Hyundai Atos: Body Repair Manual - part 27

113

BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (Assembly)

5.

Remove the rear floor panel and rear side member from the rear
body.

INSTALLATION

1.

Transcribe the cutline to the new rear side members. Drill out  the
spotwelds attaching the inner reinforcements.
Remove remaining portions of side members.

2.

Temporarily fit and clamp the rear side members in place.

NOTE
When installing the rear floor side member, temporarily
install the back panel to measure each measurement point.

3.

Measure each measurement point (Refer to BODY DIMEN-
SIONS) and correct the installation position.

4.

If necessary, make temporarily welds, and then check to confirm
that the fit of rear floor panel is correct.

PRO-1580

PRO-1590

PRO-1600

PRO-1610

114

BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (Assembly)

5.

MIG plug weld the rear side members and MIG butt weld seams.

6.

Prepare the welds and surfaces to which the rear floor will attach.

7.

Transcribe the cutline to the new rear floor panel, adding 30mm
for overlap at the old joint.

8.

Drill 8mm holes in overlap area and production locations of the
new rear floor panel for MIG plug welding.

9.

Fit and clamp the rear floor panel and attach the rear floor panel
to the rear side members and other panels.

10. MIG plug weld all holes and MIG butt weld the seams.
11. Clean all welded surfaces.

12. Drill 8 mm holes on the flange attaching the back panel to the rear

floor and side member ends.

13. Fit and clamp the back panel in place.
14. MIG plug weld the back panel.
15. Clean and prepare all welds, removing all residue.
16. Apply the two-part epoxy primer to the interior of the rear side

members.

PRO-1650

PRO-1620

PRO-1630

PRO-1640

115

BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (Assembly)

17. Apply an anti-corrosion to the interior of the rear side members

(Refer to the CORROSION PROTECTION).

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

remover.

19. Apply metal conditioner and water rinse.
20. Apply the two-part epoxy primer.

21. Apply the correct seam sealer to all joints (Refer to the BODY

SEALING LOCATIONS).

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

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

the under body (Refer to the CORROSION PROTECTION).

24. In order to improve corrosion resistance, if necessary, apply an

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

PRO-1660

PRO-1670

PRO-1330

116

REMOVAL

NOTE
Because the rear side members are designed to absorb energy
during a rear collision, care must be used when deciding to use this
repair method. This repair is recommended only for moderate
damage to the vehicle, where distortions do not extend forward of the
trunk region. If the damage is more severe, then the entire side
member assembly should be replaced at the factory seams without
employing this sectioning procedure.

The following procedure applys when only one rear side member
needs to be replaced. If both side members are damaged and need
to be replaced, then the procedure of  Rear Side members And Rear
Floor Section should be followed.

Refer to the body dimension charts and measure the vehicle to
determine straightening and alignment requirements. The body
must be returned to its original dimensions before beginning
the repair procedure.

REAR SIDE MEMBER (PARTIAL)

BODY PANEL REPAIR PROCEDURE - Rear side member (Partial)

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MIG plug welding
MIG butt welding

PRO-1690

WELDLING POINTS