Hyundai H1: Body Repair Manual - part 1

6

GENERAL INFORMATION - General guide lines and precautions

GENERAL GUIDE LINES AND PRECAUTIONS

The Hyundai H-1 is a completely new vehicle design. During its development, close attention has been given to
safety, stability, weight and corrosion protection. Typical of unit body design, the Hyundai H-1 is designed so that
the front and rear compartments will absorb much of the collision energy so that the passengers are better protected.
During collisions, these front and rear energy absorbing systems may be severely damaged. During repair, these
damaged areas must be returned to their original strength and geometry. If this is not properly done, the vehicle
will not provide the intended level of protection to its occupants in the event of another collision.

The repairs described in this manual were performed on H-1 body shells. In some instances special fixtures were
welded in place to support the structure. During the repair of an actual vehicle, the interior would be fully disassembled
and standard jack screws or portable braces may be used for temporary support.

During the repair of an accident involved vehicle, the vehicle must first be returned to pre-impact dimensions prior
to beginning the sectioning repair procedures. The extent of damage that must be repaired should then be evaluated
to determine the appropriate repair procedures. This manual provides locations and procedures where structural
sectioning may be employed. It is the responsibility of the repair technician, based upon the extent of damage,
to determine which location and procedure is suitable for the particular damaged vehicle.

During the repair of a collision damaged automobile, it is impossible to fully duplicate the methods used in the
factory during the vehicle manufacture. Therefore, auto body repair techniques have been developed to provide
a repair that has strength properties equivalent to those of the original design and manufacture.

Certain guidelines and precaution are noted as follow.

AAAC0010

7

SRSCM (SRS CONTROL MODULE)

GENERAL

The supplemental restraint system (SRS AIRBAG) is designed to supplement the seat belt to help reduce the risk or severity
of injury to the driver and passenger by activating and deploying the driver and passenger side airbag in certain frontal
collisions.
The SRS (Airbag) consists of : a driver side airbag module located in the center of the steering wheel, which contains the
folded cushion and an inflator unit ; a passenger side airbag module located in the passenger side crash pad contains the
folded cushion assembled with inflator unit ;SRSCM located on the floor under the heater core which monitors the system,
an accelerometer which senses the vehicle deceleration, a spring interconnection (clock spring) located within the steering
column; system wiring and wiring connector; and a knee bolster located under the steering column. The impact sensing
function of the SRSCM is carried out by electronic accelerometer that continuously measure the vehicle's acceleration and
delivers a corresponding signal through amplifying and filtering circuity to the microprocessor.
Deployment of the airbag is designed to occur in frontal or near-frontal impacts of moderate of severe force.
Only authorized service personnel should do work on or around the SRS components. Those service personnel should read
this manual carefully before doing any work. Extreme care must be used when servicing the SRS to avoid injury to the service
personnel (by inadvertent deployment of the airbag) or the driver (by render the SRS inoperative).

CUSTOMER CAUTIONS

Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy
during servicing, possibly leading to a serious injury. Further, if a mistake is made in servicing the airbag system, it is
possible that the airbag may fail to operate when required. Before performing service (including removal or installation of
parts, inspection or replacement), be sure to read the following items carefully.
1. Be sure to proceed airbag related service after approx. 30 seconds or longer from the time the ignition switch is turned

to the LOCK position and the negative (-) terminal cable is disconnected from the battery. The airbag system is equipped
with a back-up power source to assure the deployment of airbag when the battery cable is disconneted by an accident.
The back-up power is available for approx. 150ms.

2. When the negative(-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be

canceled. So before starting work, make a record of the contents memorized by the audio memory system. When the
work is finished, reset the audio system and adjust the clock.

3. Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most important

source of information when troubleshooting.

4. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery.
5. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
6. Never attempt to disassemble and repair the airbag modules (DAB,PAB), clock spring and wiring in order to reuse them.
7. If any component of SRS has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector,

replace them with new ones.

8. After work on the airbag system is completed, perform the SRS SRI check.

The airbag indicator lamp can be interrupted by other curcuit fault in some cases. Therefore if the airbag indicator lamp
goes on, be sure to erase the DTC codes using Scan tool just after repairing or replacing the troubled parts including fuse.

9. Especially in case of welding the body, never fail to disconnect the battery negative (-) terminal.
10. WARNING/CAUTION labels are attached to the periphery of the air-bag components.

Refer to the H-1 SHOP MANUAL.

GENERAL INFORMATION - SRS Air-bag

8

ELECTRONIC PARTS

Vehicles today include a great many electronic parts and components, and these are in general very susceptible to
adverse effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity
impacts, etc.
In particular such electronic components can be damaged if there is a large current flow during welding from the body
side.
Therefore, take the following precautions during body repair to prevent damage to the CONTROL MODULS (ECM, TCM,
ABS CM, SRS CM, etc.)

1. Before removing and inspecting the electrical parts or before starting electric welding operations, disconnect the

negative (-) terminal cable from the battery.

2. Do not expose the CONTROL MODULS to ambient temperatures above 80°C (176°F).

NOTE :
If it is possible the ambient temperatures may reach 80°C (176°F) or more, remove the CONTROL MODULS
from the vehicle before starting work.

3. Be careful not to drop the CONTROL MODULS and not to apply physical shocks to them.

CORROSION PROTECTION AND SEALING

Proper corrosion protection and sealing is an important part of any repair. When reviewing these repair procedures, it
is important to recognize the need for corrosion restoration to provide for long term strength of the repaired member.

A two part epoxy primer was applied to the metal surfaces during the latter part of the repair. For closed sections,
such as front and rear rails, rocker panels and pillars, the primer is applied without applying the metal conditioner and
the conversion coating. These steps are omitted to insure that no rinse water is trapped in the closed sections. The
primer application is followed by an application of an oil or wax based rust proofing material.

After the corrosion restoration process for the closed sections are completed, then the process can be applied to all
exterior sections. For exterior surfaces, both metal conditioner and conversion coating treatments are applied to the
exterior surface prior to application of the epoxy primer. The procedure in applying the corrosion restoration process
is important order to insure that moisture, due to the water rinsing of the metal conditioner and conversion coating is
not inadvertently trapped inside any closed section before the epoxy primer and rust proofing materials have been
applied.

Appropriate seam sealers are then applied to all joints. Follow manufacturer's recommendations for the appropriate type
of seam sealer to be used at each seam or joint.

GENERAL INFORMATION - Electronic parts

9

GENERAL INFORMATION - Welding

CON-0040

Weld around
edges first
working in to
wards the
center
(Top wiew)

PLUG WELDING

8mm or 5/16" dia. hole

Illustration-Welding in collision Repair

WELDING

All repairs in this manual require the use of a Metal-Inert Gas (MIG) welder, Gas (oxyacetylene) welding must
not be used.
Both high strength steel and mild steel can be welded using the MIG welder. The I-CAR recommendations for
welding should be followed. The shielding gas should be 75% Argon and 25% CO2.
The recommended welding wire size is 0.23" and the wire should satisfy the American Welding Society standard
code AWSER70S-6.

During the repair process, plug welds are used to duplicate original factory spot welds. All plug welds should be
done with the MIG welder. An 8 mm (5/16") hole is placed in the top (welding side) sheetmetal.

You then begin welding along the edges and the spiral towards the center (see illustration). This is important so
that weld penetration between the two metal pieces takes place along the circumference of the circle.