Kia Optima User manual

General Information
Body Construction
Body Dimensions
Body Panel Repair Procedure
Body Sealing Locations
Corrosion Protection
Body Modification Tools
Plastic Parts
Body Shop Manual
FOREWORD
This Body Shop Manual illustrates body structures and
service procedures for the OPTIMA/MAGENTIS.
Thismanualillustratesthereplacementofmajorbodypanels,
plastic parts, body dimensions, sealing treatment etc., in a
systematic manner which is necessary for effective and
lastingbody repairs.
You are encouraged to become familiar with this manual
andunderstandeachsectioninordertoperformproperrepair
procedures.Keep this manual in a convenient location so
that it is readily available.
All information in this manual including specifications,
dataand illustrationsis madebased onthe vehiclesbuilt at
the time the manual was printed.
Information regarding the removal/replacement of
componentsnotspecifically coveredin thismanual canbe
found in the OPTIMA/MAGENTIS Service Manual.
Information regarding electrical harness routing/
connections,etc. canbe foundin theOPTIMA/MAGENTIS
ElectricalTroubleshootingManual.
Thedescriptionsandspecificationscontainedinthis 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
ordesign withoutnotice andwithout incurringobligation.
Kia Motors Corporation
SEOUL, KOREA
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.
CAUTION:
Severeengineand transaxle damagemayresultfrom
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
specificationsdescribedonthespecificationsection
in the relevant group of theWorkshop Manual.
CONTENTS
Title Group
GI
BC
BD
BP
BS
CP
BT
PP
Copyright c 2005, Kia Motors Corporation
Printed in Korea, September 2005
Pub. No. : A2GB-EG58A (English)
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IN THIS MANUAL
Proper service methods and repair procedures are essential for safe, reliable operation of all
motor vehicles as well as personal safety of the operator. The service procedures and
descriptions in this shop manual provide general directions for a service and repair.
Procedure, techniques, tools, and parts for service including the skill of the technician vary.
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.
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.
Remind you to be especially careful in those areas where carelessness can
cause personal injury.
To prevent you from making errors that could damage the vehicle as well as
personal injury.
Gives you added information that will help you complete a particular procedure.
WARNING :
CAUTION :
NOTE :
IMPORTANT SAFETY NOTICE
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General
Information
GI
FUNDAMENTAL PROCEDURES
VEHICLE PROTECTION..................................GI - 2
A WORD ABOUT SAFETY ...............................GI - 2
WELDING PROCEDURES ..............................GI - 3
BODY FRAME STRAIGHTENER .....................GI - 3
ELECTRICAL PROCEDURES ........................GI - 3
FOR BEST RESULTS
DISASSEMBLY.................................................GI - 4
PREPARATION OF ASSEMBLY.......................GI - 6
ASSEMBLY.......................................................GI - 7
RUSTPROOFTREATMENT AFTER
ASSEMBLY.......................................................GI - 8
VEHICLE LIFT (2-SUPPORT TYPE) AND
SAFETY STAND POSITIONS ...................GI - 9
JACK SUPPORT POSITIONS ..................GI - 10
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GI-2 GENERAL INFORMATION
FUNDAMENTALPROCEDURES
VEHICLE PROTECTION
1. Cover the seats before performing any procedure to
keep them from getting dirty.
2. Coverall glasses,seatsandmatswith aheatresistant
coverwhen welding.
3. Protectmoldings, garnishesand ornaments.
BVQGI6001
A WORD ABOUT SAFETY
1. Wear the appropriate safety equipment that is
necessaryfor theprocedure beingperformed.
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.
BVQGI6002
Safety glasses Ear protectors
Gloves
Face shield
Mask
Safety shoes
BVQGI6003
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GENERAL INFORMATION GI-3
WELDING PROCEDURES
Observethe followingtips whenwelding.
1. Wearappropriate eyeprotection.
2. Carefully follow the manufacturers operating
instructions for the welding machine you are using.
3. Do not weld, smoke or allow open flames around
volatilechemicals, cleanersor solventsor inany area
where 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. Disconnectthe negative batteryterminal.
2. Do not pull on wires when disconnecting electrical
connectors.Becarefultoholdtheconnectoritselfwhen
disconnecting it.
3. Insert the connector until it "licks" when connecting
theconnector.
4. Handleall electricalcomponentswith care.
BVQGI6004
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GI-4 GENERAL INFORMATION
FOR BEST RESULTS
DISASSEMBLY
Measuring dimensions before beginning
Measurethedimensions ofthedamagedarea accordingto thebodydimensiondrawings beforedisassembling andrepairing.
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.
BMGGI6005
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GENERAL INFORMATION GI-5
Disassembling related parts
Use caution when removing body molding and trim from
thearea tobeworked.
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
componentsare presentneardamaged area.
BVQGI6006
Wire harness
Repair work area Cutting area
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GI-6 GENERAL INFORMATION
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.
BVQGI6008
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
carbonarc weldingmachine.
Protecting body from damage
Secure the body with clamps and jacks to prevent damage to the body when working on it.
Adjusting a new part
The new part should be cut larger than the repair area,
overlappingthe repairarea by1.2~2.0 in(30~50mm).
BVQGI6009
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
BMGGI6007
Thicker than
0.1 in (3mm)
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GENERAL INFORMATION GI-7
ASSEMBLY
Measuring dimensions before welding
When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after
checking the gaps with nearby parts.
Caution when welding
Thenumber ofwelding pointsshould bedeterminedbasedonthecriteriabelow:
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.
0.1 in
(3 mm) 0.1 in
(3 mm)
Center
diameter
Good Existing welded spots
New welded spots
Using a hammer and a chisel Using a test piece(test pin)
Nugget diameter
to be 4/5 of chip
diameter
No good
BVQGI6011
BMGGI6010
Spot welding Plug welding
Old part Repair part
Pitch:
2.0 in (50 mm)
Increase the number of
spot welds by 30%. Pitch: Same number of
welds as original part.
Pitch:
1.4 in (35 mm) Repair part
more than
0.1 in (3 mm)
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GI-8 GENERAL INFORMATION
RUSTPROOF TREATMENT AFTER ASSEMBLY
Body sealing
Applybody sealerwhere necessary.
Applying rustproof material
Applyrustproofing material(wax,oil, etc.)behind weldedarea.
Applyingundercoat
Applyundercoat onthebody wherenecessary.
BMGGI6012
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GENERAL INFORMATION GI-9
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.
BMGGI6013
Lift Block
Lift Block
[Rear]
[Front]
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GI-10 GENERAL INFORMATION
JACK SUPPORT POSITIONS
BMGGI6013
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BC
Body
Construction
BODY COMPONENTS.................................BC - 2
ZINC-GALVANIZED STEEL PANELS....BC - 4
HIGH STRENGTH STEEL PANELS.......BC - 6
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BC-2 BODY CONSTRUCTION
BODY COMPONENTS
Body construction will sometimes differ depending on specifications and country of destination.Therefore, please keep in
mind that the information contained herein is based on vehicles for general destination.
BMGBC6001
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
75
82
84
96
40
45
42
77
78
95
103
97
94
98
99
91
93
85
86
87
88
63
101
102
89
63
100
90
62
17
6
4
39
38
34
36
35
37
48
131
2
23
19
18
5
11
12
3
28
16
26
29
30
24
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BODY CONSTRUCTION BC-3
1. Radiator support lower member
2. Radiator support upper member
3. Radiator support center member
4. Fender panel
5. Fender apron inner panel
6. Front shock absorber housing panel
7. Shock absorber cover
8. Shock absorber housing reinforcement
9. Fender apron upper outer panel
10. Fender apron upper inner panel
11. Fender apron front upper reinforcement
12. Fender apron front lower reinforcement
13. Transaxle side mounting bracket
14. Engine mounting support
15. Front side inner member
16. Front side member inner reinforcement
17. Front side outer member
18. Engine mounting rear bracket
19. Engine mounting front bracket
20. Front end module mounting reinforcement
21. Front end module mounting bracket
22. Front side member outer extension
23. Front side member outer front extension
24. Sub frame mounting front support
25. Front side rear lower member
26. Front side member rear lower reinforcement
27. Front side inner rear reinforcement
28. Front side rear upper reinforcement
29. Front side member rear lower extension
30. Side sill inner front extension
31. Sub frame rear mounting bracket
32. Sub frame rear mounting reinforcement
33. Sub frame rear mounting support
34. Side inner panel
35. Cowl cross member front bracket
36. Cowl cross member rear bracket
37. Front pillar upper extension
38. Front seatbelt reel mounting bracket
39. Center pillar inner reinforcement
40. Side outer panel
41. Front pillar outer lower reinforcement
42. Front pillar outer upper reinforcement
43. Center pillar outer reinforcement
44. Center pillar outer upper reinforcement
45. Side sill outer reinforcement
46. Roof side outer reinforcement
47. Roof side outer rail
48. Fuel filler mounting
49. Side outer rear extension
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. Rear package tray side rear panel
57. Cowl top upper reinforcement
58. Cowl top lower reinforcement
59. Shock absorber housing gusset assembly
60. Cowl top panel assembly
61. Dash panel assembly
62. Center floor panel assembly
63. Side sill inner panel
64. Roof panel
65. Roof front rail assembly
66. Roof center NO.1 rail
67. Roof center rail assembly
68. Roof center NO.3 rail
69. Roof rear rail assembly
70. Sun roof reinforcement ring
71. Hood panel assembly
72. Trunk lid panel assembly
73. Back panel
74. Rear transverse member
75. Trunk lid striker support
76. Rear transverse extension
77. Rear package tray center panel
78. Rear package tray front lower member
79. Rear window opening outer frame
80. Rear floor rear panel assembly
81. Rear floor side panel assembly
82. Rear floor front panel
83. Rear seat mounting bracket
84. Rear floor front extension
85. Rear floor front cross member assembly
86. Rear floor front cross reinforcement
87. Center floor side member rear extension
88. Rear floor front filler assembly
89. Center floor side member rear extension assembly
90. Rear floor center cross member assembly
91. Rear floor center cross center reinforcement
92. Rear door panel assembly
93. Rear floor center cross member extension
94. Rear suspension mounting upper bracket
95. Rear floor side member assembly
96. Rear floor side rear member assembly
97. Rear suspension spring sheet reinforcement
98. Trailing arm mounting upper bracket
99. Rear tie down reinforcement
100. Side sill inner rear panel
101. Trailing arm mounting upper bracket assembly
102. Side sill inner rear reinforcement
103. Trailing arm mounting lower bracket assembly
104. Front door panel assembly
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BC-4 BODY CONSTRUCTION
ZINC-GALVANIZED STEEL PANELS
Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency
below.
BMGBC6002
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
131
2
23
19
18
5
11
12
3
28
16
26
29
30
24
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BODY CONSTRUCTION BC-5
1. Radiator support lower member
2. Radiator support upper member
3. Radiator support center member
4. Fender panel
5. Fender apron inner panel
6. Front shock absorber housing panel
7. Shock absorber cover
8. Shock absorber housing reinforcement
9. Fender apron upper outer panel
10. Fender apron upper inner panel
11. Fender apron front upper reinforcement
12. Fender apron front lower reinforcement
13. Transaxle side mounting bracket
14. Engine mounting support
15. Front side inner member
16. Front side member inner reinforcement
17. Front side outer member
18. Engine mounting rear bracket
19. Engine mounting front bracket
20. Front end module mounting reinforcement
21. Front end module mounting bracket
22. Front side member outer extension
23. Front side member outer front extension
24. Sub frame mounting front support
25. Front side rear lower member
26. Front side member rear lower reinforcement
27. Front side inner rear reinforcement
28. Front side rear upper reinforcement
29. Front side member rear lower extension
30. Side sill inner front extension
31. Sub frame rear mounting bracket
32. Sub frame rear mounting reinforcement
33. Sub frame rear mounting support
34. Side inner panel
35. Cowl cross member front bracket
36. Cowl cross member rear bracket
37. Front pillar upper extension
38. Front seatbelt reel mounting bracket
39. Center pillar inner reinforcement
40. Side outer panel
41. Front pillar outer lower reinforcement
42. Front pillar outer upper reinforcement
43. Center pillar outer reinforcement
44. Center pillar outer upper reinforcement
45. Side sill outer reinforcement
46. Roof side outer reinforcement
47. Roof side outer rail
48. Fuel filler mounting
49. Side outer rear extension
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. Rear package tray side rear panel
57. Cowl top upper reinforcement
58. Cowl top lower reinforcement
59. Shock absorber housing gusset assembly
60. Cowl top panel assembly
61. Dash panel assembly
62. Center floor panel assembly
63. Side sill inner panel
64. Roof panel
65. Roof front rail assembly
66. Roof center NO.1 rail
67. Roof center rail assembly
68. Roof center NO.3 rail
69. Roof rear rail assembly
70. Sun roof reinforcement ring
71. Hood panel assembly
72. Trunk lid panel assembly
73. Back panel
74. Rear transverse member
75. Trunk lid striker support
76. Rear transverse extension
77. Rear package tray center panel
78. Rear package tray front lower member
79. Rear window opening outer frame
80. Rear floor rear panel assembly
81. Rear floor side panel assembly
82. Rear floor front panel
83. Rear seat mounting bracket
84. Rear floor front extension
85. Rear floor front cross member assembly
86. Rear floor front cross reinforcement
87. Center floor side member rear extension
88. Rear floor front filler assembly
89. Center floor side member rear extension assembly
90. Rear floor center cross member assembly
91. Rear floor center cross center reinforcement
92. Rear door panel assembly
93. Rear floor center cross member extension
94. Rear suspension mounting upper bracket
95. Rear floor side member assembly
96. Rear floor side rear member assembly
97. Rear suspension spring sheet reinforcement
98. Trailing arm mounting upper bracket
99. Rear tie down reinforcement
100. Side sill inner rear panel
101. Trailing arm mounting upper bracket assembly
102. Side sill inner rear reinforcement
103. Trailing arm mounting lower bracket assembly
104. Front door panel assembly
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BC-6 BODY CONSTRUCTION
HIGH STRENGTH STEEL PANELS
Because high strength steel panel has excellent resistance, it is used in areas which have a high posibility of painting
deficiencybelow.
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
98
93
85
88
101
90
62
34
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BODY CONSTRUCTION BC-7
1. Radiator support lower member
2. Radiator support upper member
3. Radiator support center member
4. Fender panel
5. Fender apron inner panel
6. Front shock absorber housing panel
7. Shock absorber cover
8. Shock absorber housing reinforcement
9. Fender apron upper outer panel
10. Fender apron upper inner panel
11. Fender apron front upper reinforcement
12. Fender apron front lower reinforcement
13. Transaxle side mounting bracket
14. Engine mounting support
15. Front side inner member
16. Front side member inner reinforcement
17. Front side outer member
18. Engine mounting rear bracket
19. Engine mounting front bracket
20. Front end module mounting reinforcement
21. Front end module mounting bracket
22. Front side member outer extension
23. Front side member outer front extension
24. Sub frame mounting front support
25. Front side rear lower member
26. Front side member rear lower reinforcement
27. Front side inner rear reinforcement
28. Front side rear upper reinforcement
29. Front side member rear lower extension
30. Side sill inner front extension
31. Sub frame rear mounting bracket
32. Sub frame rear mounting reinforcement
33. Sub frame rear mounting support
34. Side inner panel
35. Cowl cross member front bracket
36. Cowl cross member rear bracket
37. Front pillar upper extension
38. Front seatbelt reel mounting bracket
39. Center pillar inner reinforcement
40. Side outer panel
41. Front pillar outer lower reinforcement
42. Front pillar outer upper reinforcement
43. Center pillar outer reinforcement
44. Center pillar outer upper reinforcement
45. Side sill outer reinforcement
46. Roof side outer reinforcement
47. Roof side outer rail
48. Fuel filler mounting
49. Side outer rear extension
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. Rear package tray side rear panel
57. Cowl top upper reinforcement
58. Cowl top lower reinforcement
59. Shock absorber housing gusset assembly
60. Cowl top panel assembly
61. Dash panel assembly
62. Center floor panel assembly
63. Side sill inner panel
64. Roof panel
65. Roof front rail assembly
66. Roof center NO.1 rail
67. Roof center rail assembly
68. Roof center NO.3 rail
69. Roof rear rail assembly
70. Sun roof reinforcement ring
71. Hood panel assembly
72. Trunk lid panel assembly
73. Back panel
74. Rear transverse member
75. Trunk lid striker support
76. Rear transverse extension
77. Rear package tray center panel
78. Rear package tray front lower member
79. Rear window opening outer frame
80. Rear floor rear panel assembly
81. Rear floor side panel assembly
82. Rear floor front panel
83. Rear seat mounting bracket
84. Rear floor front extension
85. Rear floor front cross member assembly
86. Rear floor front cross reinforcement
87. Center floor side member rear extension
88. Rear floor front filler assembly
89. Center floor side member rear extension assembly
90. Rear floor center cross member assembly
91. Rear floor center cross center reinforcement
92. Rear door panel assembly
93. Rear floor center cross member extension
94. Rear suspension mounting upper bracket
95. Rear floor side member assembly
96. Rear floor side rear member assembly
97. Rear suspension spring sheet reinforcement
98. Trailing arm mounting upper bracket
99. Rear tie down reinforcement
100. Side sill inner rear panel
101. Trailing arm mounting upper bracket assembly
102. Side sill inner rear reinforcement
103. Trailing arm mounting lower bracket assembly
104. Front door panel assembly
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Body
Dimensions
BD
GENERAL.........................................................BD - 2
MEASUREMENT METHOD .......................BD - 2
PROJECTED DIMENSIONS ............................BD - 2
ACTUAL-MEASUREMENT DIMENSIONS ......BD - 3
MEASUREMENT POINT..................................BD - 3
FRONT BODY .................................................BD - 4
SIDE BODY ......................................................BD - 6
INTERIOR A .....................................................BD - 8
INTERIOR B .....................................................BD - 10
INTERIOR C .....................................................BD - 12
REAR BODY ....................................................BD - 14
UNDER BODY
(PROJECTED DIMENSIONS)...................BD - 16
UNDER BODY
(STRAIGHT-LINE DIMENSIONS) ............BD - 18
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