Kia Sportage (2005+). Manual — part 3

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.

General information

00-5

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).

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.

00012

1.2~2.0 in

(30~50 mm)

Overlap

1.2~2.0 in

(30~50 mm)

Overlap

body side to modify

new part to modify

Thicker than
0.1 in (3mm)

ASD1BM007

BMKM101

00-6

General information

Assembly

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 should be determined based on the criteria below:

Caution when spot welding

The tip of the spot welding machine should be maintained to a minimum of 0.1 in (3 mm) because it greatly

affects welding strength. When possible, spot welding should be done between the existing spot welded points.

Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the

welding strength.

ASD1BM010

0.1 in

(3 mm)

0.1 in

(3 mm)

Center

diameter

Good

Existing welded spots

New welded spots

Using a hammer and a chisel

Using a test piece(test pin)

Nugget diameter
to be 4/5 of chip
diameter

No good

BMKM102

Spot welding

Old part

Repair part

Pitch: 2.0 in (50 mm)

Increase the
number of spot
welds by 30%.

Pitch:
Same number of
welds as original
part.

Pitch:
1.4 in (35 mm)

Repair part
more than
0.1 in (3 mm)

Plug welding

A

9

Applying undercoat
Apply undercoat on the body where necessary.

General information

00-7

Rustproof treatment after assembly

Body sealing
Apply body sealer where necessary.

Applying rustproof material
Apply rustproofing material(wax, oil, etc.) behind welded area.

BMKM103

00-8

General information

Vehicle Lift (2-Support Type) And Safety Stand Positions

Jack Support 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 support.

AAIE010A

AAIE010B

Lift Block

Lift Block

[Front]

[Rear]