Hyundai Elantra HD: Body Repair Manual - part 9

BODY PANEL REPAIR PROCEDURE

BP-5

5.

 Clean and prepare all welds, and remove all residue.

6.

Drill 6mm holes in the new fender apron upper outer
panel for MIG plug welding.

7.

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

8.

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

9.

MIG plug weld all holes.

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

11. Drill 6mm holes in the new fender apron lower panel

for MIG plug welding.

BHDBP6203F

BHDBP6206

BHDBP6204

BHDBP6204C

BHDBP6204B

BHDBP6207

BP-6

BODY PANEL REPAIR PROCEDURE

12. Fit and clamp the fender apron lower panel in place.

13. Measure each measurement point (Refer to the BODY

DIMENSIONS) and correct the installation position.

14. MIG plug weld all holes.

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

16. Apply the two part epoxy primer to the interior of the

each panel.

17. Apply an anti-corrosion agent as required.

(Refer to the BODY CORROSION PROTECTION)

18. Prepare the exterior surfaces for priming using wax

and grease remover.

19. Apply metal conditioner and water rinse.

20. Apply conversion coating and water rinse.

21. Apply the two-part epoxy primer.

22. Apply the correct seam sealer to all joints carefully.

(Refer to the BODY SEALING LOCATION)

BHDBP6202A

BHDBP6202B

BHDBP6202C

BHDBP6202D

BHDBP6202E

BODY PANEL REPAIR PROCEDURE

BP-7

FRONT  SIDE  MEMBER

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

MIG plug welding

MIG butt welding

MIG lap welding

BHDBP6102

BHDBP6103

BP-8

BODY PANEL REPAIR PROCEDURE

This procedure is to be used only for repair of minor
damage to  the front side member and when it is
impossible to straighten the damaged front side
member. The following procedure illustrates a repair
for the front left side member.
The procedure may also be applied to the front right
side member.

NOTE

BHDBP6101

NOTE

REMOVAL

1.

Drill out all the spotwelds(21) to front bumper mounting
bracket from front side member assembly.

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

BHDBP6102A

BHDBP6103A