Hyundai Elantra HD: Body Repair Manual - part 17

 

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Hyundai Elantra HD: Body Repair Manual - part 17

 

 

BODY PANEL REPAIR PROCEDURE

BP-37

2.

Remove the back complete panel assembly.

3.

Depending on the extent of damage, measure and mark
cutline on the rear floor side member as indicated in
the illustration.

4.

 Cut rear floor side member along the cutline.

REMOVAL

Because the rear floor side members are designed to
absorb energy during a rear collision, care must be
used when deciding to use this repair method. This
repair is recommended only for moderate damage to
the vehicle, where distortions do not extend forward of
the trunk region. If the damage is more severe, then
the entire side member assembly should be replaced
at the factory seams without employing this sectioning
procedure.

The following procedure applys when only one rear  floor
side member needs to be replaced. If both side
members are damaged and need to be replaced, then
the procedure of  rear floor side members and rear
floor section should be followed.

Refer to the body dimension charts and measure the
vehicle to determine straightening and alignment
requirements.
The body must be returned to its original dimensions
before beginning the repair procedure.

1.

Drill out all the spotwelds(59) attaching the back
complete panel assembly.

NOTE

BHDBP6702

BHDBP6703

BHDBP6704A

85mm

BHDBP6704B

BP-38

BODY  PANEL REPAIR PROCEDURE

5.

Drill out all attaching spotwelds(29) on the rear floor
side member.

6.

Remove the rear floor side member.

7.

Clean cut portions with a disc grinder.

8.

After removing, apply the welding primer.

9.

Prepare all surfaces to be welded.

BHDBP6705

BHDBP6706

BHDBP6706A

BHDBP6706B

BODY PANEL REPAIR PROCEDURE

BP-39

5.

MIG plug weld all holes and MIG butt weld seams.

6.

Clean and prepare all welds, remove all residue.

7.

 After removing, apply the welding primer.

INSTALLATION

1.

Transfer the cutline dimensions to the new rear floor
 side member, adding 30 mm overlap to the rear end.

2.

 Drill 6 mm holes in new rear floor side member for
MIG plug welding.

3.

 Fit and clamp the rear floor side member in place.

4.

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

BHDBP6707

BHDBP6705A

BHDBP6705B

BHDBP6705C

BHDBP6705D

BP-40

BODY  PANEL REPAIR PROCEDURE

8.

Fit and clamp the new back complete panel assembly
in place.

9.

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

10. MIG plug weld all holes.

11. Clean and prepare all welds, and remove all residue.

12. Apply the two-part epoxy primer to the interior of the

rear floor side member.

13. Apply an anti-corrosion to the interior of the rear floor

side member (Refer to the CORROSION
PROTECTION).

14. Prepare exterior surfaces for priming, using wax and

grease remover.

15. Apply metal conditioner and water rinse.

16. Apply conversion coating and water rinse.

17. Apply the two-part epoxy primer.

BHDBP6702A

BHDBP6702B

BHDBP6702C

BHDBP6702D

BHDBP6702E

 

 

 

 

 

 

 

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