Hyundai Elantra HD: Body Repair Manual - part 10

BODY PANEL REPAIR PROCEDURE

BP-9

2.

Remove the front bumper mounting bracket.

3.

Prepare all surfaces to be welded.

4.

After removing, apply the welding primer.

INSTALLATION

1.

Drill 6mm holes in the front bumper mounting bracket
for MIG plug welding.

2.

Fit and clamp the front bumper mounting bracket in
place.

3.

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

4. MIG plug weld all holes.

BHDBP6104

BHDBP6105

BHDBP6101A

BHDBP6102B

BP-10

BODY  PANEL REPAIR PROCEDURE

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.

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 LOCATION)

BHDBP6102C

BHDBP6102D

BHDBP6103B

BODY PANEL REPAIR PROCEDURE

BP-11

FRONT  PILLAR

B

BHDBP6408

WELDING POINTS

60mm

A

160mm

100mm

A

B

100mm

MIG plug welding

MIG butt welding

MIG lap welding

BP-12

BODY  PANEL REPAIR PROCEDURE

4.

Measure and mark the each cutline on the front pillar
outer panel 160mm and 260mm from the roof panel
end line as indicated in the illustration.

5.

Cut the front pillar outer panel along each cutline,
taking care not to damage the other panel as illustration.

6.

Drill out all the spotwelds(8) attaching the front pillar
outer panel.

REMOVAL

1.

To remove the front pillar, drill out and grind away all
spotwelds(20) and lap welds(4) attaching the cowl side
upper outer panel as shown in the illustration.

If it is possible that 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 front pillar, be sure to support roof panel.

 

BHDBP6402

BHDBP6401

BHDBP6404

100 mm

160 mm

BHDBP6404A

BHDBP6404B

NOTE