Hyundai Elantra HD: Body Repair Manual - part 11

BODY PANEL REPAIR PROCEDURE

BP-13

7.

Remove the front pillar outer panel.

8.

 Drill out all the spotwelds(12) attaching the front pillar
outer reinforcement.

9.

Measure and mark the cutlines  on front side sill outer
panel as shown in the illustration.

10. Cut the front side sill outer panel.

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

11. Drill out all the spotwelds(7) attaching the front side

sill outer panel.

12. Remove the front side sill outer panel.

BHDBP6407

BHDBP6407A

BHDBP6408A

BHDBP6408B

BHDBP6409

NOTE

BHDBP6408C

60mm

100mm

BP-14

BODY  PANEL REPAIR PROCEDURE

13. Cut the side sill outer panel reinforcement along

cutline, taking care not to damage the other panel as
illustration.

14. To remove the front pillar outer panel, drill out  and

grind away all spotwelds(88) and lap weld(1) attaching
the front pillar outer panel.

15. Remove the front pillar outer panel.

16. To remove the front pillar inner panel, drill out  and

grind away all spotwelds(35) and lap welds(4) attaching
the front pillar inner panel.

BHDBP6409A

BHDBP6410

BHDBP6411

BHDBP6412

BHDBP6413

BHDBP6413A

BODY PANEL REPAIR PROCEDURE

BP-15

17. Remove the front pillar inner panel.

BHDBP6414

BHDBP6412A

BHDBP6415

18. Clean cut portions with a disc grinder.

19. After removing, apply the welding primer.

BHDBP6415A

BHDBP6415B

BP-16

BODY  PANEL REPAIR PROCEDURE

INSTALLATION

1.

Drill 6mm holes in the front pillar inner panel for MIG
plug welding.

2.

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

3.

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

4.

MIG plug weld all holes and MIG lap weld seams.

5.

Clean and prepare all welds, and remove all residue.

6. After removing, apply the welding primer.

7.

Transfer the cutline dimensions to the new front pillar
outer panel, adding 30mm overlap to each end and cut
 to length.

8.

Drill 6mm holes along front pillar outer panel flanges in
production location for attachment to other panels.

BHDBP6413B

BHDBP6413C

BHDBP6413D

BHDBP6413E

BHDBP6417

BHDBP6416