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. Caut

     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

     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 fu


     Driving on grades

    Reduce the speed and shift to a lower gear before you start down a long or steep downgrade. If you don't shift down, you might have to use your brakes so much that they would get hot and no longer operate efficiently. On a long uphill grade, shift down and reduce your speed to around 45

     Description and Operation, Schematic Diagrams

    Description and Operation  Description The Evaporative Emission Control System prevents fuel vapor stored in fuel tank from vaporizing into the atmosphere. When the fuel evaporates in the fuel tank, the vapor passes through vent hoses or tubes to a canister filled with charcoal. The