Hyundai Getz: Body Repair Manual - part 21

89

BODY PANEL REPAIR PROCEDURE - Front pillar

5.

Drill out all welds attaching the front pillar to dash and cowl top
outer, cowl inner lower panels.

6.

Remove spotwelds and lap welds attaching cowl crossmember
bar mounting upper bracket to remove front pillar.

7.

Before cutting front pillar, be sure to support roof panel.

8.

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

9.

Before cutting the front side sill outer panel, make a rough cut the
side sill outer panel only.

NOTE
When cutting the front side sill outer panel, be careful not to
cut side outer reinforcement.

PRO-0540

PRO-0550

PRO-0560

PRO-0530

Side outer reinforcement

Front pillar outer
panel

Side inner panel

90

BODY PANEL REPAIR PROCEDURE - Front pillar

10. Cut the side outer reinforcement as shown in the illustration.
11. Cut the side outer reinforcement vertical cutline and remove the

front pillar.

12. Straighten all flanges as necessary, prepare all surfaces to be

welded.

INSTALLATION

1.

Transcribe the cutline to the new side inner panel, cut to length
and chamfer butt end to improve weld surface.

2.

Transcribe the cutline to the new side outer reinforcement and
new front pillar, adding 30mm overlap to end and cut to length.

3.

Drill 8mm holes along outer panel flanges in production location
for attachment to other panels.

PRO-0580

PRO-0590

PRO-0570

PRO-0600

91

BODY PANEL REPAIR PROCEDURE - Front pillar

4.

Transcribe the cutline to the new side inner panel, adding 30mm
overlap to end and cut to length.

5.

Drill 8mm holes in the side inner panel for MIG plug welding.

6.

Fit and clamp the new side inner panel in place for welding.

7.

MIG plug weld all holes and MIG butt weld the seams.

8.

Temporarily install front pillar outer panel in place.

9.

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

10. If necessary, make temporary welds, and then check to confirm

that the closing and fit for windshield glass, door and fender are
correct.

11. MIG butt weld front pillar outer panel and side outer reinforcement

seams.

12. Reattach the cut away front pillar outer panel section, then MIG

butt weld.

13. MIG  plug weld all holes and MIG butt weld all seams in the side

outer panel.

14. Clean and prepare all welds, remove all residue.
15. Apply body filler to joints and sand as needed.
16. Apply the two-part epoxy primer to the interior of the front pillar.

PRO-0620

PRO-0630

PRO-0610

PRO-0640

Front pillar outer panel
section

92

BODY PANEL REPAIR PROCEDURE - Front pillar

17. Clean all welds with a disc grinder.

NOTE
1.

Be careful not to grind welded portions too much.

2.

The internal parts will be stronger if the weld traces are
not ground.

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.
20. MIG plug weld all holes.
21. Clean and prepare all welds, remove all residue.

22. Apply an anti-corrosion agent to the welded parts and inside of

front pillar (Refer to the CORROSION PROTECTION).

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

remover.

24. Apply metal conditioner and water rinse.
25. Apply conversion coating and water rinse.
26. Apply the two-part epoxy primer.

PRO-0460

PRO-0660

PRO-0670

PRO-0690

PRO-0680