Hyundai i30 / Elantra Neos. Body repair manual — part 20

BODY PANEL REPAIR PROCEDURE

BP-19

This procedure is to be used only for repair of minor
damage to the front side member and when it is
impossible to straighten the damaged front side
member. The following procedure illustrates a repair
for the front left side member.
The procedure may also be applied to the front right
side member.

NOTE

BEDBP6101

REMOVAL

1.

Before cutting the front side member, remove the front
crash member assembly.

2.

Measure and mark the vertical cutlines on front side
member from tooling hole edge as shown in the
illustration.

3.

Drill out all the spotwelds to separate front side member.

BEDBP6201

BEDBP6202

143mm

BFDBP6203

260mm

BFDBP6203A

BP-20

BODY PANEL REPAIR PROCEDURE

4.

Cut the front side member inner and outer panel along
the cutlines.

5.

Remove the front side member.

6.

Prepare all surfaces to be welded.

BEDBP6202A

7.

After removing, apply the welding primer.

INSTALLATION

1.

Transcribe the front side member inner and outer
cutlines to the new front side member, cut to length
and chamfer butt end to improve weld surface.

2.

Fit and clamp the front side member in place.

3.

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

BEDBP6204

BEDBP6204A

BFDBP6203B

BEDBP6206

BFDBP6205

BODY PANEL REPAIR PROCEDURE

BP-21

4.

MIG plug weld all holes and MIG butt weld seams.

5.

Clean and prepare all welds, and remove all residue.

6.

Apply the two part epoxy primer to the interior of the
each panel.

7.

Apply an anti-corrosion agent as required.
(Refer to the BODY CORROSION PROTECTION)

8.

Prepare the exterior surfaces for priming using wax
and grease remover.

9.

Apply metal conditioner and water rinse.

BFDBP6203C

BEDBP6203D

10. Apply conversion coating and water rinse.

11. Apply the two-part epoxy primer.

12. Apply the correct seam sealer to all joints carefully.
(Refer to the BODY SEALING LOCATIONS)

13. Install the front crash member assembly.

BEDBP6202B

BFDBP6203E

BEDBP6201A

BP-22

BODY PANEL REPAIR PROCEDURE

FRONT PILLAR

120mm

BFDBP6307

WELDING POINTS

A

B

A

B

150mm

B

100mm

90mm

Laser welding

MIG plug welding

MIG butt welding

MIG lap welding