Kia Sportage (2005+). Manual — part 10

Replacing body panels

Replacing body panels

Replacing body panels

Codes for disassembling and assembling body panels

. . . . . 21- 1

Notes when welding body

Fender apron panel assembly

21-11

Cowl panel assembly

21-17

Dash panel assembly

21-22

Center floor panel assembly

21-26

Rear floor panel assembly

Side panel assembly

Roof panel assembly

21-29

21-32

21-38

Disassembling spot welded area

. . . . . . . . . . . . . . . . 21- 2

Assembling a new body frame

. . . . . . . . . . . . . . . . . 21- 4

Determining a welding method

. . . . . . . . . . . . . . . . . 21- 4

Spot welding

. . . . . . . . . . . . . . . . . . . . . . . . ..

. . . . . . . . . . . . . . . . . . . . ...

. . . . . . . . . . . . . .

21- 4

Carbon arc welding

. . . . . . . . . . . . . . . . . . . . . . 21- 5

Replacing body panel

. . . . . . . . . . . . . . . . . . . . . 21- 6

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. . . . . . . . . . . . . . . . . . . . ...

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Back panel assembly

21-43

Quarter outer rear panel assembly

21-45

. . . . . . . . . . . . . . . . . . .

Side sill panel assembly

21-46

. . . . . . . . . . . . . . . . ...

Wheel house panel assembly

21-47

. . . . . . . . . . . . . . . . . . . . ...

. . . . . . . . . . . . . . . . . . . . ...

2 1

Replacing body panels

21-1

See Notice and Cautions for disassembly

Location for cut and assembly

Rough cutting location

0.8~1.2 in.

(20~30 mm)

0.8~1.2 in.

(20~30 mm)

ARS1BD040A

Replacing body panels

Codes for disassembling and assembling body panels

Notes when welding body

Disassembling spot welded area

Most body parts are spot welded. In order to disassemble the damaged area, it is best to disassemble the spot
welded area from the body frame using a spot cutter or candle type edge drill bit. Do not use a drill bit with a tapered
edge. Center punch middle of spot weld to insure the entire spot weld will be removed.

1. Spot cutter

1. Drill(candle type edge)

1. Drill(taper edge)

2.

3.

3.

3.

2.

2.

A3EB3251

Correct

Correct

Not correct

21-2

Replacing body panels

Replacing body panels

21-3

Center punch the middle(nugget) of the spot weld.

Otherwise,

Spot welded area can be removed from the body frame.

This part will not be cut.

This part will be cut.

A3EB3252

Spot welded area cannot be removed from the body

frame.