Hyundai Elantra HD: Body Repair Manual - part 13

BODY PANEL REPAIR PROCEDURE

BP-21

INSTALLATION

1.

 Transcribe cutline dimensions to side sill outer panel,
adding 30mm overlap to each end and cut to length.

2.

Using service panel for replacement of side sill outer
panel, drill 6mm holes in overlap areas and along upper
and lower flanges.

3.

 Fit and clamp the side sill outer reinforcement in place.

4.

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

5.

MIG plug weld all holes and MIG butt weld seams.

6.

Clean and prepare all welds and remove all residue.

7.

Apply body filler to the side sill outer seams.

8.

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

9.

Apply an anti-corrosion agent to welded parts and
interior of the side sill (Refer to the CORROSION
PROTECTION).

10. Prepare the exterior surfaces for priming, using wax

and grease remover.

11. Apply metal conditioner and water rinse.

12. Apply conversion coating and water rinse.

13. Apply the two-part epoxy primer.

14. Apply the correct seam sealer to all joints (Refer to

the BODY SEALING LOCATIONS).

15. Reprime over the seam sealer.

BHDBP6301E

BHDBP6301F

BHDBP6301G

BHDBP6301H

BHDBP6301I

BP-22

BODY  PANEL REPAIR PROCEDURE

CENTER       PILLAR

C

BHDBP6506

WELDING POINTS

A

100mm

B

MIG plug welding

MIG butt welding

MIG lap welding

A

B

C

100mm

100mm

55mm

100mm

60mm

BODY PANEL REPAIR PROCEDURE

BP-23

REMOVAL

1.

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

2.

Measure and mark the horizontal cutlines on center
pillar outer panel as indicated in the illustration.

3.

 Cut  center pillar outer panel at cutlines.

When cutting center pillar outer panel, take care not to
cut through mating flanges or center pillar outer
reinforcement.

4.

Drill out all spotwelds(7), attaching the center pillar outer
panel to the center pillar assembly.

5.

Remove the center pillar outer panel.

6.

Measure and mark the horizontal cutline on center
pillar outer reinforcement as indicated in the illustration.

BHDBP6501

BHDBP6502

100mm

100mm

NOTE

BHDBP6502A

BHDBP6502B

BHDBP6503

BHDBP6503A

150mm

BP-24

BODY  PANEL REPAIR PROCEDURE

7.

Cut  center pillar outer reinforcement at cutline.

8.

Measure and mark the vertical cutlines on front side
sill outer panel 55mm and 155mm from the front door
 step trim mounting hole.

9.

Cut front side sill outer panel at cutlines.

When cutting front side sill outer panel, take care not
to cut through mating flanges or side sill outer
reinforcement.

10. Drill out all spotwelds (5) attaching the front side sill

outer panel to the side sill assembly.

11. Remove the front side sill outer panel.

BHDBP6503B

BHDBP6504

55mm

100mm

NOTE

BHDBP6504A

BHDBP6504B

BHDBP6505