Kia Sportage: Disassembly - Replacing body panel
1. Body measurement
- Before disassembling, measure the damaged area
according to the dimensions supplied in Body
Dimension, Section 31. If deformation is present,
use a frame straightener to adjust.
- When disassembling a panel, apply clamps to
prevent damage of each part, and support the
lower end of the frame to prevent deformation
during the procedure.
2. Cut and welding point selection
Cutting, 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 be done according to the following steps
to make disassembly easy:
- Use care when cutting an area close to a pipe or
- Cut an area leaving 30~50 mm of tolerance.
4. Removing paint from an area to be spot welded
Using a torch and wire brush, remove paint completely
before beginning welding.
5. Determine a cutting method
- Cutting a spot welded area
Make a hole in the middle of spot welded area with
a punch, disassemble welded area using a spot
cutter and remove using a chisel.
- Removing brazed area
Disassemble using a torch and wire brush, and
remove with a chisel.
- Removing arc welded area
Remove plug welded area using a disk grinder and
disassemble with a chisel.
Preparation for assembly
1. Spot weld finish
Use a disk grinder or similar tool to finish spot weld
mark. Do not grind more than is necessary to smooth
2. Panel preparation
Repair any bent or uneven areas with a hammer to
1. Checking welding and fitting in advance
When assembling a new part, measure the
dimensions of each part according to the body
dimensions given in Section 31, and set part to the
Prior to final weld
Cowl panel assembly
Dash panel assembly
Center floor panel assembly
Rear floor panel assembly
Engine oil is used for lubricating, cooling,
and operating various hydraulic components
in the engine. Engine oil consumption
while driving is normal, and it is
necessary to check and refill the engine
oil regularly. Also, check and refill the o
Lane Keeping Assist malfunction
Check Lane Safety system
When Lane Keeping Assist is not working
properly, the warning message will
appear and the yellow ( ) indicator
light will appear on the cluster. If this
occurs, have the function