Hyundai Elantra Neos / Hyundai i30. Manual - part 23

BP-28

BODY  PANEL REPAIR PROCEDURE

5.

 Clean and prepare all welds, and remove all residue.

6.

After removing, apply the welding primer.

7.

Transcribe the cutlines to the new front pillar outer panel,
adding 30mm overlap to each end and cut to length.

8.

Drill 8mm holes along front pillar outer panel flanges
for   attachment to other panels.

4.

MIG plug weld all holes and MIG lap weld seams.

BEDBP6315A

BEDBP6315B

BEDBP6315C

BEDBP6320

2.

Fit and clamp the new front pillar inner panel in place
for welding.

3.

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

BEDBP6315

BODY PANEL REPAIR PROCEDURE

BP-29

9.

Install the front pillar outer panel in place.

10. Measure each measurement point (Refer to the  BODY

DIMENSIONS) and correct the installation position.

11. MIG plug weld all holes.

12. Clean and prepare all welds, and remove all residue.

BEDBP6309A

BEDBP6309B

BEDBP6309C

13. After removing, apply the welding primer.

14. Reattach the cut away front pillar outer panel section,

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

15. Clean all welds with a disc grinder.

BEDBP6309D

BEDBP6321A

BEDBP6321B

BP-30

BODY  PANEL REPAIR PROCEDURE

22. Apply an anti-corrosion agent to the welded parts and

inside of front pillar (Refer to the CORROSION
PROTECTION).

23. Prepare exterior surfaces for priming, using wax and

grease remover.

24. Apply metal conditioner and water rinse.

25. Apply conversion coating and water rinse.

26. Apply the two-part epoxy primer.

27. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

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

16. After removing, apply the welding primer.

17.  Apply the two-part epoxy primer to the interior of the

front pillar.

18. Before welding the cowl side upper outer panel, apply

the two part epoxy primer and anti-corrosion agent to
the interior of the fender apron panel.

19. Install the cowl side upper outer panel in place.

20. MIG plug weld all holes.

21. Clean and prepare all welds, remove all residue.

BEDBP6321C

BEDBP6302

BEDBP6312

BFDBP6303A

BFDBP6303B

BODY PANEL REPAIR PROCEDURE

BP-31

SIDE SILL PANEL

REMOVAL

1.

Measure and mark the horizontal cutline on front pillar
outer panel 50mm from the door hinge mounting hole
as indicated in the illustration.

BEDBP6401

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

70mm

50mm

50mm

BEDBP6401A

50mm

2.

Measure and mark the horizontal cutline on center pillar
outer panel 70mm from the door hinge mounting hole.

3.

Measure and mark the vertical cutline on rear side sill
outer panel 50mm from the rear door step trim mounting
hole as indicated in the illustration.

BEDBP6401B

70mm

50mm