Hyundai Atos: Body Repair Manual - part 28

117

BODY PANEL REPAIR PROCEDURE - Rear side member (Partial)

1.

Depending on the extent of damage, if the right side member is
to be replaced it should be measured and marked 55mm from
the rear edge of the rear floor center cross member.

NOTE
The following procedure illustrates a repair for the right rear
side member. The procedure may also be applied to the left
rear side member.

2.

Cut through rear side member at cutline.

3.

Remove the rear floor side member by drilling out all attaching
spotwelds.

4.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe the cutline to the new rear side member. Cut at line.

2.

Fit and clamp the new rear side member in place for welding.
Measure to ensure dimensions are accurate as given in the body
dimension charts.

3.

MIG plug weld at the holes and MIG butt weld the seam in the
side member.

4.

Clean and prepare all surfaces to be welded, and remove all
residue.

5.

Apply the two-part epoxy primer to the interior of the rear side
member.

PRO-1690

PRO-1710

PRO-1720

PRO-1730

55mm

118

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

the under body (Refer to the CORROSION PROTECTION).

14. 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).

BODY PANEL REPAIR PROCEDURE - Rear side member (Partial)

6.

Apply an anti-corrosion to the interior of the rear side member
(Refer to the CORROSION PROTECTION).

7.

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

8.

Apply metal conditioner and water rinse.

9.

Apply conversion coating and water rinse.

10. Apply the two-part epoxy primer.

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

SEALING LOCATIONS).

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

PRO-1660

PRO-1670

PRO-1330

119

REAR DOOR

CON-0800

FRONT DOOR

WELDLING POINTS

CON-0880

CON-0890

CON-0 881

FRONT AND REAR DOOR OUTER PANELS

CON-0891

 

MIG plug welding

MIG lap welding

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CON-0750

BODY PANEL REPAIR PROCEDURE- Front and rear door outer panels

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120

BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels

REMOVAL

1.

Cut door outer panel hem with a sander.

2.

After grinding off the hemming location, remove the outer panel.

3.

Dress rusty part with a sander and prepare surface to be
hemmed.

INSTALLATION

1.

Apply adhesive or equivalent to outer panel hem.

2.

Apply mastic sealer or equivalent to the door upper member and
door reinforcement beam as shown in the figure.

PRO-1830

PRO-1840

PRO-1770/PRO1771

PRO-1800