the
reinforcement. The reinforcement is made
from UHSS so must be fitted at OEM joints
and not sectioned, take care not to cut the
reinforcement if removing the outer panel. Get
the full method if replacing the reinforcement.
Rear quarter panel
The following illustrations show the
replacement method for fitting the rear quarter
of all 3 body styles. They have a hemmed
wheel arch (check for glue around the wheel
arch joint and replace if required).
4 Door Sedan
A
B
32
Rear quarter continued
5 door hatch continued
2 Door Koup
5 Door hatch
33
Hemmed wheel arch
Lower A Pillar
Handy option, and also has a method for
partial replacement of the reinforcement.
Check full A Pillar for lower cut measurement.
Rear Dog-leg
Handy option for the 4 and 5 door models.
Lower measurement is the same as rear
quarter joint.
A
B
No measurement given
Reinforcement
Reinforcement
34
Sill panel options
Rear panel continued
The Cerato has limited options for the sill
panel; only the section in the front door
opening is available. It also has a partial
replacement option for the reinforcement
(shown in the bottom illustration).
Rear rail
The rear rail appears to have an OEM joint. No
measurements are given.
Rear panel cut option
The illustrations show a straight cut through
the rear panel with only one measurement.
35
NVH Foam and adhesive
NVH foam and adhesives are not shown in the
Cerato BRM manual.
Overview
Pro-Ceed (JD)
NZ has only released the 2 door model,
however much of the BRM shows methods for
the 5 door hatch, both models share the same
platform.
The BRM for the Cerato is very informative
plus has additional information not often
include such as door and glass adjustments,
seat-belts, seat parts removal operation. The
dash pad and the components are also
included.
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the 4 door Pro-Ceed.
Torque settings
Some of the settings for the front suspensions
are shown in the example below. The BRM
also has the wheel alignment settings
Tightening torque
(kgf.m) Nm kgf.m lb-ft
Wheel Hub nuts 88.3 ~ 107.9 9.0 ~ 11.0 65.1
~ 79.6
Strut assembly to frame 53.9~ 73.5 5.5 ~ 7.5
39.8 ~ 54.2
Strut assembly to knuckle 156.9 ~ 176.5 16.0
~ 18.0 115.7 ~ 130.2
Strut assembly lock nut 58.8 ~ 68.6 6.0 ~ 7.0
43.4 ~ 50.6
Lower arm to sub frame (Front) 98.1 ~ 117.7
10.0 ~ 12.0 72.3 ~ 86.8
Lower arm to sub frame (Rear) 156.9 ~ 176.5
16.0 ~ 18.0 115.7 ~ 130.2
36
Wheel alignment
The (JD) BRM has all measurements for
the 3 body structures
This also includes the body gaps.
Steels used for the 4 door Pro-Ceed
HSS is used for the doors, boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the B Pillar reinforcement
and under floor rail with mild steel used for
side aperture panel.
Partial replacement options
The Pro-Ceed has a good number of options.
37
Front apron upper support
This is a good option.
Front rail option
38
A Pillar
The A Pillar outer and inner reinforcement can
be replaced. The cut out sections (windows)
shown in the illustration are for gaining access
if replacing the reinforcement, you will require
the full procedure when replacing the
reinforcement.
Rear quarter panel
2 Door
Only shows one measurement for the pillar
joint, the rear sail panel is cut at the V on the
flange and the lower joint lined up with the kick
plate hole.
39
5 Door
Wagon
No measurement for the lower sill joint.
The Pro-Ceed also has a wagon.
Wheel arch has hemmed edge
No measurement given
40
Reinforcement
B Pillar
The B Pillar outer requires a window cut in the
upper cant rail panel if fitting the
reinforcement, the reinforcement is made from
UHSS so must be fitted at OEM joints and not
sectioned. Take care not to cut the
reinforcement if removing the outer panel. Get
the full method if replacing the reinforcement.
Nothing is shown for the 2 door model.
No measurement
given
41
Lower A Pillar
Rear dog-leg option
Handy option, and also has a method for
partial replacement of the reinforcement.
Check full A Pillar for lower cut measurement.
Has option for the outer panel but nothing is
shown for the reinforcement.
Reinforcement
42
Sill panel options
Rear rail option
The Pro-Ceed has limited options for the sill
panel; only the section in the front door
opening is available. It also has a partial
replacement option for the reinforcement
(shown in the bottom illustration).
The rear rail has reinforcement so a window is
required to be cut out.
Reinforcement
43
Rear Panel option
Overview
The Pro-Ceed has some good partial
replacement options as well as having
information not often seen, such as
proceedure for removing the consol along with
detailed information on seat belts and door
trims etc.
44
Kia Optima (TF)
Steels used for the Optima body
HSS is used for the doors, boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the B Pillar reinforcement
and under floor rail with mild steel used for
side aperture panel.
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the Optima.
Side panels available
The illustration below shows the partial side
panel sections available for the Optima.
Panel gap and body measurements are
given in the BRM
Tightening Torques
Torque settings are given in the BRM (refer to
dealer workshop manual)
45
Partial replacement options
Front rail continued
The Optima has some good options however
some are a little more involved than the norm.
Reinforcement
Front rail
The front rail option requires the inner
reinforcement jointed at what appears to be an
OEM joint.
A Pillar
The A pillar has 17 pages of instructions.
If fitting the reinforcements a 3 layered
sectioning joint is required as shown in the last
illustration, get the full repair method if fitting a
full A Pillar. The Optima also has a lower A
Pillar outer and reinforcement option.
46
A Pillar lower section option
Reinforcement
47
B Pillar
B Pillar continued
The Optima B Pillar also has a 3 layered
sectioning method for the sill reinforcements;
get the full method before attempting this
repair.
Reinforcement
48
Rear quarter panel
Rear dog-leg option
Reinforcement
Hemmed wheel-arch
49
Sill panel options
Rear rail option
The Optima has limited options for the sill
panel; only the section in the front door
opening is available. It also has a partial
replacement option for the reinforcement
(shown in the bottom illustration).
The rear rail appears to be joined at an OEM
joint.
NVH Adhesive and sealing
Reinforcement
The BRM for the Optima has very detailed
illustrations of sealing and anti-corrosion
requirements however NVH foams and
adhesives are not included.
50
Overview
The Optima has some good options however
some of these are a little more involved than
other methods recommended by Kia and
should be considered at the time of preparing
the estimate for repairs.
Carens (RP)
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the Carens, note the
pressure sensor for side impact?
Side panels available
The illustration below shows the partial side
panel sections available for the Carens.
51
Tightening Torques
Torque settings for bolt on parts are given in
the BRM. The illustration shows the bonnet
hinge tightening.
Panel gap and body measurements are
given in the BRM
The following illustrations are an example of
the information provided.
Steels used for the Carens body
HSS is used for the doors, boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the B Pillar reinforcement
and under floor rail with mild steel used for
side aperture panel.
Wheel alignment settings are also
given in the BRM
52
Partial replacement options
The BRM for the Carens has some good
partial replacement options.
Carrier mounting bracket
Rail to Bulk-Head at OEM joint
Front rail front cut
53
A Pillar
A Pillar Reinforcement joints
The A pillar has 17 pages of instructions.
If fitting the reinforcement get the full repair
method. The Carens also has a lower A Pillar
and reinforcement option.
Lower A Pillar only option
54
Reinforcement
Reinforcement requires full replacement.
Do not section.
B Pillar outer
55
Rear quarter panel
Rear quarter continued
No measurement given
Hemmed wheel arch
Lower dog-leg, has outer only option
56
Sill panel
Rear rail
The Carens has limited options for the sill
panel; only the section in the front door
opening is available. It also has a partial
replacement option for the reinforcement
(shown in the bottom illustration).
The rear cross-member end cap needs
removing to replace the rear section of the rail.
No measurement given
Rear panel partial
Reinforcement
57
NVH Adhesive and sealing
The BRM for the Carens has very detailed
illustrations of sealing and anti-corrosion
requirements however NVH foams and
adhesives are not included.
Overview
Additional BRM information
The Carens has some good repair options
along with some very detailed additional
information not always shown in the BRM.
It appears that more information is now being
included for each new model produced.
The Carens BRM has very detailed information
on topics not often found in manuals such as
the removal procedure for interior trims, door
trims and window mechanism’s, bonnet and
boot panels.
The seats are shown in detail along with a full
section that covers all seat belts and the
installation requirements.
The illustrations below show an example of the
door trim and seat construction information
that is in the BRM.
58
Sportage (SL)
Illustration showing side panel breakdown
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag
components used in the Sportage, note the
pressure sensor for side impact?
There are differences between the 2 and 4
wheel drive
Take care when ordering parts.
Tightening Torques
Side panels available
The illustration below shows the partial side
panel sections available for the Sportage.
The BRM has a full breakdown of all panels
used for the Sportage body.
Torque settings for bolt on parts are not given
in the BRM so refer to the Kia dealership
workshop manual.
Steels used for the Sportage body
Steel grades used for the Sportage are not
shown in the BRM so be sure to follow the
recommended repair method shown if
replacing welded panels.
59
Panel gap and body measurements are
given in the BRM
The following illustrations are an example of
the information provided.
Partial replacement options
The BRM for the Sportage has some good
partial replacement options.
Front apron upper support
This is a good option.
60
Front rail
Front rail requires a window cut out for access
to the reinforcement.
Reinforcement
Butt-weld joints
Reinforcement
61
A Pillar
A Pillar continued
The A Pillar has a 3 layer sectioning joint, so
get the full repair method if fitting an A Pillar
reinforcement. The Sportage also has a lower
A Pillar and reinforcement option.
Reinforcement
62
B Pillar
Inner reinforcements
The B Pillar inner and outer can be sectioned;
this requires cutting windows in the upper pillar
and sill panels. The upper joint is 3 layers.
Reinforcement
Reinforcement
63
Rear quarter panel
Rear quarter panel also has a lower dog-leg
only option.
Lower dog-leg option
Outer panel only option; no option shown for
sectioning the reinforcement.
64
Lower B Pillar and sill section
Sill panel
The Sportage has a good range of sill
replacement options.
Front door opening sill panel
Reinforcement
Reinforcement
65
Lower B Pillar reinforcement
Rear rail
Reinforcement
Full outer sill panel replacement
Reinforcement
NVH and adhesives
NVH and adhesives are not shown in the BRM
however it does have a detailed section on
sealing and corrosion protection application.
Overview
Reinforcement
The Sportage has some good repair options;
this is perhaps because the steels used don’t
limit what can be sectioned?
66
Sorento (UM12)
Adhesives used in the Sorento
Kia; Operation Procedures and Cautions in
Using Epoxy Adhesives
Products stated in the BRM are
(3m-PN8115) and (HENKEL–Terokal 5055)
Be sure to follow the instructions of the product
you use
Kia
1.
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The illustration below shows the Air-Bag used
in the Sorento, also shown are the side impact
sensor mounting locations, note the pressure
sensor for side impact?
2.
3.
4.
5.
6.
7.
8.
Heat up the adhesive face on the panel to
remove it. Heating temperature should be
in the range of 110℃ - 140℃. Use a torch
or a heating gun.
Using a scraper, completely remove the
remaining adhesive on the panel.
Using #50 - #80 sand paper, neatly grind
off the adhesive area. Any remaining
paint or surfacer must be removed from
the adhesive area.
After grinding, clean the surface with a
cleaner (adhesive cleaner). Cleaning the
epoxy adhesive area is important as dust
or oiliness may greatly decrease the
adhesive strength.
Follow the same procedure of removing
the paint and cleaning with a cleaner
when applying adhesive on new panels.
Apply a light coat of adhesive on new
panels or body panels, and then use a
scraper to apply a second coat as thin as
possible so that the metal surface is not
visible (Skin coat). Ordinary adhesives
are two-component types where the resin
and hardener are filled in separate
cartridges before being released from a
nozzle or a gun. As the nozzle used for
two-component type adhesive may
harden after approximately 60 minutes
without application, in case of delayed
application, replace with a new nozzle.
Check that the resin and hardener in the
adhesive are released simultaneously
before mounting the nozzle to the
adhesive gun. This is important as nonsimultaneous release of resin and
hardener may affect the hardening
process.
Use the adhesive for a secondary
application. The adhesive strength is
generated on the panel in the secondary
application in which the adhesive should
be applied in a width of approximately
10mm. Apply in a width of 5 ó 6mm on
flange areas.
Mount the panel onto the body.
67
9.
After mounting the panel, use a clamp to
firmly fix it so that there are no gaps or
shaking. While the gaps and clearing of
the panel may be adjusted before the
adhesive is dry, caution is needed as
adhesive must be applied again in case
the mounted panel is detached. Maintain
a distance of approximately 100 ó 150mm
to the panel fixing clamp.
10. Using a scraper, remove any leaking
adhesives during mounting process. As
the adhesive is difficult to remove after it
has been hardened, it must be removed
before hardening.
11. Heat up the panel to harden. The
adhesive is heat hardening type; it must
be heated to harden.
Steels used for the Sorento body
HSS is used for the doors, boot lid, bonnet,
guards and most all other structural panels.
UHSS is shown for the Sill, A and B Pillar
reinforcements plus the under floor and rear
rails with mild steel used for side aperture and
roof panels.
Illustrations show where adhesive is used
Welding
When a damaged ultra high strength steel
panel is replaced with a new one, spot welding
should be used, if possible. Apply the epoxy
adhesive and then carry out spot welding.
68
Measurements and panel gaps
Partial replacement options
These are shown in the BRM with good
illustrations.
The Sorento has some good options however
some of these are very complex. Most of the
panel replacement operations require some
adhesive but be sure to check the BRM as the
adhesive application is very specific.
Example of adhesive application
The following illustrations show the Kia
instructions for the adhesive application.
Adhesive
Torque settings
Spot weld and MIG plug weld all holes, MIG
lap weld the seam.
If spot welding is impossible, MIG plug weld all
holes.
Apply epoxy adhesive to the weld points of
new panel or body panel. Be sure to use the
recommended epoxy adhesive.
Epoxy adhesive : 3M(PN8115),
Henkel (Terokal 5055) or equivalent.
Some of the settings for the front suspensions
are shown in the example below. The BRM
also has the wheel alignment settings.
Tightening Torque
Front Suspension
Tightening torque (kgf.m) Nm kgf.m lb-ft
Tire wheel hub nuts 88.3 ~ 107.9 9.0 ~ 11.0
65.1 ~ 79.6
Strut assembly to knuckle 196.1 ~ 215.7 20.0
~ 22.0 144.7 ~ 159.1
Strut assembly lock nut 53.9 ~ 73.5 5.5 ~ 7.5
39.8 ~ 54.2
Lower arm to sub frame (Front) 117.7 ~ 137.3
12.0 ~ 14.0 86.8 ~ 101.3
Lower arm to sub frame (Rear) 156.9 ~ 176.5
16.0 ~ 18.0 115.7 ~ 130.2
69
Front rail options
Partial front rail bulkhead option continued
The BRM has 29 pages referring to the front
rail replacement options. The following
examples look at these options, the joint
location and replacement methods required.
Carrier mounting bracket
Partial front rail forward section option
Full rail replacement
Partial front rail bulkhead option
Reinforcement cut
Reinforcement
Assembly using weld bonding method
70
A Pillar continued
A Pillar option
The A Pillar has a 3 layer sectioning joint on
the sill panel and the upper joint appears to be
single layer. Reinforcements appear to be
joined at the upper bulkhead region. Be sure to
get the full method if replacing the
reinforcement.
Reinforcement joint location
Reinforcement
B Pillar replacement
71
Rear quarter panel
Reinforcement panel
72
Adhesive used around wheel-arch
Lower reinforcement
Reinforcement
Tailgate opening reinforcement joint
Lower dog-leg option
Another sill cut option given if replacing
the inner panels
Sill panel options
The BRM does not show any options for the
sill panel however the sill cut options for the A
and B pillar and rear guard do have sectioning
options as shown in the illustration. (Example
only, check for the correct measurements)
73
Rear rail option
Sealing and NVH
The cross member end cap needs to be
removed to allow access to the rail sectioning
joint location. The join location appears to be
at an OEM joint.
The BRM has very detailed information on
sealing and antivibration pads however it does
not give the foam locations, the illustrations
show examples from the BRM.
Cavity Wax Injection
Like most BRM for Kia, the Sorento also has
very detailed cavity wax installation and show
the application holes available.
74
Plastic Parts
All plastic parts are identified along with a how
to repair section. This is common for all Kia
BRMs
Overview
The Sorento is a vehicle that uses a lot of
UHSS so some repairs are perhaps limited.
Along with this the Sorento uses a good
amount of adhesive for replacing body panels.
This is common for many new vehicles being
manufactured today.
Carnival YP
ANCAP
The 2015 Carnival has limited sectioning
options. This is perhaps because of the UHSS
used for its construction. It is important to
check if and where sectioning can be done as
it appears this is limited to areas that are not
UHSS panels.
SRS Air-Bag
Refer to the SRS Air-Bag cautions information
in general information Module 1.
The following illustrations show the Carnival
front and side impact sensor locations
mounting note the pressure sensor for side
impact?
75
Adhesives used in the Sorento
Kia; Operation Procedures and Cautions in
Using Epoxy Adhesives
Products stated in the BRM are
(3m-PN8115) and (HENKEL–Terokal 5055)
Be sure to follow the instructions of the product
you use
Kia
1.
2.
3.
4.
5.
6.
7.
8.
Heat up the adhesive face on the panel to
remove it. Heating temperature should be
in the range of 110℃ - 140℃. Use a torch
or a heating gun.
Using a scraper, completely remove the
remaining adhesive on the panel.
Using #50 - #80 sand paper, neatly grind
off the adhesive area. Any remaining
paint or surfacer must be removed from
the adhesive area.
After grinding, clean the surface with a
cleaner (adhesive cleaner). Cleaning the
epoxy adhesive area is important as dust
or oiliness may greatly decrease the
adhesive strength.
Follow the same procedure of removing
the paint and cleaning with a cleaner
when applying adhesive on new panels.
Apply a light coat of adhesive on new
panels or body panels, and then use a
scraper to apply a second coat as thin as
possible so that the metal surface is not
visible (Skin coat). Ordinary adhesives
are two-component types where the resin
and hardener are filled in separate
cartridges before being released from a
nozzle or a gun. As the nozzle used for
two-component type adhesive may
harden after approximately 60 minutes
without application, in case of delayed
application, replace with a new nozzle.
Check that the resin and hardener in the
adhesive are released simultaneously
before mounting the nozzle to the
adhesive gun. This is important as nonsimultaneous release of resin and
hardener may affect the hardening
process.
Use the adhesive for a secondary
application. The adhesive strength is
generated on the panel in the secondary
application in which the adhesive should
be applied in a width of approximately
10mm. Apply in a width of 5 ó 6mm on
flange areas.
Mount the panel onto the body.
9.
After mounting the panel, use a clamp to
firmly fix it so that there are no gaps or
shaking. While the gaps and clearing of
the panel may be adjusted before the
adhesive is dry, caution is needed as
adhesive must be applied again in case
the mounted panel is detached. Maintain
a distance of approximately 100 ó
150mmto the panel fixing clamp.
10. Using a scraper, remove any leaking
adhesives during mounting process. As
the adhesive is difficult to remove after it
has been hardened, it must be removed
before hardening.
11. Heat up the panel to harden. The
adhesive is heat hardening type; it must
be heated to harden.
Illustrations show where adhesive is used
76
Torque settings
Steels used for the Carnival body
Some of the settings for the rear suspensions
are shown in the example below. The BRM
also has the wheel alignment settings.
HSS is used for the doors, boot lid, bonnet,
guards, floor, rails and most all other structural
panels.
UHSS is shown for the Sill A and B Pillar
reinforcements plus the under floor and rear
rails with mild steel used for side aperture and
roof panel.
Rear Suspension
Tightening torque (kgf.m) Nm Kgf.m lb-ft
Tire wheel Hub nuts 88.3 ~ 107.9 9.0 ~ 11.0
65.1 ~ 79.6
Trailing arm to body 98.1 ~ 117.7 10.0 ~12.0
72.3 ~ 86.8
Assist arm to sub frame 137.3 ~ 156.9 14.0
~16.0 101.3 ~ 115.7
Assist arm to knuckle 68.6 ~ 83.4 7.0 ~ 8.5
32.5 ~ 39.8
Lower arm to knuckle 137.3 ~ 156.9 14.0
~16.0 50.6 ~ 61.6
Wheel Alignment
Specification Front Rear
Toe-in Individual 0.05˚±0.1˚ 0.1˚±0.1˚
Total 0.1˚±0.2˚ 0.2˚±0.2˚
Camber angle -0.5˚±0.5˚ -1˚±0.5˚
Caster angle 4.14˚±0.5˚ King-pin angle 13.63˚±0.5˚ Ride height 433.73mm ± 10mm (17.076 ±
0.3937 in.)
Body dimensions are given
The BRM has a full section with very detailed
information giving all the body dimensions and
panel gaps.
77
Partial replacement options
The Carnival has very limited partial
replacement options. This is perhaps due to
the increased use of UHSS. Always check if
sectioning is permitted as it appears that this is
never on UHSS panels. Most of the panel
replacement operations require some
adhesive but be sure to check the BRM as the
adhesive application is very specific.
A Pillar replacement
The A Pillar has a 3 layer sectioning joint on
the sill panel and the upper joint appears to be
single layer. Be sure to get the full method if
replacing the reinforcement.
Front rail
The front rail only shows a full rail fitted at the
OEM joint at the bulkhead. The carrier
mounting bracket can be replaced as shown in
the illustration.
When cutting the side sill outer reinforcement,
take care not to cut through the matting
flanges or the side sill inner reinforcement.
78
B Pillar option
The B Pillar requires the full reinforcement cut
into the upper roof rail. Note the front sill cuts
are not cutting into the UHSS reinforcement.
Reinforcement
Reinforcement
79
B Pillar continued
Rear quarter panel
Reinforcement
Sill panel options
The BRM does not show any options for the
sill panel apart from the sill cut options for the
A and B Pillar and rear guard as shown in the
illustration. (Example only, check for the
correct measurements)
80
Inner quarter panels
Sealing and NVH
The BRM has very detailed information on
sealing and anti-vibration pads however it
does not give the foam locations, the
illustrations show an example from the BRM.
Rear panel
The Carnival has a rear panel and rail end cap
replacement method but no method is given
for the rear rail. (Perhaps because they are
UHSS)
Cavity Wax Injection
Like most BRM for Kia, the Carnival also has
very detailed cavity wax installation and shows
the application holes available.
Overview
The Carnival is very limited for partial
replacement options.
81
Kia K2500 (PU) Light truck
The K2500 has no body repair information; the
Kia general repair instructions covered in
Module 1 of this manual should be followed.
K2500 Chassis dimensions
Dimensions are available for both the 2 and 4
wheel drive models long and extra-long body.
Cab options are;
 Standard cab
 Double cab
 King cab
Note;
This manual was developed as a quick
reference tool showing the Kia replacement
methods available for the current Kia fleet.
This technical information is for fitting new
genuine Kia parts only. Your local Kia
dealerships are happy to provide the detailed
repair information when ordering panel parts.
82
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