Hyundai Elantra HD: Body Repair Manual - part 12

BODY PANEL REPAIR PROCEDURE

BP-17

BHDBP6410A

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 and MIG lap weld seams.

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

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.

15. Clean all welds with a disc grinder.

BHDBP6410B

BHDBP6410C

BHDBP6410B

BHDBP6401A

BHDBP6401B

BP-18

BODY  PANEL REPAIR PROCEDURE

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.

21. MIG plug weld all holes.

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

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

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

22. Prepare exterior surfaces for priming, using wax and

grease remover.

23. Apply metal conditioner and water rinse.

24. Apply conversion coating and water rinse.

25. Apply the two-part epoxy primer.

26.  Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

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

BHDBP6402A

BHDBP6402B

BHDBP6402C

BHDBP6412B

BHDBP6401C

BODY PANEL REPAIR PROCEDURE

BP-19

SIDE SILL PANEL

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 60mm from the rear door step trim mounting
hole as indicated in the illustration.

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.

BHDBP6301A

50mm

BHDBP6301B

70mm

60mm

BHDBP6301

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

60mm

70mm

50mm

BP-20

BODY  PANEL REPAIR PROCEDURE

4.

Cut the side sill outer panel along cutlines. Be careful
not to cut mating flanges.

5.

Drill out all spotwelds(79), attaching the side sill outer
panel to the side sill panel assembly.

6.

Remove the side sill outer panel.

7.

Clean cut portions with a disc grinder.

8.

After removing, apply the welding primer.

BHDBP6301C

BHDBP6301D

BHDBP6302

BHDBP6302A

BHDBP6302B