Kia Sportage: 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.
![](images/books/1884/2/index.62.png)
- Prior to final welding, check the fit of all related parts.
![2. Selecting number of welding points](images/books/1884/2/index.63.png)
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
factory welds
Notice
- Plug welding should be done using a carbon arc
welding machine.
- Brazing should be done only on areas that were
originally brazed at the factory.
![3. Caution when spot welding](images/books/1884/2/index.64.png)
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.
![](images/books/1884/2/index.65.png)
- 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](images/books/1884/2/index.66.png)
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](images/books/1884/2/index.67.png)
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.
![](images/books/1884/2/index.68.png)
- Finish areas that have been brazed by applying
body filler then smooth the area with a flexible file
and sander.
![6. Applying anti-rust agent and body sealer](images/books/1884/2/index.69.png)
6. Applying anti-rust agent and body sealer
After coating the surface with anti-rust agent, apply
body sealer where necessary.
Notice
- Apply body sealer before assembly.
![7. Anti-rust treatment](images/books/1884/2/index.70.png)
7. Anti-rust treatment
Apply anti-rust agent to inside of doors and sills by
spraying through access holes provided.
![Fender apron panel assembly](images/books/1884/2/index.71.png)
READ NEXT:
Welding part
Setion
Cowl panel assembly
Welding part
Section
Dash panel assembly
Welding part
Section
Center floor panel assembly
Welding part
Section
Re
Body dimension indications
Projected dimensions
The projected dimension indicates a dimension from a reference point on the
body. (Height may be different in some
cases).
Straight-line dimension
Sealing
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 ta
SEE MORE:
The LCD display modes can be changed
with the control buttons.
LCD Display Control
MODE button for changing
modes
MOVE switch for
changing
items
OK: SELECT/RESET button for setting
or resetting the selected item
LCD display modes
The LCD display provides 5 modes. You
Installation
NOTE
Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No.1 piston at TDC.
1. Install the cylinder head gasket (A) on the cylinder bloc