1997-2000 KIA CLARUS Body Service / Repair/ Workshop Manual ! 97 98 99 00

This Body Shop Manual illustrates body structures and service procedures for the CLARUS. This manual illustrates the replacement of major body panels, plastic parts, body dimensions, sealing treatment etc., in a systematic manner which is necessary for effec- tive and lasting body repairs. You are encouraged to become familiar with this manual and understand each section in order to perform proper repair procedures. Keep this manual in a convenient lo- cation so that it is readily available. All information in this manual including specifications, da- ta and illustrations is made based on the vehicles built at the time the manual was printed. Information regarding the removal/replacement of components not specifically covered in this manual can be found in the CLARUS Service Manual. Information regarding electrical harness routing/connections, etc. can be found in the CLARUS Electrical Troubleshooting Man- ual. The descriptions and specifications contained in this manual were in effect at the time this manual was ap- proved for printing. Kia Motors Corporation reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation. Kia Motors Corporation Overseas Service Engineering Dept. 1996, Kia Motors Corporation 0K-K9AA-667 Preface

As you read through the procedures, you may find Notes, Cautions and Warnings. Notes give you added information that will help you complete a particular procedure. Cautions give you information to prevent you from making an error that could damage the vehicle. Warnings alert you to be careful in areas where carelessness can cause personal injury. The following list contains general warnings that should always be followed while working on a vehicle. Leave the ignition switch OFF unless otherwise specified. Use a safety stand for underbody work. Wear safety glasses for eye protection. Run the engine only in a well ventilated area. When the engine is running, keep clear of moving parts. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, catalytic converter, etc. Do not smoke while working on a vehicle. CLARUS BODY SHOP MANUAL For your SAFETY

CLARUS BODY SHOP MANUAL GENERAL INFORMATION 00 BODY STRUCTURE 11 REPLACING BODY PANELS 21 BODY DIMENSIONS 31 WATERPROOFING AND RUSTPROOFING 41 BODY MODIFICATION TOOLS 51 PLASTIC PARTS 61 CONTENTS

GENERAL INFORMATION FUNDAMENTAL PROCEDURES ................... 00- 3 VEHICLE PROTECTION ...................................... 00- 3 A WORD ABOUT SAFETY ................................... 00- 3 WELDING PROCEDURES ................................... 00- 3 BODY FRAME STRAIGHTENER ......................... 00- 4 ELECTRICAL PROCEDURES .............................. 00- 4 FOR BEST RESULTS ..................................... 00- 5 DISASSEMBLY ..................................................... 00- 5 PREPARATION OF ASSEMBLY .......................... 00- 6 ASSEMBLY ........................................................... 00- 7 RUSTPROOF TREATMENT AFTER ASSEMBLY .............................................. 00- 8 JACK AND SAFETY STAND POSITION ........ 00- 9 FRONT .................................................................. 00- 9 REAR .................................................................... 00- 9 VEHICLE LIFT (2 SUPPORT TYPE) POSITIONS ..................................................... 00-10 FRONT END ......................................................... 00-10 REAR END ............................................................ 00-10 TOWING .......................................................... 00-10 IDENTIFICATION NUMBER LOCATIONS ........... 00-11 BODY COLORS AND MAJOR SPECIFICATIONS ........................................... 00-12 KIA EXTERIOR / INTERIOR COLOR CODES .................................................... 00-12 PAINT MANUFACTURER CODES ....................... 00-12 DIMENSIONS ........................................................ 00-13 00

FUNDAMENTAL PROCEDURES GENERAL INFORMATION 00-3 00001 00002 00003 00004 00005 FUNDAMENTAL PROCEDURES VEHICLE PROTECTION 1. Cover the seats before performing any procedure to keep them from getting dirty. 2. Cover all glass, seats and mats with a heat resistant cover when welding. 3. Protect moldings, garnishes and ornaments. 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 of an open flame near the fuel tank, disconnect and remove the tank and fuel pipe, and cap the pipe to prevent fuel leakage. WELDING PROCEDURES Observe the following tips when welding. 1. Wear appropriate eye protection. 2. Carefully follow the manufacturers operating instructions for the welding machine you are using. 3. Do not weld, smoke or allow open flames around volatile chemicals, cleaners or solvents or in any area where they have just been used. SAFETY GLASSES EAR PROTECTORS GLOVES FACE SHIELD MASK SAFETY SHOES

00-4 GENERAL INFORMATION FUNDAMENTAL PROCEDURES BODY FRAME STRAIGHTENER When using a frame straightener, do not enter the area where the body is being straightened by the chain. ELECTRICAL PROCEDURES 1. Disconnect the negative battery terminal. 2. Do not pull on wires when disconnecting electrical con- nectors. Be careful to hold the connector itself when disconnecting it. 3. Insert the connector until it “clicks” when connecting the connector. 4. Handle all electrical components with care. 00006 00007

FOR BEST RESULTS DISASSEMBLY Measuring Dimensions Before Beginning Measure the dimensions of the damaged area according to the body dimension drawings before disassembling and repairing. Adjust dimensions with body frame adjuster if deformed. Selecting Cutting Area Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding. Select an area that would allow the new part to overlap repair area by 30~50 mm. Protecting Body From Damage Secure the body with clamps and jacks to prevent damage to the body when working on it. FOR BEST RESULTS GENERAL INFORMATION 00-5 00008 Disassembling Related Parts Use caution when removing body molding and trim from the area to be worked. Apply masking tape where needed to prevent damage to the part being removed or to the vehicle body. Before starting repairs, check if pipes, hoses or electrical components are present near damaged area. 00009 WIRE HARNESS REPAIR WORK AREA CUTTING AREA

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 3 mm, do plug welding using a carbon arc welding machine 00-6 GENERAL INFORMATION FOR BEST RESULTS 00010 00012 30~50 mm OVERLAP 30~50 mm OVERLAP BODY SIDE TO MODIFY NEW PART TO MODIFY 00011 Machining Holes for Plug Welding Drill a hole of approximately 5~6 mm in diameter in those areas which are not suitable for spot welding. Adjusting a New Part The new part should be cut larger than the repair area, over- lapping the repair area by 30~50 mm. THICKER THAN 3 mm

ASSEMBLY Measuring Dimensions Before Welding When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after checking the gaps with nearby parts. Caution When Welding The number of welding points should be determined based on the criteria below: Caution When Spot Welding The tip of the spot welding machine should be maintained to a minimum of 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. FOR BEST RESULTS GENERAL INFORMATION 00-7 00014 3 mm 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 00013 SPOT WELDING OLD PART REPAIR PART PITCH: 50 mm INCREASE THE NUMBER OF SPOT WELDS BY 30%. PITCH: SAME NUMBER OF WELDS AS ORIGINAL PART. PITCH:35 mm REPAIR PART MORE THAN 3 mm PLUG WELDING

RUSTPROOF TREATMENT AFTER ASSEMBLY Body Sealing Apply body sealer where necessary.(Refer to pages 41-3 through 41-6) Applying Rustproof Material Apply rustproofing material (wax, oil, etc.) behind welded area. 00-8 GENERAL INFORMATION FOR BEST RESULTS 00015 AGX060054 Applying Undercoat Apply undercoat on the body where necessary.(Refer to page 41-7)

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1997-2000 KIA CLARUS Body Service / Repair/ Workshop Manual ! 97 98 99 00

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