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Kia Sportage: Disassembly - Replacing body panel

Kia Sportage - Second generation (JEKM) (2005-2015) - Body Workshop Manual / Replacing body panels / Notes when welding body / Disassembly - Replacing body panel

Disassembly

1. Body measurement

  1. 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.
  2. 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

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

3. Cutting rough area for replacement part

Cutting should be done according to the following steps to make disassembly easy:

  1. Use care when cutting an area close to a pipe or wiring harness.
  2. Cut an area leaving 30~50 mm of tolerance.

4. Removing paint from an area to be spot welded

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

5. Determine a cutting method

  1. 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.

  1. Removing brazed area

Disassemble using a torch and wire brush, and remove with a chisel.

  1. Removing arc welded area

Remove plug welded area using a disk grinder and disassemble with a chisel.

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