Kia Sportage: Preparation of assembly

Kia Sportage - Second generation (JEKM) (2005-2015) - Body Workshop Manual / General information / For best results / Preparation of assembly

Applying spot sealer

Remove paint from the surface of new parts and body to be spot welded, and apply spot sealer for rustproofing.

Selecting a welding method

If the thickness of the area to be welded with the panels overlapped is greater than 0.1 in (3 mm), do plug welding using a carbon arc welding machine.

Machining holes for plug welding

Machining holes for plug welding

Drill a hole of approximately 0.2~0.24 in (5~6 mm) in diameter in those areas which are not suitable for spot welding.

Adjusting a new part

Adjusting a new part

The new part should be cut larger than the repair area, overlapping the repair area by 1.2~2.0 in (30~50 mm).




    Measuring dimensions before welding When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after checking the gaps with nearby parts. Caution when welding The number of welding points sho

     Rustproof treatment after assembly

    Body sealing Apply body sealer where necessary. Applying rustproof material Apply rustproofing material (wax, oil, etc.) behind welded area. Applying undercoat Apply undercoat on the body where necessary.

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

    1. Place the lift blocks under the support points as shown in the illustration. 2. Raise the hoist a few inches and rock the vehicle to be sure it is firmly supported. 3. Raise the hoist to full height to inspect the lift points for secure su


     Roof panel (Without sunroof)

    Roof front rail assembly Roof rear rail assembly Roof panel Roof center No.1 rail Roof center No.2 rail Roof center No.3 rail Roof panel (With sunroof) Roof front rail assembly Roof rear rail assembly Roof panel Sunroof

     Temperature control

    The temperature control knob allows you to control the temperature of the air flowing from the ventilation system. To change the air temperature in the passenger compartment, turn the knob to the right for warm and hot air or to the left fo