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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).

Assembly

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    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

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    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

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     Opening the hood

    The hood serves as a cover for the engine compartment. Open the hood if maintenance work needs to be performed in the engine compartment or if you need to look at the compartment. Opening the hood Pull the release lever to unlatch the hood. The hood should pop open slightly.

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    Components and Components Location  Components Tie rod end Locknut Bellows Bellows band Tie rod Rack bar Dust packing Pinion assembly Dust cap Oil seal Ball bearing Needle bearing Lock nut Yoke plug Yoke spring O-ring Spring Support yoke assembly Rep

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