Hyundai H1: Body Repair Manual - part 17

70

7.

Drill out all spotwelds and MIG plug welds to separate front end
crossmember inner and outer panel.

8.

Remove the front end crossmember.

NOTE

 NOTE

This procedure is to be used only for repair of minor
damage on to the front sidemember and front end
crossmember when it is impossible to straighten the
damage on them. The following procedure illustrates a
repair for the front left sidemember. The procedure may
also be applied to the front right sidemember.

9.

Drill out all spotwelds and MIG butt welds to separate front apron
outer panel.

10. Remove the front apron outer panel.

11. Measure and mark the cutline on front apron panel and front

sidemember as illustration.

12. Drill out all spotwelds to separate front wheelhouse extension

from front sidemember.

13. Cut through the front apron panel and front wheel house at

cutlines.

14. Remove the front apron panel and front wheelhouse.

RFAC4030

RFAC4090

RFAC4020

RFAC4100

RFAC4110

BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember

Front apron
outer panel

(2WD)

120 mm

20 mm

Front end
crossmember

71

15. Remove the front sidemember partial.

<2WD>

1) Drill out all spotweld and MIG lap welds to separate cover

panel from front sidemember.

2) Cut the front sidemember at 80 mm apart from the air

conditioning discharge pipe hole.
Then, cut the front sidemember outer panel at 45 mm inside
from the font sidemember cut point. Be careful not to
damage the front sidemember reinforcement.

<4WD>

1) Drill out all spotwelds and cut the front sidemember cover

panel.

2) Cut the cover panel from the front sidemember as shown in

the illustration.

3) Cut the front side inner panel at 40 mm away from the cut.

At this time, careful not to cut the reinforcement.

16. Grind and smooth any weld traces which might be left on the

body surface by using an air grinder or similar tool, being careful
not to damage any of the panels which is not to be replaced.

40 mm

RFAC4120

RFAC4130

RFAC4190/RFAC4140

RFAC4150

BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember

(4WD)

120 mm

20 mm

Cover
panel

45

mm

80 mm

55 mm

15 mm

Cover panel

Location hole

72

INSTALLATION

1. Transcribe the cutlines to the new front sidemember, cut to

length and chamfer butt end to improve weld surfaces.

<2WD>

1) Cut the new front sidemenber at 45 mm from the air

conditioning discharge pipe hole .

RFAC4160

BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember

3) MIG butt weld to the remaining section of the front sidemember.

<4WD>

1) Cut the new front sidemember at 55 mm from the location

hole and remove the front sidemember inner panel by
detaching spotwelds.
Then prepare the sidemember outer panel and the reinforce-
ment after cutting them at 15 mm from the location hole.

RFAC4170

RFAC4161

2) MIG butt welds at the front sidemember reinforcement.

45 mm

60 mm

80mm

RFAC4140

55 mm

15 mm

Cover panel

Front sidemember
reinforcement

Location
hole

73

2) Temporarily install front sidemember outer panel and rein-

forcement.

NOTE

If necessary, make temporary welds so as not to twist.

BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember

3) Temporarily install front sidemember inner panel and cover

panel.

4) MIG plug weld all holes and MIG butt weld all seams.

2. Measure each measurement point (Refer to the BODY DIMEN-

SIONS) and correct the installation position.

3. Transcribe the cutline to the new front apron panel and wheel-

house.
Cut and chamfer butt end to improve weld surface.

4. Temporarily install new front apron panel and front wheelhouse.

RFAC4210

RFAC4190

RFAC4200

RFAC4180

Cover panel