Hyundai i30 / Elantra Neos. Body repair manual — part 23

BODY PANEL REPAIR PROCEDURE

BP-31

SIDE SILL PANEL

REMOVAL

1.

Measure and mark the horizontal cutline on front pillar
outer panel 50mm from the door hinge mounting hole
as indicated in the illustration.

BEDBP6401

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

70mm

50mm

50mm

BEDBP6401A

50mm

2.

Measure and mark the horizontal cutline on center pillar
outer panel 70mm from the door hinge mounting hole.

3.

Measure and mark the vertical cutline on rear side sill
outer panel 50mm from the rear door step trim mounting
hole as indicated in the illustration.

BEDBP6401B

70mm

50mm

BP-32

BODY PANEL REPAIR PROCEDURE

7.

Clean cut portions with a disc grinder.

8.

After removing, apply the welding primer.

4.

Cut the side sill outer panel along the cutlines.

When cutting the side sill outer panel, be careful not to
cut mating flanges.

5.

Drill out all spotwelds, attaching the side sill outer panel.

6.

Remove the side sill outer panel.

NOTE

BEDBP6401C

BEDBP6401D

BEDBP6402A

BEDBP6402B

BEDBP6402C

BODY PANEL REPAIR PROCEDURE

BP-33

6.

Clean and prepare all welds and remove all residue.

7.

Apply body filler to the side sill outer seams.

8.

Apply the two-part epoxy primer to the interior of the
side sill.

9.

Apply an anti-corrosion agent to welded parts and
interior of the side sill (Refer to the CORROSION
PROTECTION).

10. Prepare the exterior surfaces for priming, using wax

and grease remover.

11. Apply metal conditioner and water rinse.

12. Apply conversion coating and water rinse.

13. Apply the two-part epoxy primer.

14. Apply the correct seam sealer to all joints (Refer to

the BODY SEALING LOCATIONS).

15. Reprime over the seam sealer.

INSTALLATION

1.

Transcribe the cutlines to the new side sill outer panel,
adding 30mm overlap to each end and cut to length.

2.

Using service panel for replacement of side sill outer
panel, drill 8mm holes in overlap areas and along upper
and lower flanges.

3.

Fit and clamp the side sill outer panel in place.

4.

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

5.

MIG plug weld all holes and MIG butt weld seams.

BEDBP6401E

BEDBP6401F

BEDBP6401G

BEDBP6401H

BEDBP6401I

BP-34

BODY PANEL REPAIR PROCEDURE

CENTER PILLAR

BFDBP6508

WELDING POINTS

A

100mm

100mm

35mm

100mm

35mm

C

B

A

B

C

100mm

Laser welding

MIG plug welding

MIG butt welding

MIG lap welding