Hyundai i30 / Elantra Neos. Body repair manual — part 18

BODY PANEL REPAIR PROCEDURE

BP-11

c)

The tip of the spot welding machine should be
maintained to a minimum tolerance of 3 mm. Also
let area cool after 5 or 6 welds to minimize
problems caused by excessive heat.

4.

Cutting and welding an removed area
To align a roof panel and a center pillar together for
butt welding, temporarily fasten a steel flange to the
roof panel and then apply the new center pillar panel.
Remove the flange when final welding is done.

5.

Finishing after welding
a)

Grind any areas that were plug welded or butt
welded using a disk grinder. Grind carefully to avoid
removing too much material. This degrades the
strength of the weld.

b)

Finish areas that have been brazed by applying
body filler then smooth the area with a flexible file
and sander.

6.

Applying anti-rust agent and body sealer
After coating the surface with anti-rust agent, apply
body sealer where necessary.

NOTE

Apply body sealer before assembly.

7.

Anti-rust treatment
Apply anti-rust agent to inside of doors and sills by
spraying through access holes provided.

BVQBP6026

3mm(0.2 in)

BVQBP6027

BVQBP6028

BVQBP6029

BVQBP6030

BFDBP6031

BP-12

BODY PANEL REPAIR PROCEDURE

FENDER APRON PANEL

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

MIG plug welding

MIG butt welding

MIG lap welding

BFDBP6102

BFDBP6104

290mm

BODY PANEL REPAIR PROCEDURE

BP-13

REMOVAL

Before repairing, remove Engine and Suspension
Components.
Refer to the body dimension charts and measure the
vehicle to determine straightening and alignment
requirements. The body must be returned to its original
dimension before begining the repair procedure.

1.

Drill out all the spotwelds to separate fender apron inner
panel assembly from fender apron upper panel
assembly and front side member assembly.

When spotwelded portions are not apparent, remove
paint with a rotary wire brush.

2.

Remove the fender apron inner panel assembly.

On the right side, remove engine mounting support
assembly before removing the fender apron inner panel
assembly.

3

Drill out all the spotwelds to separate fender apron
upper outer panel from fender apron upper inner panel
assembly.

NOTE

NOTE

NOTE

BEDBP6101

BFDBP6102

BFDBP6103

BFDBP6109

BFDBP6104A

BP-14

BODY PANEL REPAIR PROCEDURE

4.

Remove the fender apron upper outer panel.

5.

Measure and mark the cutline on the fender apron upper
inner panel 290mm from front fender apron upper inner
panel end on the fender apron upper panel assembly
as shown in the illustration.

6.

Cut the fender apron upper inner panel along the cutline.

7.

Remove the fender apron upper inner panel.

8.

Prepare all surfaces to be welded.

9.

After removing, apply the welding primer.

BFDBP6105

BFDBP6106

290mm

BFDBP6106A

BFDBP6106B

BFDBP6106C