Kia Sportage (2005+). Manual — part 1

Title

GENERAL INFORMATION

BODY STRUCTURE

REPLACING BODY PANELS

BODY DIMENSIONS

WATERPROOFING AND
RUSTPROOFING

BODY MODIFICATION TOOLS

PLASTIC PARTS

00

11

21

31

41

51

61

Group

This Body Shop Manual illustrates body structures and
service procedures for the SPORTAGE.

This manual illustrates the replacement of major body
panels, plastic parts, body dimensions, sealing
treatment etc., in a systematic manner which is
necessary for effective and lasting body repairs.
You are encouraged to become familiar with this
manual and understand each section in order to
perform proper repair procedures. Keep this manual in
a convenient location so that it is readily available.

All information in this manual including specifications,
data and illustrations is made based on the vehicles
built at the time the manual was printed.

Information regarding the removal/replacement of
components not specifically covered in this manual can
be found in the SPORTAGE Service Manual. Information
regarding electrical harness routing/ connections, etc.
can be found in the SPORTAGE Electrical Troubleshooting
Manual.

The descriptions and specifications contained in this
manual were in effect at the time this manual was
approved for printing. Kia Motors Corporation reserves
the right to discontinue models at any time, or change
specifications or design without notice and without
incurring obligation.

Body shop Manual

FOREWORD

Kia Motors Corporation

SEOUL, KOREA

CONTENTS

All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or
transmitted in any form or by any means without the prior written permission of Kia Motors Corporation.

Copyright 2004, Kia Motors Corporation
Printed in Korea, August 2004
Pub. No. : A1FB-EG48A (English)

CAUTION :

Severe engine and transaxle damage may
result from the use of poor quality fuels and
lubricants that do not meet Kia specifications.
You must always use high quality fuels and
lubricants that meet the specifications
described on the specification section in the
relevant group of the Workshop Manual.

21-18

Replacing body panels

BMKM

030

B

A

C

D

5 Points

6 Points

C

D

E

E

A

B

IN THIS MANUAL

IMPORTANT SAFETY NOTICE

Proper service methods and repair procedures are essential for safe, reliable operation of all
motor vehicles as well as personal safety of the operator. The service procedures and
descriptions in this body shop manual provide general directions for a service and repair.

Procedure, techniques, tools, and parts for service including the skill of the technician vary.
It is impossible to provide advice or caution as to each case in this manual.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is
not recommended by the vehicle manufacturer, must first assure thoroughly that neither their
personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement
part, service procedure, or tool they select.

The following list contains some general WARNINGS that you should follow while working on a
vehicle.

Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Make sure that the ignition switch is always in the OFF position, unless otherwise required by
the

procedure.

Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in
park unless instructed otherwise for a specific operation
Place supporters against the front and rear surfaces of the tires to help prevent the vehicle
from

moving

Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide
poisoning.
Keep yourself and your clothing away from moving parts when the engine is running,
especially the drive belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
Do not smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing
before beginning to work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the
radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even
though the ignition switch is in the OFF position. For this reason care should be taken to
ensure that the radiator fan electric motor is completely disconnected when working under the
hood and the engine is not running.

Remind you to be especially careful in those areas where carelessness can

cause personal injury.

To prevent you from making errors that could damage the vehicle as well as

personal

injury.

Gives you added information that will help you complete a particular procedure.

WARNING :

CAUTION :

NOTE :

General information

Fundamental procedures

Vehicle protection

. . . . . . . . . . . . . . . . . . . . . . 00- 1

A word about safety

. . . . . . . . . . . . . . . . . . . . . . 00- 1

Welding procedures

. . . . . . . . . . . . . . . . . . . . . 00- 1

Body frame straightener

. . . . . . . . . . . . . . . . . . . . 00- 2

Electrical procedures

. . . . . . . . . . . . . . . . . . . . .. 00- 2

For best results

Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . .. 00- 3

Preparation of assembly

. . . . . . . . . . . . . . . . . . . 00- 5

Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . 00- 6

Rustproof treatment after assembly

. . . . ..

00- 7

Vehicle lift (2-Support type) & safety stand positions

00- 8

Jack and safety stand positions

. . . . . . . . . . . . . . . . 00- 8

Towing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..00- 9

Body colors and major specifications

Kia color codes

. . . . . . . . . . . . . . . . . . . . . . . 00- 10

Paint manufacture codes

. . . . . . . . . . . . . . . . . . . 00- 10

General information

0 0