Hyundai Elantra Neos / Hyundai i30. Manual - part 1

GENERAL INFORMATION

GI-3

FUNDAMENTAL PROCEDURES

VEHICLE PROTECTION

1.

Cover the seats before performing any procedure to
keep them from getting dirty.

2.

Cover all glasses, seats and mats with a heat resistant
cover when welding.

3.

Protect moldings, garnishes and ornaments.

BVQGI6001

SAFETY FACTORS

1.

Disconnect the negative(-) battery cable before
performing any work on the vehicle.

2.

Protect yourself by wearing goggles, earplugs,
respirators, gloves, safety shoes, caps, etc. when
working on a vehicle.

3.

Safely support the vehicle before any work is done.
Block the front or rear wheels if the vehicle is not lifted
off of the ground.

4.

When welding or performing other procedures that
require the use of an open flame near the fuel tank,
disconnect and remove the tank and fuel pipe, and
cap the pipe to prevent fuel leakage.

5.

Insure proper ventilation of your working area. Some
paint and sealant can generate toxic gases when
heated. Use an air chisel or saw to remove damaged
panels instead of a gas torch.

6.

Observe all local and national safety regulations when
performing any work.

7.

Cover interior with heat-resistant cover to insure safety
when welding.

8.

Take care when using gas or cutting torches so as not
to burn body sealer or interior. Extinguish immediately
if they should catch fire.

GI-4

GENERAL INFORMATION

SRS AIR-BAG

The i30 / ELANTRA NEOS is equipped with a Supplemental Restraint System AIR-BAG to provide the vehicle's driver and/
or the front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal impact
of sufficient severity.

When handling airbag components (removal, installation or inspection, etc.), always follow the directions given in the repair
manual for the relevant model to prevent the occurrence of accidents and airbag malfunction.

Also take the following precautions when repairing the body:

1.

Work must be started after approximately 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 so that if work is started within 30 seconds of disconnecting the negative (-) terminal cable of the
battery, the airbag may be deployed.)
When the negative(-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be
cancelled. So before starting work, make a record of the contents memorized by the audio memory system. Then when
work is finished, reset the audio system as before and adjust the clock.

2.

When using electric welding, first disconnect the air-bag connectors under the steering column near the MULTI-FUNCTION
SWITCH and the passenger's side crash pad before starting work.

3.

Store the air-bag modules where the ambient temperature remains below 93  C  (200   F ), without high humidity and
away from electrical noise.

4.

WARNING/CAUTION labels are attached to the periphery of the air-bag components.
Refer to the i30 / ELANTRA NEOS  SHOP MANUAL

ERKB012A

Front impact sensor

Clock spring

PAB

BPT

Buckle pretentioner

Side impact sensor

When it is deployed

GENERAL INFORMATION

GI-5

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% CO

2

.

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.

Observe the following tips when welding.
1.

Wear appropriate eye protection.

2.

Carefully follow the manufacturers operating instructions for the welding machine you are using.

3.

Do not weld, smoke or allow open flames around volatile chemicals, cleaners or solvents or in any area where they have
just been used.

BODY FRAME STRAIGHTENER

When using a frame straightener, do not enter the area where the body is being straightened by the chain.

CON-0040

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

PLUG WELDING

8mm or 5/16" dia. hole

Illustration-Welding in collision repair

GI-6

GENERAL INFORMATION

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 MODULES (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 MODULES to ambient
temperatures above 80  C (176   F ).

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

3.

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

NOTE