Hyundai Elantra HD: Body Repair Manual - part 14

BODY PANEL REPAIR PROCEDURE

BP-25

12. Drill out all spotwelds (20) attaching the font side sill

outer reinforcement to the side sill inner panel.

13. Measure and mark the vertical cutlines on rear side

sill outer panel 60mm and 160mmfrom the rear door
step trim mounting hole.

14. Cut rear side sill outer panel at cutlines.

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

15. Drill out all spotwelds (6) attaching the rear side sill

outer panel to the side sill assembly.

16. Remove the rear side sill outer panel.

17. Measure and mark the cutline on side sill outer

reinforcement as indicated in the illustration.

BHDBP6505A

BHDBP6506A

100mm

60mm

BHDBP6506B

NOTE

BHDBP6506C

BHDBP6507

BHDBP6507A 

110mm

BP-26

BODY  PANEL REPAIR PROCEDURE

18. Cut side sill outer reinforcement at cutline.

19. Drill out all spotwelds (102) attaching the center pillar

outer panel to center pillar and side sill assembly.

20.  Drill out all spotwelds (4) attaching the center pillar

outer panel to side sill inner panel.

BHDBP6507B 

BHDBP6508

BHDBP6509

21. Remove the center pillar outer panel.

22. Measure and mark the horizontal cutline on center

pillar inner panel as indicated in the illustration.

23.  Cut through center pillar inner panel at cutline.

BHDBP6510

BHDBP6511

80mm

BHDBP6511A

BODY PANEL REPAIR PROCEDURE

BP-27

27. After removing, apply the welding primer.

24. Remove MIG lap welds (3) attaching the center pillar

inner panel to side sill inner panel.

25. Remove the center pillar inner panel.

26. Prepare all surfaces to be welded.

BHDBP6509A

BHDBP6512

BHDBP6512A

BHDBP6512B

BP-28

BODY  PANEL REPAIR PROCEDURE

INSTLLATION

1.

Transfer the cutline dimensions to the new center pillar
inner panel, adding 30mm overlap the end and cut to
length.

2.

Fit and clamp the new center 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 lap welds and MIG butt 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 side outer
panel, adding 30mm overlap to each end and cut to
length.

8.

Drill 6mm holes in overlap areas and along center pillar
outer panel flanges.

BHDBP6514

BHDBP6510A

BHDBP6510C

BHDBP6510D

BHDBP6515

BHDBP6510B