Kia Sportage (2005+). Manual — part 11

21-4

Replacing body panels

Spot welding

1. Commercial spot welding machines do not perform

as well as the machines used in the manufacturing
process. When spot welding, increase the number
of spot welds by 30%(1.3 times the original number
of welds).

2. When spot welding, weld in the middle of the joint.

Spot welding on the edge of the joint will reduce

welding strength.

Assembling a new body frame

The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness of plate,
shape and size of a cross section, damage of parts, variance of joints, welding method, and/or welding locations. Therefore, a
new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the body.

Determining a welding method

It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the

or carbon arc(plug) welding. Do not braze any body

components other than the ones brazed at the factory. Do not use an oxy-acetylene torch for welding.

body be used when making repairs, Try to use either spot welding or carbon arc(plug) welding, Do not braze any body

Welding

Symbol

Details

The most reliable welding method

Spot welding

(provides high efficiency and quality of assembled part.)

Carbon arc welding

Use when spot welding cannot be done or spot welding is

(Plug welding)

not necessary.

Oxygen-acetylene welding

Not used

A3EB3253

Good

A3EB3254

No good

A3EB3255

Replacing body panels

21-5

Carbon arc welding

In areas where spot welding is not suitable, do plug
welding using a carbon arc welding machine.
1. Clamp the parts to be welded together tightly. Do not

exceed 1 mm of space between parts. A tolerance
greater than 1 mm will reduce the strength of the
welded area.

2. Weld in the middle of the flange joint.

a) Drill a hole 5~6 mm on one side of the flange only,

and weld within the hole.

b) Do not weld on the edge of the flange joint.

1mm

Maximum tolerance

A3EB3256

Good

A3EB3254

No good

A3EB3257

21-6

Replacing body panels

Replacing body panel

Disassembly

1. Body measurement
a) Before disassembling, measure the damaged area

according to the dimensions supplied in Body
Dimension, Section 31. If deformation is present,
use a frame straightener to adjust.

b) When disassembling a panel, apply clamps to

prevent damage of each part, and support the
lower end of the frame to prevent deformation
during the procedure.

2. Cut and welding point selection

Cutting, if necessar y, should not be done in a
reinforcement area. Select an area which will result in
the least amount of deformation after welding.

3. Cutting rough area for replacement part

Cutting should be done according to the following steps
to make disassembly easy:

a) Use care when cutting an area close to a pipe or

wiring harness.

b) Cut an area leaving 30~50 mm of tolerance.

4. Removing paint from an area to be spot welded

a

Using a torch and wire brush, remove paint completely

before beginning welding.

A3EB3261

A3EB3258

ASD1BM005

Tracking gauge

Reinforcement

Reinforcement

Cut area

Replacing body panels

21-7

5. Determine a cutting method

a) Cutting a spot welded area

Make a hole in the middle of spot welded area with
a punch, disassemble welded area using a spot
cutter and remove using a chisel.

b) Removing brazed area

Disassemble using a torch and wire brush, and
remove with a chisel.

c) Removing arc welded area

Remove plug welded area using a disk grinder and
disassemble with a chisel.

Preparation for assembly

1. Spot weld finish

Use a disk grinder or similar tool to finish spot weld
mark. Do not grind more than is necessary to smooth
surface.

2. Panel preparation

Repair any bent or uneven areas with a hammer to
improve the assembly process.

3. Cutting a rough area for a new part

tolerance of 30~50 mm.

1SD1BM015

1SD1BM016

1SD1BM017

1SD1BM018

1SD1BM019

1SD1BM020

When rough cutting an area for a new part, leave a