2009 KIA MOHAVE / BORREGO Body Service / Repair/ Workshop Manual ! 09

General Information Body Construction Body Dimensions Body Panel Repair Procedure Body Sealing Locations Corrosion Protection Body Modification Tools Plastic Parts Body Repair Manual FOREWORD This Body Repair Manual provides detailed repair procedures for repair of commonly damaged structural panels on the 2009 MOHAVE / BORREGO. To aid in the information of the damaged vehicle, body construction, body dimensions, Body Panel Repair Procedure, Body Sealing Locations, Corrosion Protection, Body Modification Tools and Plastic Parts are contained herein. The repair procedures specify locations where body mem- bers may be structurally sectioned. All of the repair procedures have been performed on MOHAVE / BORREGO body shells and that is currently available in most auto body repair shops. The repair procedures illustrated in this manual were developed to simplify body repair in order to reduce insurance costs, and indirectly, cost of ownership. The vehicle should not be sectioned in locations other than those illustrated in this repair manual. Furthermore, these repair procedures DO NOT apply to any other vehicle. The individuals performing the work must assume full responsibility for the quality of their workmanship. We believe this manual to be helpful for Kia dealers, and anticipate it to be effectively used for Kia vehicle bodies. For the services of other than collision-damaged body parts of the MOHAVE / BORREGO, refer to the MOHAVE / BORREGO shop manual. The illustrations and descriptive text in this manual were corrected at the time of printing. It is the policy of KIA MOTORS CORPORATION to continu- ously improve its products. Specifications and procedures are subject to change at any time without notice. April 2008, Printed in 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 . CONTENTS TITLE GROUP GI BC BD BP BS CP BT PP

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 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

General Information GI GENERAL GUIDE LINES AND PRECAUTIONS .............................................. GI - 2 FUNDAMENTAL PROCEDURES VEHICLE PROTECTION .................................. GI - 3 SAFETY FACTORS .......................................... GI - 3 SRS AIR BAG ................................................... GI - 4 WELDING ......................................................... GI - 5 BODY FRAME STRAIGHTENER ..................... GI - 5 ELETRONIC PARTS ........................................ GI - 6 FOR BEST RESULTS REMOVAL ........................................................ GI - 7 PREPARATION OF INSTALLATION ................. GI - 9 INSTALLATION ................................................. GI - 10 CORROSION PROTECTION AND SEALING .............................................................. GI - 11 SIDE BODY PALELS ........................................ GI - 12 VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS ................... GI -13

GI-2 GENERAL INFORMATION GENERAL GUIDE LINES AND PRECAUTIONS The MOHAVE / BORREGO is a completely new vehicle design. During its development, close attention has been given to safety, stability, weight and corrosion protection. Typical of unit body design, the MOHAVE / BORREGO 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 MOHAVE / BORREGO 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 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.

GENERAL INFORMATION GI-3 FUNDAMENTAL PROCEDURES VEHICLE PROTECTION 1. Cover the seats before performing any procedure to keep them from getting dirty. 2. Cover all glasses, seats and mats with a heat resistant cover when welding. 3. Protect moldings, garnishes and ornaments. BBHGI6000 SAFETY FACTORS 1. Disconnect the negative(-) battery cable before performing any work on the vehicle. 2. Protect yourself by wearing goggles, earplugs, respirators, gloves, safety shoes, caps, etc. when working on a vehicle. 3. 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. 4. 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. 5. Insure 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. 6. Observe all local and national safety regulations when performing any work. 7. Cover interior with heat-resistant cover to insure safety when welding. 8. Take care when using gas or cutting torches so as not to burn body sealer or interior. Extinguish immediately if they should catch fire.

GI-4 GENERAL INFORMATION SRS AIR-BAG The MOHAVE / BORREGO 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. Also take the following precautions when repairing the body: 1. 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. 2. When using electric welding, first disconnect the air-bag connectors under the steering column near the MULTI-FUNCTION SWITCH and the passenger's side crash pad before starting work. 3. Store the air-bag modules where the ambient temperature remains below 93 C (200 F ), without high humidity and away from electrical noise. 4. WARNING/CAUTION labels are attached to the periphery of the air-bag components. Refer to the MOHAVE / BORREGO SHOP MANUAL. Side airbag BHMGI6001 Clock spring Airbag control unit Front side impact sensor Curtain airbag Seat belt pretensioner Front impact sensor Passenger airbag Driver airbag Rear side impact sensor

GENERAL INFORMATION GI-5 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 8 mm (5/16") hole is placed in the top (welding side) sheetmetal. You then begin welding along the edges and the spiral towards the center (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 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. BODY FRAME STRAIGHTENER When using a frame straightener, do not enter the area where the body is being straightened by the chain. CON-0040 Weld around edges first working in towards the center (Top view) PLUG WELDING 8mm or 5/16" dia. hole Illustration-Welding in collision repair

GI-6 GENERAL INFORMATION ELECTRONIC PARTS Vehicles today include a great 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. Therefore, 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. NOTE

GENERAL INFORMATION GI-7 FOR BEST RESULTS REMOVAL Measuring dimensions before beginning Measure the dimensions of the damaged area according to the body dimension drawings before removing 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 (1.2~2.0 in) . Protecting body from damage Secure the body with clamps and jacks to prevent damage to the body when working on it. BHMGI6005

GI-8 GENERAL INFORMATION Removing 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. BVQGI6006 Wire harness Repair work area Cutting area

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2009 KIA MOHAVE / BORREGO Body Service / Repair/ Workshop Manual ! 09

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