Kia Sportage: Preparation for assembly - Replacing body panel
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
surface.

2. Panel preparation
Repair any bent or uneven areas with a hammer to
improve the assembly process.

3. Cutting a rough area for a new part
When rough cutting an area for a new part, leave a tolerance of 30~50 mm.

4. Preparation for spot welding
Remove paint on spot welded area and on the area
overlapped by the new part using a belt sander or
similar tool.

5. Drilling a hole for plug welding
If the thickness of the part to be welded is less than 3
mm, drill a 5~6 mm diameter hole. If the thickness of
the part to be welded is greater than 3 mm, drill a hole
using a 7 mm diameter drill.
Notice
- Do not spot weld where thickness is greater than
3 mm.

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Assembly
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
Welding part
Setion
Cowl panel assembly
Welding part
Section
Dash panel assembly
Welding part
Section
Center floor panel assembly
Welding part
Section
Re
Body dimension indications
Projected dimensions
The projected dimension indicates a dimension from a reference point on the
body. (Height may be different in some
cases).
Straight-line dimension
SEE MORE:
WARNING
Do not start the vehicle with the accelerator
pedal engaged. The vehicle can
move and lead to an accident.
Wait until the engine rpm is normal.
The vehicle may suddenly move if the
brake pedal is released when the r pm
is high.
Starting the engine with smart
key
At the t
Components and Components Location
Component Location
Repair procedures
Replacement
1. Discharge refrigerant from refrigeration system.
2. Replace faulty tube or hose.
CAUTION
Cap the open fittings immediately to keep moisture or dirt out of the system.
3. Tighten joint of bolt or nu