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Kia Sportage: Preparation for assembly - Replacing body panel

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

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

2. Panel preparation

Repair any bent or uneven areas with a hammer to improve the assembly process.

3. Cutting a rough area for a new part

3. Cutting a rough area for a new part

When rough cutting an area for a new part, leave a tolerance of 30~50 mm.

4. Preparation for spot welding

4. Preparation for spot welding

Remove paint on spot welded area and on the area overlapped by the new part using a belt sander or similar tool.

5. Drilling a hole for plug welding

5. Drilling a hole for plug welding

If the thickness of the part to be welded is less than 3 mm, drill a 5~6 mm diameter hole. If the thickness of the part to be welded is greater than 3 mm, drill a hole using a 7 mm diameter drill.

Notice

Do not spot weld where thickness is greater than 3 mm.

Assembly - Replacing body panel

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 reference dimensions. Prior to final weld

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