Kia Sportage: Disassembly - Replacing body panel
Disassembly
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
wiring harness.
- 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.

READ NEXT:
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
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
SEE MORE:
The driver's and front passenger's seats
are equipped with a headrest for the
occupant's safety and comfort.
The headrest not only provides comfort
for the driver and front passenger, but
also helps protect the head and neck in
the event of a rear collision.
For maximum effe
Repair procedures
Replacement
CAUTION
When removing and installing the fender, an assistant is necessary.
Be careful not to damage the fender and body.
When removing the clips, use a clip remover.
1. Remove the front bumper cover.
(Refer to the BD group - "Front bum