Kia Sportage: Assembly - Replacing body panel
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
- Prior to final welding, check the fit of all related parts.
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
- Plug welding should be done using a carbon arc
- Brazing should be done only on areas that were
originally brazed at the factory.
3. Caution when spot welding
- 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.
- Before spot welding, check if welding debris, oil or
paint is present on the area where surfaces meet.
Clean or sand as necessary.
- 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
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
- 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.
- Finish areas that have been brazed by applying
body filler then smooth the area with a flexible file
6. Applying anti-rust agent and body sealer
After coating the surface with anti-rust agent, apply
body sealer where necessary.
- Apply body sealer before assembly.
7. Anti-rust treatment
Apply anti-rust agent to inside of doors and sills by
spraying through access holes provided.
Cowl panel assembly
Dash panel assembly
Center floor panel assembly
Rear floor panel assembly
Body dimension indications
The projected dimension indicates a dimension from a reference point on the
body. (Height may be different in some
Straight-line dimensions (Actual measured dimensions)
To waterproof and rustproof the vehicle, apply sealer on assembled area of
the body panel and on any areas in
contact with the body, such as doors (inner/outer), hood (inner/outer), and tail
Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one
of the most important sensors of the
engine control system. If there is no CKPS signal input, the engine may stop
Description and Operation
The 4WD ECM controls the Pump Motor Pump (Actuator) to generating an oil
pressure. The pressure engages a multiple
disk clutch to transfer torque to the rear wheels. The torque to the rear