Hyundai Atos: Body Repair Manual — part 23
97
BODY PANEL REPAIR PROCEDURE - Front side outer panel
INSTALLATION
1. In order to install center inner pillar drill out all spotwelds attaching
the roof side inner rail to center inner pillar to separate them.
2. Transcribe the front side outer panel cutlines to the new front side
outer panel, adding 30mm overlap at center inner pillar ends.
3. Cut and chamfer butt end to improve weld surface.
4. Drill 8mm holes in overlap area and along outer panel flanges.
PRO-0850
PRO-0880
PRO-0840
PRO-0860
PRO-0870
30 mm
5. MIG butt weld all seams in center inner pillar and side sill outer
reinforcement and front side outer panel as show in the illustra-
tion.
98
BODY PANEL REPAIR PROCEDURE - Front side outer panel
6.
Transcribe the cutline dimensions to the new side sill outer
reinforcement, adding 30mm overlap to each end and cut to
length.
7.
Drill 8mm holes in overlap areas on each end of new side sill
outer reinforcement and clamp, the new side sill outer reinforce-
ment in place.
8.
MIG plug weld all holes and MIG butt weld seams.
NOTE
The reinforcement will be stronger if the weld traces are not
ground.
9.
Temporarily install new front side outer panel in place.
10. Screw center pillar in place.
11. Measure and each measurement point (Refer to the BODY
DIMENSIONS) and correct the installation position.
12. Check the fit of the front and rear doors.
13. Reinstall front side outer panel and screw in place.
14. MIG plug weld all holes and MIG butt weld all seams.
15. Clean and prepare all welds, and remove all residue.
16. Apply body filler to the front side outer panel seam. Sand and
finish.
17. Apply the two-part epoxy primer to the interior of the center inner
pillar.
PRO-0890
PRO-0900
PRO-0910
PRO-0920
99
BODY PANEL REPAIR PROCEDURE - Front side outer panel
18. Apply an anti-corrosion agent to the welded parts and interior of
the center inner pillar (Refer to the CORROSION PROTEC-
TION).
19. Prepare exterior surfaces for priming, using wax and grease
remover.
20. Apply metal conditioner and water rinse.
21. Apply conversion coating and water rinse.
PRO-0940
PRO-0930
22. Apply the two-part epoxy primer.
23. Apply the correct seam sealer to all joints carefully (Refer to the
BODY SEALING LOCATIONS).
24. Reprime over the seam sealer to complete the repair.
100
BODY PANEL REPAIR PROCEDURE - Side sill outer panel (Assembly)
SIDE SILL OUTER PANEL (ASSEMBLY)
REMOVAL
1.
Measure and mark vertical cutline from the front side outer panel
and rear side outer panel connecting portion.
2.
At the front side outer panel, measure and mark horizontal
cutlines from the door hinge mounting hole on the front side outer
panel as shown in the illustration.
WELDLING POINTS
PRO-0970
PRO-0950
PRO-0960
$
$
$
$
$ MIG plug welding
MIG butt welding
xx MIG lap welding
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