Hyundai Getz: Body Repair Manual - part 20

85

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

3.

Cut through the front side member inner and outer at cutlines.

NOTE
Take care not to cut through front side member inner
reinforcement.

4.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe the front side member inner and outer cutline to the
new front side member, cut to length and chamfer butt end to
improve weld surface.

2.

Drill 8mm holes in new front side member for MIG plug welding.

3.

Fit and clamp the front side member inner and outer in place.

4.

MIG plug weld all holes and MIG butt weld all seams.

5.

Measure each measurement point (Refer to the BODY DIMEN-
SIONS) and correct the installation position.

PRO-0390

PRO-0400

PRO-0100

PRO-0380

86

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

6.

Clean and prepare all welds, remove all residue.

7.

Apply the two-part epoxy primer to the interior of the front side
member.

8.

Apply an anti-corrosion agent as required
(Refer to the CORROSION PROTECTION).

9.

Prepare the exterior surfaces for priming using wax and grease
remover.

10. Apply metal conditioner and water rinse.
11. Apply conversion coating and water rinse.
12. Apply the two-part epoxy primer.
13. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

14. Reprime over the seam sealer to complete the repair.

PRO-0420

PRO-0430

87

FRONT PILLAR

BODY PANEL REPAIR PROCEDURE - Front pillar

z

z

z

z

z

MIG plug welding
MIG butt welding

xx MIG lap welding

WELDLING POINTS

Ô

Ô

Ô

Ô

Ô

A

Ô

Ô

Ô

Ô

Ô

C

PRO-0450

PRO-0480

PRO-0470

Ô

Ô

Ô

Ô

Ô

D

PRO-0481

Í

Í

Í

Í

Í

Ó

Ó

Ó

Ó

Ó

C

ÎÎÎÎÎ

A

Ô

Ô

Ô

Ô

Ô

B

PRO-0460

ΠΠΠΠÎ

D

B

88

BODY PANEL REPAIR PROCEDURE - Front pillar

REMOVAL

1.

Measure and mark the each cutline on the front outer pillar at
150mm from the roof panel end line as indicated in the illustration.

2.

Measure and mark the cutline on front side sill outer panel as
shown in the illustration.

3.

Depending on the extend of damaged area, it may be possible to
determine the cutting range within indicated in the illustration.

4.

To remove the front pillar, grind away and drill out all welds
attaching the cowl side upper outer panel as shown in the
illustration.

NOTE
If it is possible that the cowl side upper outer panel is
reusable, be careful not to damage it while removing.

PRO-0510

PRO-0520

PRO-0500

30mm

PRO-0490

50mm

80mm

130mm

150mm