Hyundai H1: Body Repair Manual - part 28

 

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Hyundai H1: Body Repair Manual - part 28

 

 

114

REMOVAL

Refer to the body dimension chart and measure the vehicle to
determine straigthtening and alignment requirments.

NOTE
The body must be returned to its original dimension before
beginning the repair procedure.

BODY PANEL REPAIR PROCEDURE - Rear floor

1.

Measure and mark the cutline on the rear floor from the rear edge
of rear floor as shown in the figure.

NOTE
The cutline in the illustration is provided for rear floor panel
replacement in case it has been damaged from rearside
inpacts. In case it has been damaged from side impact, it
may be easy to replace it if you are working on the front of
the cutline.

RRAF3030

RRAF3040

RRAF3050

2.

Before drilling out spotwelds, remove floor corner panel and body
sealant.

(LONG BODY)

1055 mm

975 mm

(SHORT BODY)

115

3.

Drill out all spotwelds attaching the rear floor panel to the body.

NOTE
Drill the outer panel with a spot cutter so as not to damage
the members.

4.

Cut the rear floor panel between No.7 crossmember welding
points. In that case, be careful not  to damage rear sidemember
and mating flangers.

5.

Remove the rear floor panel.

6.

Prepare all surfaces to be welded.

INSTALLATION

1. Transfer the cutline to the new rear floor panel, adding 25 mm for

overlap at the old joint.

2. Drill 8 mm holes in overlap area and production locations of the

new rear floor panel for MIG plug welding.

BODY PANEL REPAIR PROCEDURE - Rear floor

RRAF3060, AAAA9000

RRAF3070

RRAF3080

RRAF3090

116

BODY PANEL REPAIR PROCEDURE - Rear floor

3. Fit and clamp the rear floor panel and attach the rear floor panel

to the rear sidemembers and other panels.

4. MIG plug weld all holes and MIG butt weld the seam.

5. Clean and prepare all welds, removing all residue.

NOTE
In order to prevent distortion caused by the welding heat,
make the welds alternately at regular intervals.

6. Apply the two-part epoxy primer to the interiror of the welded

parts.

7. Apply an anti-corrosion to the interior of the welded parts (Refer

to the CORROSION PROTECTION).

8. Prepare exterior surfaces for priming, using wax and grease

remove.

9. Apply metal conditioner and water rinse.
10. Apply the two-part epoxy primer.
11. Apply the correct seam sealer to all joints (Refer to the BODY

SEALING LOCATIONS).

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

RRAF3100

RRAF3110

RRAF3130

RRAF3140

13. After completing body repairs, carefully apply under coating to

the under body (Refer to the CORROSION PROTECTION).

14. In order to improve corrosion resistance, if necessary, apply a

under body anti-corrosion agent to the panel which is repaired or
replaced (Refer to the CORROSION PROTECTION).

117

DOOR PANEL

BODY PANEL REPAIR PROCEDURE - Door panel

z MIG plug welding or spot welding

MIG batt welding
MIG lap weldling

xx

FRONT DOOR

REAR DOOR

D0AF0020

<Inner panel>

DOAF0040

WELDING POINTS

<Inner panel>

<Outer panel>

D0AF0010

D0AF0030

<Outer panel>

 

 

 

 

 

 

 

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