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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