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Kia Sportage: Assembly - Replacing body panel

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

Assembly

1. Checking welding and fitting in advance

  1. 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 reference dimensions.

  1. Prior to final welding, check the fit of all related parts.

2. Selecting number of welding points

2. Selecting number of welding points

  Spot welding : Multiply the original number of factory welds by 1.3 times

  Plug welding : Same number as original number of factory welds

Notice

  • Plug welding should be done using a carbon arc welding machine.
  • Brazing should be done only on areas that were originally brazed at the factory.

3. Caution when spot welding

3. Caution when spot welding

  1. Do a test welding on a piece of material of the same type and thickness as the part to be welded and proceed if test weld is good.
  2. Before spot welding, check if welding debris, oil or paint is present on the area where surfaces meet.

    Clean or sand as necessary.

  1. The tip of the spot welding machine should be maintained to a minimum tolerance of 3 mm. Also let area cool after 5 or 6 welds to minimize problems caused by excessive heat.

4. Cutting and welding an assembled area

4. Cutting and welding an assembled area

To align a roof panel and a center pillar together for butt welding, temporarily fasten a steel flange to the roof panel and then apply the new center pillar panel.

Remove the flange when final welding is done.

5. Finishing after welding

5. Finishing after welding

  1. Grind any areas that were plug welded or butt welded using a disk grinder. Grind carefully to avoid removing too much material. This degrades the strength of the weld.

  1. Finish areas that have been brazed by applying body filler then smooth the area with a flexible file and sander.

6. Applying anti-rust agent and body sealer

6. Applying anti-rust agent and body sealer

After coating the surface with anti-rust agent, apply body sealer where necessary.

Notice

  • Apply body sealer before assembly.

7. Anti-rust treatment

7. Anti-rust treatment

Apply anti-rust agent to inside of doors and sills by spraying through access holes provided.

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