Hyundai Elantra Neos / Hyundai i30. Manual - part 21

BP-20

BODY  PANEL REPAIR PROCEDURE

4.

Cut the front side member inner and outer panel along
the cutlines.

5.

Remove the front side member.

6.

Prepare all surfaces to be welded.

BEDBP6202A

7.

After removing, apply the welding primer.

INSTALLATION

1.

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

2.

Fit and clamp the front side member in place.

3.

Measure each measurement point (Refer to the BODY
DIMENSIONS) and correct the installation position.

BEDBP6204

BEDBP6204A

BFDBP6203B

BEDBP6206

BFDBP6205

BODY PANEL REPAIR PROCEDURE

BP-21

4.

MIG plug weld all holes and MIG butt weld seams.

5.

Clean and prepare all welds, and remove all residue.

6.

Apply the two part epoxy primer to the interior of the
each panel.

7.

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

8.

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

9.

Apply metal conditioner and water rinse.

BFDBP6203C

BEDBP6203D

10. Apply conversion coating and water rinse.

11. Apply the two-part epoxy primer.

12.  Apply the correct seam sealer to all joints carefully.
    (Refer to the BODY SEALING LOCATIONS)

13. Install the front crash member assembly.

BEDBP6202B

BFDBP6203E

BEDBP6201A

BP-22

BODY  PANEL REPAIR PROCEDURE

FRONT PILLAR

120mm

BFDBP6307

WELDING POINTS

A

B

A

B

150mm

B

100mm

90mm

Laser welding

MIG plug welding

MIG butt welding

MIG lap welding

BODY PANEL REPAIR PROCEDURE

BP-23

REMOVAL

1.

To remove the front pillar, drill out and grind away all
spotwelds and plug welds attaching the cowl side upper
outer panel.

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

2.

Remove the cowl side upper outer panel.

3.

Before cutting the front pillar, be sure to support roof
panel.

4.

Measure and mark the each cutline on the front pillar
outer panel 150mm and 270mm from the roof panel
corner as indicated in the illustration.

5.

Cut the front pillar outer panel along the cutlines.

When cutting the front pillar outer panel, take care not
to cut through mating flanges or front pillar outer
reinforcement.

NOTE

BEDBP6321

NOTE

BFDBP6303

BFDBP6305

120mm

150mm

BFDBP6305A