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Kia Magnetis Bodyshop Manual Download Page 57

BODY PANEL REPAIR PROCEDURE

BP-19

SIDE SILL PANEL

REMOVAL

1.

Measure and mark vertical cutting line from the rear
door step trim mounting hole on the side sill outer panel.

2.

At the front and center pillar, measure and mark
horizontal cutting lines from the door hinge mounting
hole on the side sill outer panel as shown in the
illustration.

3.

Cut through the side sill outer panel at cutlines.

4.

Drill out the spotwelds, attaching to the side sill outer
panel to side sill reinforcement.

NOTE

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

5.

Remove the side sill outer panel.

6.

Prepare all surfaces to be welded.

7. Clean MIG welds with a disc grinder.

BMGBP6201A

110 mm

BMGBP6201B

55 mm

BMGBP6201C

70 mm

BMGBP6201D

BMGBP6201E

BMGBP6202A

mashinesoft.com

  09120146259

Summary of Contents for Magnetis

Page 1: ...ervice Manual Information regarding electrical harness routing connections etc can be found in the OPTIMA MAGENTIS ElectricalTroubleshooting Manual The descriptions and specifications contained in thi...

Page 2: ...ucted 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...

Page 3: ...I 3 BODY FRAME STRAIGHTENER GI 3 ELECTRICAL PROCEDURES GI 3 FOR BEST RESULTS DISASSEMBLY GI 4 PREPARATION OF ASSEMBLY GI 6 ASSEMBLY GI 7 RUSTPROOF TREATMENT AFTER ASSEMBLY GI 8 VEHICLE LIFT 2 SUPPORT...

Page 4: ...ornaments BVQGI6001 A WORD ABOUT SAFETY 1 Wear the appropriate safety equipment that is necessary for the procedure being performed 2 When welding or performing other procedures that require the use o...

Page 5: ...ere they have just been used 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 nega...

Page 6: ...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...

Page 7: ...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 d...

Page 8: ...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 Protecting body from damage Secure the body with clamps and...

Page 9: ...h 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 weldin...

Page 10: ...Y Body sealing Apply body sealer where necessary Applying rustproof material Apply rustproofing material wax oil etc behind welded area Applying undercoat Apply undercoat on the body where necessary B...

Page 11: ...r 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...

Page 12: ...GI 10 GENERAL INFORMATION JACK SUPPORT POSITIONS BMGGI6013 m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 13: ...BC Body Construction BODY COMPONENTS BC 2 ZINC GALVANIZED STEEL PANELS BC 4 HIGH STRENGTH STEEL PANELS BC 6 m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 14: ...vehicles for general destination BMGBC6001 70 71 69 64 79 72 80 81 83 56 55 54 52 53 44 46 43 41 47 51 50 49 74 76 104 92 68 67 66 65 60 27 25 14 13 33 32 58 59 57 59 61 21 22 8 7 10 9 20 15 76 73 81...

Page 15: ...sion 50 Rear combination lamp housing panel 51 Quarter inner lower panel 52 Quarter inner upper panel 53 Quarter panel reinforcement 54 Wheel house inner panel 55 Rear package tray side front panel 56...

Page 16: ...cellent resistance it tis used in areas which have a high possibility of painting deficiency below BMGBC6002 71 72 104 92 60 27 25 14 13 33 32 58 59 57 59 61 21 22 8 7 10 9 20 15 87 17 6 4 1 31 2 23 1...

Page 17: ...sion 50 Rear combination lamp housing panel 51 Quarter inner lower panel 52 Quarter inner upper panel 53 Quarter panel reinforcement 54 Wheel house inner panel 55 Rear package tray side front panel 56...

Page 18: ...el panel has excellent resistance it is used in areas which have a high posibility of painting deficiency below BMGBC6003 71 69 64 79 72 80 53 43 41 74 68 67 66 65 61 73 75 82 84 96 42 77 95 103 97 94...

Page 19: ...sion 50 Rear combination lamp housing panel 51 Quarter inner lower panel 52 Quarter inner upper panel 53 Quarter panel reinforcement 54 Wheel house inner panel 55 Rear package tray side front panel 56...

Page 20: ...CTUAL MEASUREMENT DIMENSIONS BD 3 MEASUREMENT POINT BD 3 FRONT BODY BD 4 SIDE BODY BD 6 INTERIOR A BD 8 INTERIOR B BD 10 INTERIOR C BD 12 REAR BODY BD 14 UNDER BODY PROJECTED DIMENSIONS BD 16 UNDER BO...

Page 21: ...sed in this manual BMCBD6001 Projected Dimension Height MEASUREMENT METHOD PROJECTED DIMENSIONS 1 These are the dimensions measured when the measurement points are projected into the reference plane a...

Page 22: ...se if a tracking gauge is used for measurement 2 Measure by first adjusting both probes to the same length A A CAUTION Check the probes and gauge itself to make sure there is no free play MEASUREMENT...

Page 23: ...E A B E E B B F F C C G G D D G H D E G H D E H H 1416 390 709 1054 1660 980 1585 984 1178 1505 978 747 390 1476 1054 1077 These dimensions indicated in this figure are actual measurement dimensions...

Page 24: ...MGBD6007A Tooling hole 8 BMGBD6003 Hood hinge mounting hole 11 BMGBD6006 Transaxle bracket mounting hole 15 BMGBD6008 Front side outer edge BMGBD6004 Tooling hole 11 BMGBD6007 Wiring mounting hole S7x...

Page 25: ...ons BMGBD6101 Point symbol Length mm Point symbol Length mm Point symbol Length mm A B C F G H A C C G H K A D D E A E D F B C D G B D E G B E F G C D F H 568 1103 895 1217 1128 935 1164 308 1117 1174...

Page 26: ...r lower hinge mounting hole 13 BMGBD6103 Wiring mounting hole S7x12 BMGBD6105A Fender mounting hole 10 BMGBD6108 Door switch mounting hole 17 BMGBD6104 Front door upper hinge mounting hole 13 BMGBD610...

Page 27: ...ol Length mm A A K K B B C C D D E E F F G G H H 1222 1457 1389 1450 1235 1429 1423 1205 1456 These dimensions indicated in this figure are actual measurement dimensions BMGBD6201 C C B A D E E G H K...

Page 28: ...cket mounting hole 6 6 BMGBD6203 Front cab mounting hole 6 6 BMGBD6206 Center pillar lower trim mounting hole 8 5 BMGBD6209 Rear door switch mounting hole 17 BMGBD6204 Front cowl side trim mounting ho...

Page 29: ...l Length mm M A M K M B M C M D M E M F M G M H 1111 1244 1147 1021 1144 927 738 1565 1393 These dimensions indicated in this figure are actual measurement dimensions BMGBD6301 C C B A D E M M E G H K...

Page 30: ...6 BMGBD6203 Front cab mounting hole 6 6 BMGBD6206 Center pillar lower trim mounting hole 8 5 BMGBD6209 Rear door switch mounting hole 17 BMGBD6204 Front cowl side trim mounting hole 8 5 BMGBD6207 Fro...

Page 31: ...bol Length mm N A N K N B N C N D N E N F N G N H 1380 816 1560 1557 1074 890 828 1142 934 These dimensions indicated in this figure are actual measurement dimensions BMGBD6401 C C B A D E E G H K K H...

Page 32: ...6 BMGBD6203 Front cab mounting hole 6 6 BMGBD6206 Center pillar lower trim mounting hole 8 5 BMGBD6209 Rear door switch mounting hole 17 BMGBD6204 Front cowl side trim mounting hole 8 5 BMGBD6207 Fron...

Page 33: ...mbol Length mm A A E E A B E F A B E F B B B G C C D D D G 1085 1119 623 364 1303 1227 1206 860 680 1243 894 These dimensions indicated in this figure are projected dimensions BMGBD6501 C D E F F G G...

Page 34: ...ole 7 BMGBD6508 Tooling hole 16 BMGBD6503 C Pillar edge BMGBD6506 Trunk hinge mounting hole 9 BMGBD6509 Trim mounting hole 8 5 BMGBD6504 Tooling hole 7 BMGBD6507 Rear bumper mounting hole 8 5x8 5 B B...

Page 35: ...th mm A A K K O F C D B B M M O G D E C C N N O H E F D D O A O K F G E E O B O M G H F F O C O N H K G G O D A B K M H H O E B C M N 1004 1089 5 79 133 1012 1028 97 882 630 1030 130 7 368 848 175 6 1...

Page 36: ...A Sub frame front mounting hole 25 BMGBD6603 Tooling hole 10 BMGBD6605 Rear suspension mounting hole 16 BMGBD6602 Sub frame rear pipe nut 16 BMGBD6603A Tooling hole 10 BMGBD6605A Tooling hole 20 BMGBD...

Page 37: ...Point symbol Length mm Point symbol Length mm A A D G H M A B E F H N A D E G K K B D E H M N B E F G N N C C F H D E G H D F G M 1004 2000 1163 2 1028 5 924 4 1374 1439 1314 6 1089 5 1321 7 1589 6 1...

Page 38: ...A Sub frame front mounting hole 25 BMGBD6603 Tooling hole 10 BMGBD6605 Rear suspension mounting hole 16 BMGBD6602 Sub frame rear pipe nut 16 BMGBD6603A Tooling hole 10 BMGBD6605A Tooling hole 20 BMGBD...

Page 39: ...AL BP 7 PREPARATION FOR INSTALLATION BP 9 INSTALLATION BP 10 FRONT SIDE MEMBER REMOVAL BP 12 INSTALLATION BP 13 FENDER APRON INNER FRONT PANEL AND FENDER APRON UPPER MEMBER REMOVAL BP 15 INSTALLATION...

Page 40: ...EDURE REPLACING BODY PANELS CODES FOR REMOVING AND INSTALLING BODY PANELS BVQBP6001 Location for cut and assembly Rough cutting location 0 8 1 2 in 20 30 mm 0 8 1 2 in 20 30 mm m a s h i n e s o f t c...

Page 41: ...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 wi...

Page 42: ...ch the middle nugget of the spot weld Otherwise Spot welded area can be removed from the body frame Spot welded area cannot be removed from the body frame This part will not be cut This part will be c...

Page 43: ...arbon 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 SPOT WELDING 1 Commercial spot welding machines do not p...

Page 44: ...Do not exceed 1 mm of space between parts A tolerance greater than 1 mm will reduce the strength of the welded area 2 Weld in the middle of the flange joint a Drill a hole 5 6 mm on one side of the fl...

Page 45: ...ting if necessary should not be done in a reinforcement area Select an area which will result in the least amount of deformation after welding 3 Cutting rough area for replacement part Cutting should...

Page 46: ...welded area with a punch remove welded area using a spot cutter and remove using a chisel b Removing brazed area Remove using a torch and wire brush and chisel c Removing arc welded area Remove plug...

Page 47: ...a hole using a 7 mm diameter drill NOTE Do not spot weld where thickness is greater than 3 mm BVQBP6020 BVQBP6021 PREPARATION FOR INSTALLATION 1 Spot weld finish Use a disk grinder or similar tool to...

Page 48: ...eas that were originally brazed at the factory 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 i...

Page 49: ...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 b Finish areas that have been bra...

Page 50: ...side member The procedure may also be applied to the front right side member 1 Seperate the front end module mounting reinforcement from the front side member assembly by drilling out spotwelds 2 Dri...

Page 51: ...ON 1 Transcribe the front side member inner and outer cutline to the new front side member cut to length and chamfer butt end to improve weld surface 2 Drill 6mm holes in new front side member for MIG...

Page 52: ...ion agent as required Refer to the CORROSION PROTECTION 9 Prepare the exterior surfaces for priming using wax and grease remover 10 Apply metal conditioner and water rinse 11 Apply conversion coating...

Page 53: ...welds to separate fender apron upper member front side member and shock absorber housing panel NOTE When spotwelded portions are not apparent remove paint with a rotary wire brush 3 Remove the fender...

Page 54: ...anscribe the fender apron upper member inner and outer cutline to the new fender apron upper member cut to length and chamfer butt end to improve weld surface 2 Fit and clamp the fender apron upper me...

Page 55: ...r butt end to improve weld surface BMGBP6103B BMGBP6103C BMGBP6107 8 Fit and clamp the fender apron inner front panel inner and outer in place 9 Measure each measurement point Refer to the BODY DIMENS...

Page 56: ...orrect seam sealer to all joints carefully Refer to the BODY SEALING LOCATION 19 Reprime over the seam sealer to complete the repair 20 After completing body repairs carefully apply under coating to t...

Page 57: ...nel as shown in the illustration 3 Cut through the side sill outer panel at cutlines 4 Drill out the spotwelds attaching to the side sill outer panel to side sill reinforcement NOTE When spotwelded po...

Page 58: ...gth 2 Using service panel for replacement of side sill outer panel drill 8mm holes in overlap areas and along upper and lower flanges 3 Crimp flanges on the remaining portion of the side sill outer pa...

Page 59: ...nt to welded parts and interior of the side sill Refer to the CORROSION PROTECTION 8 Prepare the exterior surfaces for priming using wax and grease remover 9 Apply metal conditioner and water rinse 10...

Page 60: ...ndicated in the illustration 4 To remove the front pillar grind away and drill out all welds attaching the cowl side upper outer panel as shown in the illustration NOTE If it is possible that the cowl...

Page 61: ...re to support roof panel 8 Cut front pillar through each cutline tasking care not to damage the other panel as illustration 9 Before cutting the front side sill outer panel make a rough cut the side s...

Page 62: ...ner panel adding 30mm overlap to end and cut to length 5 Drill 6mm holes in the side inner panel for MIG welding 6 Fit and clamp the new side inner panel in place for welding 7 MIG plug weld all holes...

Page 63: ...n MIG butt weld 13 MIG plug weld all holes and MIG butt weld all seams in the side outer panel 14 Clean and prepare all welds remove all residue 15 Apply body filler to joints and sand as needed 16 Ap...

Page 64: ...on side sill outer panel 50mm from the front and rear door step trim mounting hole 3 Before cutting center pillar be sure to support roof panel 4 Drill out all spotwelds attaching the center outer pil...

Page 65: ...pillar be careful not to cut front seat belt mounting upper bracket 5 Cut through center outer pillar and side sill outer panel at cutlines NOTE When cutting side sill outer panel take care not to cu...

Page 66: ...fter removing apply the welding primer BMGBP6413A INSTLLATION 1 In order to install center inner pillar drill out all spotwelds attaching the roof side outer rail to center inner pillar to separate th...

Page 67: ...ill 8mm holes in overlap areas on each end of new side sill outer reinforcement and clamp the new side sill outer reinforcement in place 8 MIG plug weld all holes and MIG butt weld seams NOTE The rein...

Page 68: ...the center pillar 18 Apply an anti corrosion agent to the welded parts and interior of the center pillar Refer to the CORROSION PROTECTION 19 Prepare exterior surfaces for priming using wax and greas...

Page 69: ...cutlines on the quarter outer panel as indicated in the illustration 2 Drill out all attaching spotwelds on the quarter outer panel including the seam around the door lip opening BMGBP6501 BMGBP6502A...

Page 70: ...dding 30mm for overlap at the old joint 2 Drill out 6mm holes in overlap areas and along upper and lower flanges of the new quarter outer panel for MIG plug welding 3 Fit and clamp the quarter outer p...

Page 71: ...surfaces for priming using wax and grease remover 9 Apply metal conditioner and water rinse 10 Apply conversion coating and water rinse 11 Apply the two part epoxy primer 12 Apply the correct seam sea...

Page 72: ...repare all surfaces to be welded INSTALLATION 1 Transcribe the cutline to the new rear floor side member Cut at line and drill out the spotwelds attaching the reinforcement and separate it 2 Fit and c...

Page 73: ...rt epoxy primer 11 Apply the correct seam sealer to all joints Refer to the BODY SEALING LOCATIONS 12 Reprime over the seam sealer to complete the repair 13 After completing body repairs carefully app...

Page 74: ...Body Sealing Locations BS FLOOR BS 2 UNDER BODY BS 4 SIDE BODY BS 5 DOOR BS 7 HOOD BS 11 TRUNK LID BS 12 m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 75: ...BS 2 BODY SEALING LOCATIONS FLOOR BMGBS6004 BMGBS600A BMGBS6002 BMGBS6003 BMGBS6001 A B C D B C A E D F H G N M K Views m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 76: ...BODY SEALING LOCATIONS BS 3 BMGBS6010 BMGBS6011 BMGBS6009 K M BMGBS6008 BMGBS6007 G H BMGBS6006 BMGBS6005 E F N m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 77: ...BS 4 BODY SEALING LOCATIONS UNDER BODY BMGBS6015 BMGBS600B BMGBS6013 BMGBS6014 BMGBS6012 A B C D Views A D B C m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 78: ...BODY SEALING LOCATIONS BS 5 SIDE BODY BMGBS6102 BMGBS6100 BMGBS6101 A B F G H K B C E D A Views m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 79: ...BS 6 BODY SEALING LOCATIONS BMGBS6108 BMGBS6109 BMGBS6107 G H BMGBS6106 BMGBS6105 E F BMGBS6104 BMGBS6103 C D K m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 80: ...01 A B C D Views Front door frame assembly Front door frame assembly Front door inner panel Front door outer panel Front door frame assembly Front door outer panel Front door frame assembly Front door...

Page 81: ...frame assembly Rear door frame assembly Rear door frame assembly Rear door inner panel Rear door inner panel Rear door outer panel Rear door outer panel BMGBS6209 K BMGBS6208 BMGBS6207 G H BMGBS6206 B...

Page 82: ...ODY SEALING LOCATIONS BS 9 BMGBS6214 BMGBS6210 BMGBS6212 BMGBS6213 BMGBS6211 A B C D Section C C D D A A E E B B B B A A B B C C D D x x 3 3 3 3 94 mm m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 83: ...BS 10 BODY SEALING LOCATIONS BMGBS6215 E E E m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 84: ...CATIONS BS 11 B B A A C C BMGBS6303 BMGBS6300 BMGBS6301 BMGBS6302 A C B x w w y 5 mm 1 5 mm y Hood outer panel Hood rail Hood inner panel A A B B C C x Section HOOD m a s h i n e s o f t c o m 0 9 1 2...

Page 85: ...C B B B Section z y x w Trunk lid outer panel assembly Trunk lid outer panel assembly Trunk lid outer panel Trunk lid inner panel Trunk lid inner panel Trunk lid inner panel B B C C A A 5 mm 1 mm 5 m...

Page 86: ...TEEL PANELS CP 2 ZINC PHOSPHATE COAT CATIONIC ELECTRODEPOSITION PRIMER CP 4 ANTIVIBRATION PADS LOCATION SECTION CP 5 UNDER BODY COAT CP 8 CAVITY WAX INJECTION CP 11 ANTI CORROSION AGENT CP 14 m a s h...

Page 87: ...xcellent resistance it tis used in areas which have a high possibility of painting deficiency below BMGBC6002 71 72 104 92 60 27 25 14 13 33 32 58 59 57 59 61 21 22 8 7 10 9 20 15 87 17 6 4 1 31 2 23...

Page 88: ...nsion 50 Rear combination lamp housing panel 51 Quarter inner lower panel 52 Quarter inner upper panel 53 Quarter panel reinforcement 54 Wheel house inner panel 55 Rear package tray side front panel 5...

Page 89: ...n of the paint coat on the steel panel and also to improve the corrosion resistance the entire body is coated with a film of Zinc phosphate and a cationic electrodeposition primer BMCCP6020 Cationic e...

Page 90: ...panel 84123 2G000 84125 2G000 84161 2G000 84172 2G000 84113 2G000 84115 2G000 84151 2G000 84171 2G000 84172 2G400 84171 2G000 LPI 84128 2G000 LHD 84128 2G900 RHD 84113 23 2G000 84113 23 2G000 H A B B...

Page 91: ...2G000 84115 25 2G000 Front seat mounting member 84151 61 2G000 Rear floor front panel Cowl top panel 22mm 84128 2G000 900 Cowl top lower reinforcement Cowl top upper reinforcement Rear floor rear ext...

Page 92: ...IBRATION PADS Antivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat If these antivibr...

Page 93: ...6204 BMGCP6203 C C VIEW X BMGCP6202 BMGCP6201 A A B B BMGCP6200 Tie down front reinforcement Side outer rear extension Sub frame mounting rear bracket Sub frame mounting rear reinforcement Front side...

Page 94: ...r panel Feder apron upper inner panel Shock absorber housing lower panel Wheel house inner panel Side outer panel Quarter inner lower panel Center floor side sill inner panel Center floor panel Side o...

Page 95: ...CP 10 CORROSION PROTECTION BMGCP6306 BMGCP6305 VIEW W VIEW Z Rear suspension mounting bracket Wheel house inner panel m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 96: ...n replacing these parts be such to apply cavity wax to the appropriate areas of the new parts BMGCP6404 BMGCP6400 BMGCP6403 C C D D BMGCP6402 BMGCP6401 A A B B Cavity wax injection Thickness 40 50 Whe...

Page 97: ...ess holess marked Trunk lid inner panel assembly Trunk lid outer panel assembly 60 mm 30 m m 30 mm R200 mm R 1 5 0 m m 100 mm 100 mm 30 mm A A B B B B A A R 6 0 m m R100 mm R30 m m R25 mm Wax injectio...

Page 98: ...V V1 V2 V3 BMGCP6506 A A A A Cavity wax injection Thickness 40 50 Wax injection must be done through access holess marked A A A A V1 V V3 V2 130 mm 130 mm Wax injection holes 6places 80 mm 30 mm m a...

Page 99: ...apply under body anti corrosion agent to that part NOTE Do not apply the under body anti corrosion agent to come in contact with tires muffler and exhaust pipe BMGCP6603 A A BMGCP6602 BMGCP6600 A A B...

Page 100: ...TION TOOLS BT 2 CUT AND DISASSEMBLY TOOLS BT 3 ASSEMBLY TOOLS BT 4 MEASUREMENT TOOLS BT 4 WELDING MACHINE BT 5 BUFFING AND GRINDING TOOLS BT 6 HANDHELD TOOLS BT 8 REPAIR TOOLS SET BT 9 m a s h i n e s...

Page 101: ...Body puller Modify twisted or bent body Push out stretch pull in damaged area Stretch damaged area BODY MODIFICATION TOOLS MODIFICATIONTOOLS A3EB3501 A3EB3502 A3EB3503 A3EB3504 A3EB3505 Name Used for...

Page 102: ...e spot welded area CUT AND DISASSEMBLY TOOLS Name Used for Figure Hand saw and metal scissors Cut or bend a panel cut and disassemble spot welded area Fix a spot cutter or drill to cut or disassembly...

Page 103: ...Finish contact area of flange Name Used for Figure Finish contact area of flange and finish a hole for plug welding MEASUREMENT TOOLS Centering gauge Tracking gauge Measure distortion of body and fra...

Page 104: ...tud welding machine Cut a panel Weld a panel Weld a panel A3EB3518 A3EB3519 A3EB3520 A3EB3521 Name Used for Figure WELDING MACHINE Carbon arc welding machine Stretch a panel weld a stud bolt to fix fr...

Page 105: ...bital sander short Buff Buff Buff paints Buff paints or smooth finishing BUFFING AND GRINDING TOOLS Name Used for Figure Grind rough area of puttee assembled area A3EB3522 A3EB3523 A3EB3524 A3EB3525 A...

Page 106: ...Hand file Used for puttee grinding of wide area Buff rough area of puttee area Grind body puttee pulley finish puttee Name Used for Figure A3EB3528 A3EB3529 A3EB3506 A3EB3530 A3EB3531 Grind touch up a...

Page 107: ...sassemble a panel Used when greater force is required Used when smaller force is required HANDHELD TOOLS Name Used for Figure Punch a hole in the middle of a spot welding area A3EB3532 A3EB3533 A3EB35...

Page 108: ...aints rust slag on welded area which are hard to recognize Window tool set Repair window collar Repair plastic parts Name Used for Figure A3EB3540 A3EB3541 Bend rough body line damaged or sheet metal...

Page 109: ...Plastic Parts PP POLYPROPYLENE PP BUMPER REPAIRABILITY PP 2 BUMPER REPAIR PROCEDURE PP 3 REPAIR METHOD FOR PP BUMPER PP 4 m a s h i n e s o f t c o m 0 9 1 2 0 1 4 6 2 5 9...

Page 110: ...th 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 2 If a crack on a bumper is less than 4 in 100 mm 3 If a crack on bumper sectionis...

Page 111: ...aged 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...

Page 112: ...hen sand the angle smooth Hole Section A A Section D D Section B B Section C C Crack Scar 4 2 1 D D D D 3 1 2 3 4 Upper layer coating Primer layer Primer surface layer Polypropylene layer VQPP002 C C...

Page 113: ...y 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 Heat gun Apply on surfac...

Page 114: ...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 C 68 F for about 30 minutes before sanding Filler mat...

Page 115: ...eate air bubbles on the top layer VQPP011 Use the primer within 16 hours after it is mixed Polypropylene primer Primer hardener VQPP012 7 Sand the damaged area with sandpaper using 180 240 grit paper...

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