Hyundai Elantra Neos / Hyundai i30. Manual — part 20

BP-16

BODY PANEL REPAIR PROCEDURE

7.

Drill 8mm holes in the new fender apron upper outer
panel for MIG plug welding.

8.

Fit and clamp the fender apron upper outer panel in
place.

9.

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

10. MIG plug weld all holes.

11. Clean and prepare all welds, and remove all residue.

12. Drill 8mm holes in the new fender apron inner panel

assembly for MIG plug welding.

BEDBP6107

BEDBP6108

BFDBP6104B

BFDBP6104C

BFDBP6104D

BFDBP6104E

BODY PANEL REPAIR PROCEDURE

BP-17

13. Fit and clamp the fender apron inner panel assembly

in place.

14. MIG plug weld all holes.

15. Clean and prepare all welds, and remove all residue.

BFDBP6102A

16. Apply the two part epoxy primer to the interior of the

each panel.

17. Apply an anti-corrosion agent as required.

(Refer to the BODY CORROSION PROTECTION)

18. Prepare the exterior surfaces for priming using wax

and grease remover.

19. Apply metal conditioner and water rinse.

20. Apply conversion coating and water rinse.

21. Apply the two-part epoxy primer.

22. Apply the correct seam sealer to all joints carefully.

(Refer to the BODY SEALING LOCATIONS)

BFDBP6102B

BFDBP6102C

BFDBP6102D

BFDBP6102E

BP-18

BODY PANEL REPAIR PROCEDURE

FRONT SIDE MEMBER

WELDING POINTS

MIG plug welding

MIG butt welding

MIG lap welding

MIG plug welding

MIG butt welding

MIG lap welding

BFDBP6203

BFDBP6202F

260mm

143mm

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