Hyundai Elantra HD: Body Repair Manual - part 8

BODY PANEL
REPAIR
PROCEDURE

GI

BC

BD

BP

BS

CP

BT

PP

BP-2

BODY PANEL REPAIR PROCEDURE

FENDER APRON PANEL ASSEMBLY

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

MIG plug welding

MIG butt welding

MIG lap welding

400 mm

BHDBP6202

BHDBP6203

BODY PANEL REPAIR PROCEDURE

BP-3

REMOVAL

NOTE

Before repairing, remove Engine and Suspension
Components.
Refer to the body dimension charts and measure the vehicle
to determine straightening and alignment requirements. The
body must be returned to its original dimension before
begining the repair procedure.

1.

Drill out all the spotwelds(24) to separate fender apron
lower panel from fender apron upper panel assembly
and front side member assembly.

When spotwelded portions are not apparent, remove
paint with a rotary wire brush.

2.

Remove the fender apron lower panel.

3.

Measure and mark the cutline on the fender apron upper
inner panel 400mm from front fender panel mounting
hole center on the fender apron upper assembly as
shown in the illustration.

 

BHDBP6101

NOTE

BHDBP6202

BHDBP6203A

400 mm

4.

Drill out all the spotwelds(33) to separate fender apron
upper outer panel from fender apron upper panel
assembly.

BHDBP6204

BP-4

BODY PANEL REPAIR PROCEDURE

5.

Remove the fender apron upper outer panel.

6.

Cut through the fender apron upper inner panel along
cutline.

INSTALLATION

1.

Transcribe the fender apron upper inner panel cutline
to the new fender apron upper inner panel, cut to length
and chamfer butt end to improve weld surface.

2.

Fit and clamp the fender apron upper inner panel in
place.

3.

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

4.

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

BHDBP6205

BHDBP6203B

7.

Remove the fender apron upper inner panel.

8.

Prepare all surfaces to be welded.

9.

After removing, apply the welding primer.

BHDBP6203C

BHDBP6203D

BHDBP6201

BHDBP6203E