Hyundai i30 / Elantra Neos. Body repair manual — part 27

BODY PANEL REPAIR PROCEDURE

BP-47

REMOVAL

1.

Depending on the extent of damage, measure and mark
cutlines on the quarter outer panel as indicated in the
illustration.

2.

Cut the quarter outer panel along the cutlines and
remove the quarter outer panel as illustration.

When cutting the quarter outer panel, be careful not to
cut quarter inner panel.

NOTE

3.

Drill out all attaching spotwelds and laser welds on the
quarter outer panel, including the seam around the door
lip opening.

BFDBP6603

50mm

50mm

BFDBP6602

50mm

BFDBP6601A

BEDBP6606

BFDBP6604

BEDBP6605

BP-48

BODY PANEL REPAIR PROCEDURE

6.

After removing, apply the welding primer.

7.

Prepare all surfaces to be welded.

INSTALLATION

1.

Transcribe the cutlines to the new quarter outer panel,
adding 30 mm overlap each end.

2.

Drill 8 mm holes in overlap areas and along upper and
lower flanges of the new quarter outer panel for MIG
plug welding.

4.

Remove the quarter outer panel.

5.

Clean cut portions with a disc grinder.

BFDBP6607

BFDBP6607A

BFDBP6607B

BFDBP6608

BODY PANEL REPAIR PROCEDURE

BP-49

7.

Clean and prepare all welds, remove all residue.

8.

Apply an anti-corrosion agent to the welded parts and
interior of the quarter outer panel (Refer to the
CORROSION PROTECTION).

9.

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

10. Apply metal conditioner and water rinse.

11. Apply conversion coating and water rinse.

12. Apply the two-part epoxy primer.

3.

Apply body filler to the welded seam. Sand and finish.
Apply the two-part epoxy primer to the interior of the
quarter outer panel.

4.

Fit and clamp the quarter outer panel in place.

5.

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

6.

MIG plug weld all holes and MIG butt weld seams.

BFDBP6601B

BFDBP6601C

BFDBP6601D

BFDBP6601E

BP-50

BODY PANEL REPAIR PROCEDURE

13. Apply the correct seam sealers to all joints.

14. Reprime over the seam sealer to complete the repair.

15. In order to improve corrosion resistance, if necessary,

apply an under body anti-corrosion agent to the wheel
well (Refer to the CORROSION PROTECTION).

BFDBP6604A

BFDBP6601F