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Hyundai Hyundai Coupe Hyundai Coupe Workshop Manual 2

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510 views131 pages

Hyundai Hyundai Coupe Hyundai Coupe Workshop Manual 2

Uploaded by

DDJAM
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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CONTENTS GENERAL INFORMATION ‘GENERAL GUIDELINES AND PRECAUTIONS SRSAIRBAG. ELECTRONIC PARI ‘CORROSION PROTECTION AND SEALING ‘SIDE BODY PANELS... ‘WELDING BODY CONSTRUCTION BODY COMPONENTS ronson oie ZINC-GALVANIZED STEEL PANELS... HIGH-STRENGTH STEEL PANELS... FRONT BODY SIDE BODY ... UNDER BODY, REAR BODY.... REPLACEMENT PARTS FRONT BODY noone SIDEBODY .. EARBODY oc consst cnn BOOR ......- BODY DIMENSIONS GENERAL... UPPERBODY SIDE BODY. INTERIOR UNDER BODY. ENGINE COMPARTMENT LUGGAGE COMPARTMENT. BODY PANEL REPAIR PROCEDURE RADIATOR SUPPORT PANEL... FENDER APRON AND FRONT SIDEMEMBER (ASSEMBLY) ... FRONT SIOEMEMER (PARTIAL), FRONT PILLAR ron SIDE SILL(ASSEMBLY). SIDE SILL(PARTIAL} QUARTER PANEL REAAFLOOR .... REAR SIDEMEMBER (ASSEMBLY) FEAR SIDEMEMBER (PARTIAL) BODY SEALING LOCATIONS. FLOOR... ae eee UPPER & SIDE BODY CORROSION PROTECTION ZINC-GALVANIZED STEEL PANELS... eee ZINC-PHOSPHATE GOAT CATIONIGELECTODEPOSITIONPRIMER,... ANTLCORROSION PRIMER. oo ANTIMIBRATION PADS-LOGATION & SECTION , ATTACHMENT OF ANTIVIBRATION PADS UNDER BODY COAT... SIDE BODY «een nee CAVITY WAX INJECTION UNDER BODY ANTI-CORT GENERAL te INFORMATION GENERAL INFORMATION - General guide lines and precautions. ER A GENERAL GUIDE LINES AND PRECAUTIONS ‘The Hyundai TIBURON/COUPE is a completely new vehicle design. During its development, close attention has bbeen given to safety, stability, weight and corrosion protection. Typical of unit body design, the Hyundai TIBURON/ COUPE is designed 80 thal the front and rear compartments will absorb rhuch of the collision energy 30 thal the passengers are belter protected, During collisions, these front and rear anergy absorbing systoms may be severely damaged. During repair. these Camaged areas must be retumied to their original strength and’ geometry. It this is not properly done, the vehicle well not provide the intended level of protection to its cocupants in the ‘event of another collision, ‘The repairs described in this manual were pertcrmed on TIBURON/COUPE body shells. In some instances special fixtures were welded in place to support the structure. During the repair of an actual vehicle, the interior would bbe fully disassembled and standard jack screws or portable braces may be used for temporary support. During the repair of an accident involved vehicle, the vehicle must first be retumed to pre-impact dimensions prior ‘to beginning the sectioning repair procedures. The extent of damage that must be repaired should then be evaluated to determine the appropriate repair procedures. This manual provides locations and procedures where structural sectioning may be employed. It is the responsibilty of the repair technician, based upon the extent of damage, to determine which location and procedura is suitable for the particular damaged vehicle, During the repair of @ collision damaged automobile, it is Impossible 10 fully duplicate the methads used in the factory during the vehicle manulacture. Therefore, auto body repair techniques have been developed ta provide ‘4 repair that has strength properties equivalent to those of the original design and manulaciure, Cantain guidelines and precaution are noted as follows. GENERAL INFORMATION - SRS Airbag SRS AIRBAG SYSTEM COMPONENT lack spring ‘The Hyundai TIBURON/GOUPE Is equipped with a Supplemental Restraint System (AIRBAG) to provide the vehicle's Griver and/or the front passenger with additional protection than that offered by the sest-belt system alone, in case of a frontal or lateral impact of sufficient severity. ‘When handling airbag components (remaval, installation er inspection, etc.), always follaw the directions given in ‘the repair manual for the relevant model to prevent the occurrence ‘ol accidents and airbag mallunction ‘Also take the follwing precautions when repairing the body: 1. Work must be started after approximately 30 seconds cr longer from the time the ignition switch is tumed to the LOCK position and the negative {-) terminal cable is disconnected irom the batiery. (The airbag system is equipped with a back-up power source so that i work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.) When the negative(-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled, So belore starting work, make a record of the contents memorized by the audio memory system. Then when work is finished, reset the audio system as belore and adjust the clock 2. When using electric welding, first diacennect the SRSCM connectors under the lower crash pad center. 3. Store the aitbag module where the ambient temperature remains below 80°C (176°F), without high humility and away from olectrical noise. 4, WARNINGICAUTICN labels are attached to the periphery of the airsag components, Refer ta the TIBUROM/COUPE SHOP MANUAL, GENERAL INFORMATION - Electronic parts ELECTRONIC PARTS ‘Vehicles today include & great many electronic parts and components, and these are in general vary susceptible to adverse effects caused by over current, reverse current, electromagnetic waves, high temperature, high humidity impacts, etc. In particular such electronic components can be damaged if there is a large current flow during welding from the body side ‘Therefore, take the following precautions during body repair to prevent damage to the CONTROL MODULES (ECM, TCM, ABS CM, SRS CM, etc.) 1, Batora removing and inspecting the electrical parts or betore starting electric welding operations, disconnect the negative (-) terminal cable from the battery. 2, Do not expose the CONTROL MODULES to ambient temperatures above 60°C (176°F), NOTE = If it is possible the ambient temperatures may reach 80°C (176°F) or more, remove the CONTROL MODULES from the vehicle before starting work 8. Be careful not to drop the CONTROL MODULES and not to apply physical shecks to them. CORROSION PROTECTION AND SEALING Proper corrasion protection and sealing is an important part of any repair. When reviewing these: repair procedures, itis important to recognize the need tor corrosion restoration to provide far long term strength of the repaired member. ‘A two part epoxy primer was applied to the metal surfaces during the latter part of the repair. For closed sections, Such as front and rear rails, rocker panels and pillars, the primer is applied without applying the metal conditioner and the conversion coating, These steps are omitted to insure that no rinse water is trapped in the closed sections, The: primer application is followed by an application of an oil or wax based on rust proofing material ‘Alter the corrosion restoration pracess for the closed sections are completed, then the procass can be applied to all ‘exterior sections. For exterior surfaces, beth metal conditioner and conversion coating treatments are applied to the exterior surface prior to application of the epaxy primer. The procedure in applying the corrosion restoration process. important in order to ingure that moisture, due to the water rinsing of the metal conditioner and enversion costing is not inadvertently trapped inside any closed section before the epoxy primer and rust proofing materials have been applied. ‘Appropriate seam sealers are then applied ta all joints. Follow manufacturer's recommendations for the appropriate: {ype of seam sealer to be used at each seam of joint SIDE BODY PANELS ‘The side body panel for TIBURON/CGUPE is designed and stamped as single piece of sheet metal in factory as shown in the figure. While the entire side panel is available for service, the partial panels sectioned by several ‘damaged areas are also available. Therefore when repairing side body, refer to "Replacement parts section” of this manual to select and use the appropriate peri. — : Service part tine GENERAL INFORMATION - Welding od WELDING All repairs in this manual require the use of a Meialinet Gas (MIG) welder, Gas (oxyacetylene) welding must rot be used. Both high strength steel and mild steel can be welded using the MIG welder. The I.CAR recommendations for welling should be followed, The shielding gas shouk be 78% Argon and 25% CO,. The recommended welding wire size \5 0.23" and the wire should satisfy the American Welding Sociely Standard code AWSER?0S-6. During the repair process, plug welds are used to duplicate original factory spot welds. All plug welds should be dene with the MIG welder, An 8 mm (8/16") hele is placed in the top (welding side) sheet metal You than begin welding along the edges and the spiral towards the center (see ilustration). This is important so that weld penetration between the two metal pieces may take plaice along the circumference of the circle. Weld around exiges first working in towards the center (Tap wiew) PLUG WELDING. N\ Qa > S&S 8mm or 8/16" dia. hole lustration- Welding in collision Repair SAFETY FACTORS Disconnect the negative,-) battery cable before performing any work on the vehicle. Protect yourself by woaring goggles, samlugs, respirators, oloves, safety shoes, caps, etc. when working on a vehicle Salely support the vehicle before any work is done, Block the front or rear wheels if the vehicle is not Ifted off of the ground. Cap cr remave the fuel tank when working on the rear section of the car, Ingure proper ventiation of your working area. Some paint and sealant can generate toxic gases when heated. Use an air chisel or saw to remove damaged panels instoad of a gas torch. Observe all local and national safely regulations when performing any work. Cover interior with heat-resistant cover fo insure safety when welding. Take care when using gas or cuting torches $0 as not to burn bedy sealer oF interior. Extinguish immediately if they should cateh fire. BODY CONSTRUCTION BODY CONSTRUCTION - Body components: BODY COMPONENTS Body construction will somatimes ditfer depending on specications and country of dastination. Therefore, please keep in mind that the information contained herein ig based on vehicles for general destination. 12 BODY CONSTRUCTION - Body components a an REESE 1. Radiator support unper center member 2. Radiator support center member 3. Radiator upper mounting bracket 4, Radiator support upper side member 8, Head lamp support panel 8. Head lamp support gusset 77. Front shipping hook bracket '8, Radiator support lower inner member '9. Radiator support lower outer member 10. Dash pane! 17, Dash panel reinforcement 42, Dash lower member 19. Fender apron upper outer panel 14, Fender apron inner rear upper extension 15. Fender apron inner rear lower extension 16. Fender apron upper inner panel 17, Front shack absorber housing panel 16. Front shock absorber housing upper panel 19. Fender apron inner front panel 20, Front side inner member 221. Front side member inner gusset 22. Engine mounting reinforesment 23, Transmission mounting reintorcemont ‘2d. Frontside outer member 25, Frontside rear lower member 26, Front side rear upper member 27. Front side member rear lower extension 28, Frontside member lower reinforcement 28. Center floor panel ‘30. Muftlerhanger mounting bracket 31, Center foor reinforcement 32, Front seat cross member 89, Front seat cross No.2 membar 34, Center oor side member 85. Center floor side member reinforcement 96, Side sil inner panel 37. Parking brake lever rear mounting reinfarcement ‘38, Rear floor panel 39, Rear floor side panel 40, Rar floor center cross upper 41. Rear floor side member 42, Rear bumper mounting reinforcement 43, Rear {loor side member center reinforcement 44, Side sil inner rear panel 45, Rear floor centr cross mamber 46, Rear floor side member front reinforcement 47, Rear floor front extension 48, Rear floor front cross member 48, Jack up cross center member 80, Jack up eross rear member 51. Fenderpanel 52. Cow side upper panel 53. Cow inner lower panel 54, Com inner lower reinforcement 55, Cowl side upper inner panel 56, Hood hinge mounting reinforcement 57, Cowl top outer pan! 58, Roof pane! 59, Roo! pansi(sun roof) 60, Roo! front lower 61, Roof rear upper rail 62. Tail gate hinge mounting reinforcement 63, Roo! roar lower rail 64, Roof center rail 85, Roo! centr rail No.2 (66, Sun root ring reinforcement 67. Sun roof rear lower reinforcement 68, Back pane! 69, Rear transverse member 70, Rear transverse side extension 71. Front inner lower pillar 72, Front inner upper pillar 73. Center pillar inner panel 74, Front seat belt upper mounting bracket 78, Wheel housing inner pane! 76, Wheel housing inner front extension 77. Rear spring housing cover 78, Wheel housing inner rear cover 78. Quarter inner panel 80, Quartar innar reinforcement 81, Quariar inner upper panel 82. Side outer panel 83, Side outor reinforcement £84, Front door striker reinforcement 85, Front door striker upper reinforcement £86, Side outer rear upper extension 87. Quarter outer upper reinforcement 88, Rear combination lamp housing pane! 89, Hood outer panel 90, Hood inner rail 81. Boor outer panel 92. Door belt cuter ral 93, Door reinforcement beam. 84. Door upper member 95. Door inner panel 96, 00" belt inner ral 97. Tail gate outer panel 98, Tail gate inner panel 99, Tail gate side reinforcement 13 BODY CONSTRUCTION - Zinc-galvanized steel panels 1. Radiator support upper center member 2 Radiator support center member 3, Radiator support upper side member 4. Haad lamp support panel 5, Head lamp support gusset ‘6, Front shipping hook bracket 7. Radiator support lower inner member 8, Radiator support lower outer member 8, Dash panel 10, Dash lower member 11. Fender apron upper outer panel 12, Fender apron inner rear upper extension 18, Fender apton inner rear lower extension 14, Fender-apron upper inner panel 18, Front shock absorber housing panel 16, Front shock absorber housing upper panel 117. Fender apron inner front panel 418, Front side inner member 19, Front side member inner gusset 20, Front side member rear jawer extension 21, Center flaor panel 22, Muffler hanger mounting bracket 23, Center floor sida member 24, Center floor side member reinforcement 25. Sida sill inner panel 26. Rear tlocr pane! 27, Roar floor side panel 28, Rear floor side member 29, Rear bumper mounting reinforcement 90, Rear floor side member center reinforcement 31, Side sill inner rear panel ‘82, Rear floor center crass member 99, Rear floor sido member front reinforcement ‘34, Rear floor front cross member 95, Jack up cross center member ‘36, Jack up cross rear member 87. Fender panel 38, Cowl side upper panel ‘88. Cow! inner lower pan 40. Cow! side upper inner panel 41, Hood hinge mounting reinforcement . Cow! top outer panel Back panel |. Front inner lower pillar Wheel housing inner panel Wheel housing inner front extension Fiear spring housing cover Quarter inner panel Side cuter pane! Side cuter reinforcement Side cuter rear upper extension Rear combination lamp housing panel Hood auter panel Hood inner rail Door outer panel 56, Door inner panel 57. Tail gate outer panel $58, Tail gate inner pane BRESESSSSERREERES 15 BODY CONSTRUCTION - High - strength steel panels HIGH STRENGTH STEEL PANELS Bocause High strength steel panel has excellent resistance, itis used in areas which have a high passibilty of painting iow doficianey bak BODY CONSTRUCTION - High-strength steel panels 1. Radiator support lawer inner member 2. Radiator support lower outer member 3. Dash lower member 4. Front shock absorber housing upper panel 5. Front side inner member 8, Front side member inner gusset 7. Engine mounting reinforcement 8, Transmission mounting reinforcement 8, Front side rearlower member 10. Front side rear upper member 111. Front side memier rear lower extension 12. Front side member lower reinforcement 18, Front seat cross member 114, Fromt seat cross No. 2 member 18, Canter floor side member 16. Genter tloor side member reinforcement 117. Side sil innigr panel 18. Rear bumper mounting reinforcement 19, Rear floor side member center sainforcment 20. Rear floor side member front reinforcement 21. Rear floor Iront cross member 22. Fender panel 23, Cow! inner lower panel 24. Cowl top outer panel 25, Raof front lower 26, Tall gate hinge mounting reinforcement 27, Root rear lower rail 28, Roo! center rail 28. Back pane! 0, Front inner lower pillar 31. Front inner upper pillar ‘32. Center pillar inner panel 35. ear spring housing cover 24, Front door striker reinforcement 435, Front door striker upper reinforcement 36. Door outer panel 37, Door belt outer rail 38. Door upper member 38, Door belt inner rail 40, Tail gate cuter panel 41, Tall gate side reinforcement 7 BODY CONSTRUCTION - Front body FRONT BODY No. | PART NAME Radiator support panel complete Fiadiator support center complete member assembly Fender apron panel assembly, LHRH Front side member assembly, LAH Corr side outer panel assembly Corr pane! inna lower panel assembly Dash pane! cower side outer uoper panel, URH Corl cross bar assembly 1 2 3 4 5 6 7 8 BODY CONSTRUCTION - Front body 1. RADIATOR SUPPORT PANEL onan PART NAME Radiator support upper center member Radiator suppon center member Radiator upper mounting bracket Radiator support upper side member Head lamp support panel Head lamp suppon gusset Radiator kawer mounting bracket Frant shipping hook bracket Radiator support lower inner member Radiator lower mounting reinforcement Radiator support lower outer member tgeavamsens 19 BODY CONSTRUCTION-Front body Front bumper mounting, ranfercament Front bumper stay; Front eid member inner ‘tort extension f Frontside member inner ussst SECTION AA” Radiator suapert center memior supper — hawer outer member Ae — Fedor support wer stale SECTION C.-C" I ca ewer inet mambee CL SECTION B-B" Fasano support lowe, ower member cont 0 Ariinoiae pad. Fladiter support lower ‘near mame ‘dato supgor lower tor member SECTION D-D" cow. ote BODY CONSTRUCTION - Front body «Cross-Sectional Views> canons ‘Shock absorber housing ‘complete panel Fendor aon upper Palais cater pal Front shock abeorber ' inner compile panel (housing penet Fenger Aproninner compile panel Front ids member SECTION And” cousin SECTION B-B" oma BODY CONSTRUCTION - Front body 3. FRONT SIDE MEMBER 18 9 envate No, | PART NAME No. | PART NAME 1 Front side inner member 4 Front side rearlower member 2 Front side member inner gusset 15 Front side rear upper member 3 ‘Sublrame mounting front plate 16 Front side membar roar lower extension 4 ‘Sublrarne mounting front support 7 Front side member lower reinforcement 5 Engine maunting reinforcement 18 Front back beam mounting bracket 6 Engine mounting front bracket 19 ‘Subframe rear mounting bracket 7 Engine maunting rear bracket 20 ‘Subframe rear mounting reinforcement 8 ssmigsion mounting reinforcement a1 ‘Subframe rear mounting support 8 Transmission mounting front bracket 2 Subframe front mounting bracket 10 Transmission mounting rear bracket 2a Front sige member inner front extension " Front side outer member 24 Front side member outer front ext 12 Sublrame mounting stud bolt 25 Front tie down hook 13 Brake hose mounting bracket 26 Undercover mounting bracket BODY CONSTRUCTION - Front body hy Front see camps i mabe | | SECTION A-AY sovca SECTION 8-8" came rent ede compists ere eprer emer orgie pare SECTION C-C' sonsore 24 BODY CONSTRUCTION - Front body 4. DASH PANEL PART NAME Dash panel Dash panel reinforcement Dash lower member Cluich pedal mounting bracket(RHD ONLY) Blower lawer mounting bracket Foot rest bracket E.C.U, mounting bracket 25 BODY CONSTRUCTION - Front body onsen ‘Cow comp paral [Dash panel contar ant pad j—Dach panel sie weaceeing ach panal mest Das pane center antipact ‘Sash pant. ae a Dash reinforcement (ast tomer memisr SECTION A-A’ on ase SECTION B-B’ coven ‘Dash reinforcement Dash panel: Feo rest bracket Dash pane! SECTION C-C" sors SECTION D-D omassa BODY CONSTRUCTION - Front body 5. COWL PANEL No. COIR O REN PART NAME PART NAME cones ‘Plenum chamber guide panel ‘Corr inner lower panel ‘Cowr inner lower reinforcement \Wipar pivot side mounting bracket ‘Cowl inner lower center reinforcement ‘Corll side upper inner panel Hood hinge mounting reinforcement Hood hinge mounting suppert Side column upper support extension ‘Side column lower support extension Clutch pedal mounting bracket Cow tap outer panel Wiper mounting side reinforcement Wiper motor mounting bracket Wiper pivot center mounting bracket Cov side upper inner panel BODY CONSTRUCTION - Front body SECTION A-A’ BODY CONSTRUCTION - Side body SIDE BODY No. | PART NAME No. | PART NAME 1 Front inner lower pillar 18 | Front door upper hinge extension 2 ‘Con conter member mounting frant bracket 49. | Front door sirker reinforcement 3 ‘Cow center member mounting rear bracket 20 | Front door striker upper reinforcement 4 ‘Cowl center member mounting bracket 21 | Side outer rear upper feinforcernant 5 Frontier upper pillar 22 | Side-outer rear fitor 6 ‘Center pillar inner panat 23 | Side outer rear upper extension 7 Front seat belt upper mounting bracket 24 | Quarter outer trot rointercement 8 Seat bol upper maunting reinfexcement 25 | Quamar outer upper filer 8 Side outer panel 26 | Quamer outer lower reinforesment 10 | Fender mounting bracket 27 | Quarter euler upper reinforcement 41 | Side outer reinforcement 28 | Tailgate gas tt mauniing bracket 12. | Front pillar outer upper reinforcement 28 | Fuelfilr housing mounting plate 18 | Front door hinge mounting lower 30 | Fuol flr housing catch mounting bracket reinforcement 31 | Rear combs iamp housing panel 14 | Front pillartower gusset 32 | Connector mounting bracket 18 | Front door lower hinge extension 33. | Rearbumper side mounting bracket 16 | Front door hinge mounting upper 34 | Ree bumper mounting bracket reinforcement 35 | Side cuterrear extension 17 | Front door chacksr reinforcement 36 | Tall gate quide bumper mounting bracket BODY CONSTRUCTION - Side body 1, FRONT PILLAR Front pier outer panel Frontside outer paral Front pile oxter upper Front door Noga mounting rareraama Side oust raifereomart ~ 4 Side outer ranircerent Front ane pcr plat boil Dd conse SECTION B-B' a Frontside quter panel nN ~Side outer panet ent oa a Sion ok rltrcemern see comft ran pa! SECTIONC-C' a SECTION D-0' ea 30 BODY CONSTRUCTION - Side body 2. SIDE SILL ghee AS (Corte oor panel ‘Sida iar complet Sid8 ovter rinforesmant SECTION A-AY compo SECTION B-B* conse a BODY CONSTRUCTION - Side body 3. QUARTER PANEL PART NAME No. | PART NAME ‘Quarter panel Whee! housing inner panel Wheel housing inner front extension Wheel housing inner rear exterssion Rear seat back side bracket Roar seat back upper brads Rearseat upper bracket Wheel housing inner front cover Wheel housing inner rear gusset Rear spring housing upper gusset Seat belt reel mounting bracket Covering shelf side trim mounting bracket ‘Wheel housing inner upper reinforcement ‘Whee! housing inner upper rear reinforcment ‘Wheel housing inner upper gusset ‘Wheel housing inner front reinforcement Luggage net mounting bracket 7 18 | Quarerinner pane! 12 | Quarterinner reinforcement 20 | Quarter inner upper panel 21 | Quarter antipad mounting brackat 22 | Jack mounting bracket 32 BODY CONSTRUCTION - Side body Side outer part ‘Side outer panal Cone ineilor “Cantar pita inner Baal SECTION A.A’ one SECTION B-B' Sige al innat ae Cent Inner pliar Quanerinner wee! rouse She ausar complete panel Canter toar‘panat eee SECTION C-C concen 33 BODY CONSTRUCTION - Under body
UNDER BODY 1. CENTER FLOOR No, | PART NAME 1 | Genter floor pane! 2 | Muffler hanger mounting bracket 3 | Mutter hanger mounting bar 4 | Centersioor reinforcement 5 | Center'support mounting reintorcement 6 7 8 T.GS. lever mounting reinforcement Parking brake lever mounting reinforcement Parking brake eable guide pipe 9 Parking brake cable mounting reinforcement 10. | Front seat cross member 11 | Front seat cross No. 2 member 12 | Centertoor side member 13 | Genter floor side member reinforcement 14 | Sidesillinner pane! 18 | Parking brake lever rear mounting reinforcement 16 | Front seat mounting bracket 17 | Wiring protector mounting bracket BODY CONSTRUCTION - Under body 2. REAR FLOOR & SIDE MEMBER 11. Rear floor pane! 2. Spare tre mounting bracket 3, Rear floor side panel 4. Rear floor eenier cross upper 5. Rear seat side mounting bracket 6, Flear seat isofx mounting bar 7. Rear seat mounting bracket B. Rear seal belt center mounting bracket 8, Rear seal belt center mounting reinfarcement +10. Rear seat center mounting bracket 111. Rear seat back side protector ‘12, Rear seat cushion protector 13, Floor to wheel housing inner reinforcement 114. Rear floor side member 15. Rear bumper mounting reintarcement 46. Rear floor side member center reiniorcement 177. Brake hase rhounting front bracket 18, Side sill inner rear reinforcement 19. Side sill inner rear panal 20. Rear seat bet mounting side bracket 21. Trailing arm mounting bracket 22. Rear floor center cross extension 223. Murler hanger front pips 24, Rear cross member mounting pipe 25. Rear floor center cross member 26. Fusl tank maunting rear bracket 27. Reet floor side member front reinforcement 28, Flear floor front extension 29. Rear flocs trent cross member 30. Rear floar front side extension ‘31. Parking cable mounting center bracket ‘82, Fuel tank mounting front bracket 33. Centar floor side member rear extension 34, Flear floar side member front extension 95, Flear tis down reinforcement 26. Jack up cross center member 37. Canister mounting front bracket 98. dack up cross rear member 39, Jack up cross rear extension 440. Canister mounting rear bracket 41. Flear towing hook bracket 42, Muttler hanger rear pipe 43, Rear towing hook 44, Parking cable mounting side bracket 45, Trailing arm mounting plate 46, Rear tie down suppor 36 BODY CONSTRUCTION - Under body < Rear floor> 1. REAR FLOOR Fear tee pans Roar foor complais member SECTION B-B' SECTION A-A’ BODY CONSTRUCTION - Under body 2. REAR SIDE MEMBER como Rast ter sia memeber Far toor skis renter Sideline neat — ows toor center ‘crass extension Taiing em mer meurting bracket les beedcdin cane sireorcamant SECTION AA’ SECTION B-B' 38 BODY CONSTRUCTION - Rear body i ne REAR BODY 1. BACK PANEL PART NAME Back panel Tail gate strikar support Rear transverse member Reear transverse side extension Trunk net rear mounting bracket Rear transverse upper extension License plate mounting bracket Reear bumper upper side mounting bracket 39 BODY CONSTRUCTION - Rear body cows Fear bumper side vein Baca ac panel Fass tareverse ae tanto ‘poe eens mene Back pana SECTION A-A cone 018 SECTION B-t coments aartrareverse rember ack pane SECTION C-C" coun comms BODY CONSTRUCTION - Rear body sg SESE, 2. TAIL GATE ras No. | PART NAME Tailgate outer panel Tall gate inner panel Tai gate latch reinforcement Tail gate high mounting stop lamp mounting bracket Tail gate side reinforcement Tail gate wiper motor mounting reiniorcement Tail gate inside handle housing bracket at BODY CONSTRUCTION - Rear bodyeT: TAIL GATE PANEL gate> Tall gate outer panel Mastic eeslat SF Tall got inna pans Tal gate wiper motor mounting ratorcemend SECTION Cc" sass Tal gag vt pa Tal utr pr ae | a ‘Tall gate iit Tall gate inner pained “ SECTION A-AY Tene SECTION B-B' pena Tal onic oterpanel Pa } Tail gate site rarrcarent SECTION D-D" tenet BODY CONSTRUCTION - Fender & Hood FENDER & HOOD soar No | PART NAME 1 Hood panel assembly 2 Hood hinge assembly BODY CONSTRUCTION - Root ROOF PART NAME Roof panel Roof panelisun root) Roof front lower Over head console mounting bracket Roof rear upper rail Tail gate hinge mounting reinforcement Roof rear lower rail Roof center rail Roof center rail No. 2 Sun roof ring reinforcement ‘Sun roof rear side reinforcement Sun roof rear lower reiniorcement Sun roof side mounting bracket BODY CONSTRUCTION - Door DOOR 1. FRONT DOOR Door suet panel = SECTION D-D’ con SECTION A-AY cower SECTION 8-8" emer REPLACEMENT PARTS REPLACEMENT PARTS - Front body a REPLACEMENT PARTS: ‘The following section llustrates replacement parts used in the repairs described in this manual. It is important that only Hyundai replacement parts be used in making these repairs to ensure the repairs are made with the highest possible standards for fi, safety and corrosion protection. For a more complete listing of service parts, referto an authorized Hyundai dealership, FRONT BODY PART NAME RADIATOR SUPPORT PANEL COMPLETE RADIATOR SUPPORT CENTER COMPLETE MEMBER ASSEMBLY FRONT SIDEMEMBER ASSEMBLY, LHRH FENDER APRON PANEL ASSEMBLY, LHRH COWL TOP OUTER PANEL ASSEMBLY COWL INNER LOWER PANEL ASSEMBLY COWL SIDE OUTER UPPER PANEL, LHRH COWL CROSS BAR ASSEMBLY ToOurmocoo> REPLACEMENT PARTS - Side body SIDE BODY PART NAME FRONT INNER PILLAR ASSEMBBLY, LHRH ‘CENTER INNER PILLAR ASSEMBLY, LH/RH 'STDE OUTER REINFORCEMENT ASSEMBLY, LHRH PILLAR QUTER PANER ASSEMBLY, LHIRH ‘SIDE SILL OUTER PANEL, LH/RH ‘QUARTER INNER PANEL ASSEMBLY, LHRH REAR COMBI LAMP HOUSING PANEL ASSEMBLY, —LH/RH SIDE OUTER REAR EXTENSION ASSEMBLY, LHIRH QUARTER OUTER PANEL ASSEMBLY, 43 REPLACEMENT PARTS - Re: REAR BODY PART NAME REAR FLOOR PANEL REAR FLGOR SIDE COMPLETE MEMBER ASSEMBLY, —LH/RH REAR FLOOR FRONT EXTENSION ASSEMBLY REAR FLOOR CENTER CROSSMEMBER ASSEMBLY JACK UP CROSSMEMBER ASSEMBLY REAR SEAT BELT MOUNTING BRACKET ASSEMBLY REAR SEAT CENTER MOUNTING BRACKET ASSEMBLY REAR SEAT MOUNTING BRACKET ASSEMBLY, RH REAR FLOR SIDE PANEL, BH REAR SEAT MOUNTING BRACKET ASSEMBLY, LH FEAR FLOOR SIDE PANEL, re REAR FLOOR CROSSEMBER ASSEMBLY SPARE TIRE MOUNTING BRACKET ASSEMBLY BACK PANEL ASSEMBLY ZERO -ToemMmSoOos REPLACEMENT PARTS - Door DOOR cima conan PART NAME DOOR PANEL ASSEMBL’ LHIRH DOOR OUTER PANEL, LHRH DOOR UPPER HINGE ASSEMBLY, LHRH DOOR LOWER HINGE ASSEMBLY, LH/RH coaD 51 BODY DIMENSIONS (GENERAL 1. Basically, all measurements in this manual are taken with a tracking gauge, 2. When a measuring tape is used, check to be sure thera is no elongation, twisting or bending, 3. For measuring dimensions, both projected dimensian and ac- tualsmeasurement dimension are used in this manual. MEASUREMENT METHOD PROJECTED DIMENSIONS. 1, These are the dimensions measured when the measurement Paints are projected into the reference plane, and are the reference dimensions used for body alterations, 2, tthe length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the amount equivalent to the difference in height of the twa surfaces, ACTUAL-MEASUREMENT DIMENSIONS: 4. These dimensions indicate the actual linear distance between ‘measurement points, and arethe reterence dimensions for use fa tracking gauge is used for measurement, 2, Measure by first adjusting both probes ta the same length (AeA). NOTE Check the probes and gauge itself to make sure there is no free play. MEASUREMENT POINT 4, Measurements should be taken at the hole center, Hole center EEE EEE BODY DIMENSIONS - Upper body UPPER BODY * These dimensions indicated in this figure are actual-measurement dimensions. Paint symbol Length (mm) Paint symbol Length (mm) Point symbol Length (mm) BODY DIMENSIONS - Upper body oe Fender mounting hole (26.6) Front suspension mounin: 9 ps hrale(o1 1) F S ‘Cowl top cover mounting hole (a7) Hoad hinge mounting hole (13) G ‘Comer of side outer pane! Tal gate striker mounting hole (214) Member side mounting hole (26) BODY DIMENSIONS - Side body SIDE BODY “These dimensions indicated in this figure are projected dimensions. > = Pointsymbol | AB | Ac | Bc | BE | BF | BG | CD | CE __Length (mm) aos | 72 372_| 1220 | 1340 | 1646 | 1208 | 1224 Fointsymbol | cr | ca | oe | ef | ec | ea | wz | tz Length (mmm) | ioe | 76s | rae | see | oo2 | 298 | 142 | 229 Pointsymbol | vz | Kz | M2 | NZ | Oz | Pz | HL | KL Length mm) | 635 | 6a | 67 | 72 | 127 | 238 | 1159 | aso | Point symbol | SL | KL | GM | LN | Lo | LP | Length (mm) | ass | 22a | 1925 | 2074 | 2050 | 2666 7 BODY DIMENSIONS - Side body sous Tooling & hood cable passage holel@15) Door hinge mounting hole(213) Retainer mounting hole (067x687) Fixed glass mounting hole (9x7 stot) Fixed lass mounting hale (9x7 slot) Front tie down hook mounting hole(@12) Front suspension passage hole (251) Sub-frame mounting hole (220) Tooling hole (228) BODY DIMENSIONS - Side body Rear suspension passage hole (213) (e334) Bumper stay mounting hole (a13) so Rear cross member mounting, hotest a) BODY DIMENSIONS - interior INTERIOR wen * These dimensions indicated inthis figure are actualmeasurement dimensions. Point symbol | Aa’ | BB | Gc! | OD | EE | FF | GG’ | HH Length (mm) | 1480 | 1348 | 1164 | 987 | 1122 | ts07 | 1153 | 1059 Point symbol uw fw w | Length (mm) twat | 1063 | 1013 BODY DIMENSIONS - Interior Front daor checker maunting hole(t1) Floor wiring mounting hole (7x12 slot) D F Ih N \ | It | | {| PE we Seal bl ce mung ol Fear aeat bets ower Door aiker moving hoe (oi2.2) a Wore mounting hoie( 215.7) (13) ~—— == 1 Bu eatae aster meuteg 4 eee brackel mounting Rear suspension mounting hole (29) Sun reat side bracket mounting hola(@6.6) BODY DIMENSIONS - Under body UNDER BODY * These dimensions indicated in this figure are projected dimensions. on Peintaymbol | AA’ | BB | OC | DD | Be | FF | Go | HH Length (mm) geo | 960 | 1136 | 560 7s4 | 1192 | 1196 | 970 Point symbol az | ez | ez [oz | rz | oz | wz | ae Length (mm) toz | 20 | 635 | ca_| 67 | 772 | 238 | 1078 Pointsympol | BE | ce | oe | EF | EG | En Lengt(mm) | aso | ass | 223 | 1aas | 2ora | 2666 BODY DIMENSIONS - Under body Front suspension passage hole (e102) 7H Ge Sub-frame mounting hole(@20) Trailing arm mounting hole (213) Rear suspension passage Bumper stay mounting hole hole(aa4) (o13) BODY DIMENSIONS - Under body UNDER BODY * These dimensions indicated in this figure are actual-measurement dimensions. Pointsymbol | 40 | ee | ec | cc | co | oo | oe | De Length (mm) 957 960 904 960 | 1046 | 956 | 1165 | BIT Pointsymbol | Ee | EF | FF | FG | GG | GH | HH | Hel Length (mm) seo | vor | 754 | s66 | 754 | 1012 | 754 | 1002 Point symbol TS ee Length (mm) qie2_ 1175 | 1126 | 1170 | 959 | 995 961 970 Pointsymbol | Mat | MK | WK —_bength (mm) [avai | 1153) 656 BODY DIMENSIONS - Under body Traling arm mounting hole Rear crass momber mounting Tooting hole( 13) 3) (or hhole(a14y BODY DIMENSIGNS - Under body ner Bumper slay mounting hole Tooling & paint desir hale 22" (3) BODY DIMENSIONS - Engine compartment ENGINE COMPARTMENT "These dimensions indicated in this figure are aetual-measurement dimensions. Pointsymbat | AA | Be’ | co | o> | oe | oF | Be | RF Length (mm) | so7o | 980 | 77a_| 1210 | 1a77_| 1260 | 1972 | 996 Pointsymbol | FH | GG | HHT | HD | Length (mm) | 21a | 1498 | 1905 | 1583 _ _ BODY DIMENSIONS - Engine compartment (216) Front bumper mounting hole (212) E Fender mounting hole(@6.8) Front suspension mounting ole(@t 1) Tooling hote(a15) Hood hinge mounting hole (213) BODY DIMENSIONS - Luggage compartment LUGGAGE COMPARTMENT “These dimensions indicated in this figure are actual-measurement dimensions. Pointsymbol | aa | ee | co | po | pe | ee |__Length (mm) wae 1390_| 1176 | 1179 | 1456 1119 Pointsymbol | FF | FG | GF | GE | GO | Length (mim) eas] 1410 | 1421 | tava | 668 | BODY DIMENSIONS - Luggage compartment ‘Cover mounting hole Comb lamp mounting hole Rear combi lame mounting (85x85) (28) hole(@e) Tail gate guide bumper mount- Tailgate ift mounting hole Tail gate hinge mounting hole ing hole(29) (125) (14) Tail gate stiker mounting hole (ary BODY PANEL REPAIR PROCEDURE BODY PANEL REPAIR PROCEDUER - Radiator support panel RADIATOR SUPPORT PANEL em 3 © MIG plug welding 72 BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) FENDER APRON AND FRONT SIDE MEMBER (ASSEMBLY) ere © MIG plug welding it MIG butt welding xx MIG lap welding “73, BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) NOTE Before repairing, remove Engineand Suspension Components, Reler to the body dimension charts and measure the vehicle to determing straightening andalignment requirements. The body must be returned to its original dimension before you begin the repair procedure, REMOVAL 1. Drilleutallthe spotwelds to separate radiator support panel ram front side: member. NOTE When spotwelded portions.are not apparent, remove paint with a rotary wire brush. 2. Remove the radiator support panel. 3. Drill out all the spotwelds attaching the cow! side upper outer panel, NOTE If it is possible that the cow! side upper outer panel is reusable, be careful! not to damage it while removing. 74 pro. BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) 4, Using a spotweld cutter, dril out all the spotwelds attaching the fender apron to the dash panel and iront side member. 5. Remove the fender apron panel NOTE Hf collision demage requires replacement of fender apron and front side member together, remove both of thematthe same time, 6. Using a spotweldeutter, remove the frontside member by driling ‘out the spatwelds. 7. Grind and smooth any weld traces which might be left cn the body surface by using an air grinder or similar tool, being caretul riot to damage any of the panels which is not to be replaced. 15 BODY PANEL REPAIR PROCEDURI ron and front side member (As: 8. Usingahammerand dolly, correctany flanges that becomebent or deformed when spetwelds are broken. INSTALLATION 1, Dri mm holes inthe new tender apron and front side member for MIG plug welding. 2. Remove paint frombath sides of ll portions that aretobe welded such as peripheries of MIG plug weld holes. 3. Temporaniy install new pars in place, 4, Measure each measurement point (Reter tothe BODY DIMEN- SIONS) and correet the installation position. exoee BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) 5. MIG plug weld all holes 6. Clean MIG welds with a disc grinder. NOTE 1. Becareful not to grind welded portions too much. 2. The internal parts will be stronger if the weld traces are not ground. 7. Before welding the cow! side upper auter panel, apply the two part epoxy primer and anti-corrosion agent to the interior of the fonder apron panel. 10. " 2 12 4, 18 16, 17. 18 18, 20, BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) Install the cowl side upper eutet panel in place, MIG plug wield all holes. Clean and prepare ail welds, remove all residue. ‘Apply the two part epoxy primerta theinteriarcfthe each pane! ‘Apply an snti-comosion soent 25 requitsd (Refer to the CORROSION PROTECTION}. Prepare the exterior surfaces for priming using wax and grease remover, ‘Apply matal conditioner and water ringe. Apply conversion coating and wate’ rinse, Apply the two-part epoxy primer: Apply the correct seam sealer to all joints carefully (Reler to the BODY SEALING LOCATION) Reprime over tho seam eealer to. complete the repair Alter compiating body repairs, carefully apply under coating to tha fran sidemember and fender apron (Heter ic the CORRO- SION PROTECTION}. In order to improve corrosion resistance, if nacessary, apply an Under body anti-conmsion agont ta the paral which i rapaired orreplaced (Rieferto the CORROSION PROTECTION), 78 BODY PANEL REPAIR PROCEDURE - Front side member (Partial) FRONT SIDE MEMBER (PARTIAL) SENT © MIG plug welding {MIG butt welding @ MIG plug welding MIG butt welding 7 BODY PANEL REPAIR PROCEDURE - Front side member (Partial) rT REMOVAL NOTE This procedure Is to be used only for repair of miner damage ‘o the front side member and whenitis impossible to straighten ‘the damaged side member. The following procedure illustrates a repair for the front left side member. The procedure may also be applied fo the front right side- member, 1, Measure and mark the vertical cutines on front side member outer and inner trom rear edge of frant side member gusset 2. Drill out all the spotwolds to separate radiator support panel {rom front side member NOTE 1, When spotwelded portions are not apparent, remove, paint with a rotary wire brush. 2. Inarder to perform cuttingand:separation of spetwelded points use a spot weld cutter which is larger than the size of the nugget to make a hole only in the panels to be replaced, 80 BODY PANEL REPAIR PROCEDURE - Front side member (Partial) 8. Cut through the front side member inner and outer at cutlines. NOTE Take care not to cut through front side member inner reinforcement. 4. Propareall surfaces tobe welded. INSTALLATION 1. Transeribe the front side member inner and outer cutline ta the revs front side member, cut to length and charnfer butt end to improve weld surtace. 2. _Drillamm holes in new frant side member for MIG plug welding, 3. Fitand clamp the front side member inner and outer in place. 4. MIG plug weld all holes and MIG butt weld all seams. 5, Measure each measurement point (Refer to the BODY DIMEN- SIONS) and correct the installation positian, a1 BODY PANEL REPAIR PROCEDURE - Front side member (Partial) .Fitand clamp the radiator support panel in place. MIG plug weld all holes. Clean and prepare all welds, remove all residue. ‘Apply the two-part epoxy primer tothe interior of the front side member. 10, Apply an anti-corrosion agent as required (Refer to the CORROSION PROTECTION). Propare the exlerior surfaces for priming using wax andgrense remover. 12. Apply metal conditioner and water rinse. 13. Apply conversion coating and water rinse, 14, Apply the two-part epoxy primer, 415. Apply the correct seam sealer to all joints carefully (Rofer to the BODY SEALING LOCATIONS). 16. Reprime over the seam sealer to complete the repair. BODY PANEL REPAIR PROCEDURE - Front pillar FRONT PILLAR Meenas) @ MIG plug welding fit MIG butt welding ox MIG lap welding 83 BODY PANEL REPAIR PROCEDURE - Front pillar 5 A SE REE REMOVAL 1. Measure and mark the each cutline on the front outer pillar, front ‘outer upper pillar and front inner upper pillar rom the windshild ass moulding mounting hole indicated in the illustration. 2. Measure and mark the cutline on front side sill outer panel as shown in the lustration, 3, Depending on the extent of damaged area, it may be possible to determine the cutting range within indicated in the ilustration, 4.To remove the front pillar, grind away and drill out all welds attaching the cow/ side upper outer panel as ilustration. NOTE If it is possible that the cow! side upper outer panel is reusable, be careful not to damage It while removing. 84 BODY PANEL REPAIR PROCEDURE - Front 5. Diilloutail welds attaching the front pillar to dash, cowl top outer and cow! inner lower panel, 6. Remove spotwelds and lap welds altaching cowl crassmember bar mounting upper bracket to remove front pillar 7. Before cutting front pillar, be sure to suppert root panel. Cut the front pillar through each cutline, taking care not te damage the other panel as illustration. ‘9. Before cutting thetront side sll outerpanel,make aroughcut the front side sil outer panel only. NOTE When cutting the front side sill outer panel, be careful not to-cut side sill outer front reinforcement. BODY PANEL REPAIR PROCEDURE - Front pillar 10. Cut the side sil euter front reinforcement as lustration “11. Cut the front side sill outer panel vertical cuting and remove the front pil 12. Straighten all flanges as necessary, prepare all surfaces tobe welled INSTALLATION 1. Transcribe the cutlina to the new frant inner upper pillar, cut to. length and chamfer butt end to improve weld surtace, 2. Transcribe the cutline to the new front side sill outer panel and ‘new front pillar, adding 0mm overlap to 6nd and cut to length. 8, Drill mm holes along outer panel anges in production location for attachment to other panels. BODY PANEL REPAIR PROCEDURE - Front pillar & a. 10, " 12, 13, 14, 15, 16. Transcribe the cutline to the new side sill outer front reinforce- ment panel, adding 30mm overlap to end and cut to length, Drill dram holes in the side sill outer front reinforcement for MIG plug welding, Fitand clamp the new side sill outer front reinforcement panelin place tor welding, MIG plug weld all holes and MIG butt weld the seams. Temporarily install front inner pillar and front side outer panetin place. Magura and each maasurement point (Refer to the BODY DIMENSIONS) and correct the installation position. Iinecessany, make temporary welds, and then check to contiem thatthe closing and fit for windshield glass, door and fender are carrect. ‘MiG butt weid front outer pilar and front side outer panel seams. Reattach the cut away frant inner pillar saction, then MIG butt wold. MIG plug weldall holes and MIG butt weld all seams in tho front side sill outer panel, Clean and prepare all welds, remove all residue, Apply body filer to joints and sand as nesded, ‘Apply the two-part epoxy primerto the interior ofthe tran pillar a7 ae oat BODY PANEL REPAIR PROCEDURE - Front pillar 17, Clean all welds with a disc grinder, NOTE 1. Be careful not to grind welded portions too much. 2. Theinteral parts will be stronger if the weld traces are not ground. 18. Before welding the cow! side upper outer panel, apply the two part epoxy primer and anti-corrosion agent to the interior of the fender apron panel, 19. Install the cow! side upper outer panel in place 20. MIG plug weld all holes. 21, Clean and prepare all welds, remove all residue. ‘Apply an anti-corrosion agent to the welded parts and inside of front pillar (Refer to the CORROSION PROTECTION). Prepare exterior surlaces for priming, using wax and grease ‘Apply canversian coating and water rinse, ‘Apply the two-part epoxy primer. BRE BB BODY PANEL REPAIR PROCEDURE - Front pillar 27. Apply the correct seam sealer to all joints carefully (Peler to the BODY SEALING LOCATIONS). 28, Rleprime over the seam sealer to complete the repair. BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) SIDE SILL (ASSEMBLY) © MIG plug welding 4H MIG butt welding REMOVAL 1. Measure and mark vertical cutline from the rear door ecutt trim ‘mounting hola on the rear side sill outer pans, 2. Al tha front and side sill, measure and mark horizontal cuttines from the door hinge mounting hole on the side outer panel as ilustration. BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 8, Cutthe side sill outer panel along cutlines, Be careful not to cut mating flanges. 4, Drill out all spotwelds, attaching the side sill outer panel. 5, Remove the side sill outer panel. 6. Determine tthe side outer reinforcementis damaged and needs ‘wo replaced, moaaure cutling on reinforoament asillustration. 7. Cut side-outer reinforcement along the cutine 8. Drillout spatwelds attaching the side outer reieforcemant to the kody and remave side sil outer reintarcemer 8. Prepare all surfaces to be welded. INSTALLATION 1. Trangerite cutline dimension to side outer reinforcement, add Ing 80mm averlap to rear end and cut to length. 2. Drill 6mm holes in overlap area on rear end and along front flange. 8. Fitand.clamp the side outer reinforcement in place. 4. MIG plug weldall holes and MIG butt weld seams 5. Botore welding the side silloutarpanel, apply the two-part epoxy primer and anti-corrosion agent to the welded parr, NOTE ‘Tho reinforcement wil be stronger if the weld traces are not ground. 1 BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 6. Using service panel far repiacement ot side sil outer pal, drill ‘8mm holes in overlap areas and along upper and lower flanges, 7, Crimp flanges.on ine remaining portion ofthe side silouter panel al all joint for overlap 8, Fitand clamp the side sill outer panel in place, 8, MIG plug weld all holes and MIG butt weld seams. 10, Clean and prepare all welds and remove all residue 11, Apply body filer to the side sill outer seams. 12, Apply the two-pait epoxy primer to the interior of the ice Sil 1, Applyan anti-corrosion agent to welded parts and interior of the side sill (Refer to the GGRROSION PROTECTION), 14. Prepare the exterior surfaces for priming, using wax and grease remover, 15. Apply metal conditioner and water rinse. 16, Apply conversion costing and water rin 17. Apply the two-part epoxy primer. 18, Apply the correct seam sealer to-all joints (Refer to the BODY ‘SEALING LOCATIONS). 419, Reprime aver the seam sealer. BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 20. Apply the anti-corrosion primer to the side sill outer panel to complete the repair (Refer to the CORROSION PROTECTION), BODY PANEL REPAIR PROCEDURE - Side sill (partial) SIDE SILL (PARTIAL) ELDLI INTS © MIG plug welding HE MIG butt welding proonss REMOVAL 4. Depending on the extent of damage, mark aut the damaged portion of the: side sil. 2. Drill out the spatwelds in upper and lower flanges of side sill between cutlines to remove side sill Outer panel and cut the damaged portion of the side silat the cutines, a4 BODY PANEL REPAIR PROCEDURE - Side sill (partial) 3, Determine ifthe side outer reinforcement is damaged and needs to be replaced. If replacing is necessary. mark out the damaged portionatthaside outer reinforcement, Cutatcutinesand remove the damaged portion. 4, Prepare all surlaces to be welded, INSTALLATION 1. Transcribe the cutline tothe nawside outer reinforcement, adding 30 mm overlap to each end and cut to length. 2. Dri mmoles in overlap areas an gach end and upper flange ‘of new side outer reinforcement and clamp tha new side oular reinforcement in piace, 3. MIG plug weld all holes and MIG butt weld all seams, NOTE ‘Thereinforcement willbe stronger ifthe weld traces are not ground. 4. Botore woloing the side silouterpane!, apply the two partenoxy primer and anti-corrosion agent fo the welded parts. 5. Transcribe the side sill outer pane! cutline to the new side sil, adding 30mm overiap to each end, cut and chamter buit end to improve weld surface. 6. Dri mmoles in overlap areas on each end and along upper and lower flanges of the nev side sill cuter panel for MIG plug welding BODY PANEL REPAIR PROCEDURE - Side sill (partial) 7. Fitand clamp the side sill place. 8. MIG plug weld alf holes and MIG but weld seams. 8. Clean and prepare all welds, remove all residue. 10, Apply body filer ta the side sill outer seams. 11. Apply the two-part epoxy primer to the interior of the sic sil 12. Apply an anti-corrosion agentto the welded parts and interior of tho side sill (Refer to tha CORROSION PROTECTION). 18. Prepare the exterior surfaces for priming, using waxand grease ‘Apply metal conditioner and water rinse. ‘Apply conversion coating and water rinse. }. Apaly the two-part epoxy primer, 17, Apply the anti-corrosion primer to the side sill outer panel to complete the repair (Rieterto the CORROSION PROTECTION). BODY PANEL REPAIR PROCEDURE - Quarter panel QUARTER PANEL BODY PANEL REPAIR PROCEDURE - Quarter panel REMOVAL 1. Depending on the extent of damage, measure and mark cutlinas ‘on the quarter outer panel as ilustraton. 2, Dell out all attaching walds on the quarter outer pans, Inclucing the seam around the door lip opening. 2, Cut the quarter outer panel al cartines and remove the quarter ‘outer pane! as iustration NOTE When cutting the quarter outer panel, be careful not to cut quarter inner panel. 4. Prepare all surfaces to bo wolded, INSTALLATION 1. Transerbe the cutting to the new quarter outer panel, adding 30 men for overlap at the old joint 2, Dill 8 mm holes in overlap areas: and slong upper and lower flanges of the new quarter auter panel for MIG plug welding. 13. Fit and clamp the quarter outer panel in place, 4. MIG plug weld all holes and MIG butt wald seams. At the wheel Well the édge must be crimped over the wheel housing. This joint may be welded after crimping or may be made by ‘applying a bead of adhesive which may be appliad to the joint betore or after crimping. 6, Clean and prepare all welds, remove all residue, 98 ras pro-1080 BODY PANEL REPAIR PROCEDURE - Quarter panel 6. Apply body filer to the welded seam. Sand and finish. ‘Apply the: two-part epoxy primer to the interior of the quarter ‘outer panel 7. Apply an anti-corrosion agent to the welded parts and interior of ‘the quarter outer panel (Refer to the CORROSION PROTEC- TION}. 8. Prepare exterior surfaces for priming, using wax and grease 8. Apply metal conditioner and water rinse, 10. Apply conversion costing and water rinse 11, Apply the two-part epoxy primar. 12. Apply the correct seam sealers to all joints, 13. Reprime over the seam sealer to completa the reparr 14, In order to improve corrosion resistance, if necessary, apply an Under body anti-corrosion agent to the whee! well (afer to the CORROSION PROTECTION). BODY PANEL REPAIR PROCEDURE - Rear floor REAR FLOOR ems Pmoszt ‘© MIG plug welding Hk MIG butt welding soc MIG lap welding 100 BODY PANEL REPAIR PROCEDURE - Rear side member (assembly) REAR SIDE MEMBER (ASSEMBLY) WELDLING POINTS A : 7 || hell Ta] SAE 2o/ (alll {| ri Hy i wy £3) io ey & a. Hep CE? a © MIG plug welding HE MIG butt welding 101 BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) en SSR NOTE Because the rear side members are desigened io absorb energy ‘during a rear collision, care must be taken when decking fo use this repair method. This repair is recommended only for maderate dam- -ag@ (0 vehicle, where distortions do not extend forward of the trunk region. I the damage is mote severe, then the entire side member assembly should be replaced at faciory seams without employing ‘his sectioning procedure, Refer to the body dimension chart and measure the vehicle 10 determin straigthening and alignment requirements. The body must bereturned te its original dimension before beginning the ‘repair procedure, REMOVAL 4. Drill out all the spotwelds atlaching the rear floor panel ta the wheel housings and rear side members. 2. Make a rough cutting of the rear floor panel as shawn In the figure. rca 3. Remove the rear floor panel (front section}, 4, Remove the back panel by drilling out all ataching spotwelds. BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) 5. Remove the reariloor pane! (rearsectionjandrear sidemember from the rear body. INSTALLATION 1, Transcribe the cutiine tothe new rear side members. Drillout the ‘spotweids attaching the inner reinforcements. Flemove remaining portions of side members. ge FRot0e 2 Temporariy ft and clamp the rasr side members in place. NOTE When installing the rear floor side member, temporarily Ingtallthe back panel to measure each measurement paint, 3. Measure each measurement point (Refer to BODY DIMEN- SIONS) and correct the installation position 4. necessary. make temporarily welds, and then check to contin that the fit of rear floor panel is correct 103 BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) som 40. Ww 12, 13, 14, 18 16 MIG plug weld the rear side members and MIG buttweld seams. Prepare thewelds andsurfacesto which the rearficorwillatiach. Transcribe the culine to the new rear floor panel, adding 3mm for overlap at the ald joint. rit 6mm holes in overlap area and production locations of ine ew rear floor panel for MIG plug welding. Fit andclamp the rear floor panel and attach the rear floor panel ta the rear side members and other panels. MIG plug weld all holes and MIG but! weld the seams. Clean all welded surfaces, Drill mm holes onthe flange attachingthe backpanelto therear floor and side mamber ends. Fit and clamp the back panel in place. MIG plug weld the back panel. Clean and prepare all welds, remove all residue. Apply the two-part epoxy primer to the interior of the rear sido rhemibers. 104 9 pro. BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) 17. Apply an anti-corrosion to the interior of the rear side members (Reter io the CORROSION PROTECTION). 18, Propare exterior surfaces for priming, using wax and grease remover, 19. Apply metal conditioner and water rinse. 20, Apply the two-part epoxy primer, 21. Apply the correct seam sealer to all joints (eter ta the BODY SEALING LOCATIONS). 22, Alprime over the seam sealer to complete the repair. 23, Alter completing bady repairs, caretully apply under coating to the under body (Refer to the GORRGSION PROTECTION). 24, In order to imprave corresion resistance, if necessary, apply an Underbody ant-corroston agent tothe panel which isrepairedor replaced (Refer to the CORROSION PROTECTION). 108 BODY PANEL REPAIR PROCEDURE - Rear side member (Partial) REAR SIDE MEMBER (PARTIAL) me eran) © MIG plug welding 4 MIG butt welding REMOVAL NOTE Because the rear side members are designed to absorb energy during a rear eolision, care must be used when deciding to use this repair method. This repair is recommended only for moderate damage to the vehicle, where distortions ro not extend forward of the trunk region. If the damage Is more severe, then the entire side member assembly should be replaced at the factory seams without ‘employing this sectioning procedure, ‘The following procedure applys when only one rear side member needs to be replaced. If beth side members are damaged and need to be replaced, then the procedure af Rear Side members ‘And Fear Fico Section should be followed. Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements, The body ‘must be returned to its original dimensions betore beginning the repair procedure, 106 BODY PANEL REPAIR PROCEDURE - Rear ide member (Partial) 1. Depending on the extent of damage, if the right side member is ta be replaced it should be measured and marked 210mm from the tooling hole center of the rear floor center crossmember. NOTE The flowing procedure illustrates a repair for the right rear side member. The procedure may also be applied the left rear side member. 2. Cutthrough rear side member at cutline being careful not to cut rear'side member reinforcement. 8. Remove the rear floor side member by driling out al attaching spotwelds. 4, Prepare all surfaces to be welded, INSTALLATION 1. Transcribe the cutline to the new rear side member. Cut at line and dril out the spotwelds attaching the inner reintercement and separate it 2, Find clamp the new rear side member in place fer welding. Measure to ensure dimensions areaccurate as givenin the body ‘dimension chan, 8, MIG plug weld at the holes and MIG butt weld the seam in the ‘side member. 4, Clean and prepare all surfaces to be welded and remove all residue, 8. Apply the two-pan epoxy primer to the interior of the rear side member, 107 BODY PANEL REPAIR PROCEDURE - Rear side member (Partial) 6, poly an anti-cocrosion to the interior of the rear side member (Refer to the CORROSION PROTECTION) 7. Prepare exterior surfaces for priming, using wax and grease remover. 6. Apply matal conditioner and water rinse 9, Apply conversion coating and water ince 10. Apply the two-part epoxy primer. 11. Apply the correct seam sealer to all jolnts (Rlofar te tha BODY SEALING LOCATIONS), 12, Reprime over the seam sealer to complata tha reaait 19, After completing body repairs, carefully apoly unde? coating 10 the under Body (Flter te the CORROSICH PROTECTION) 14, In orderto improve corrosion resistance, if necessary, apply an under body anti-corrosion agent to the panel which Is repaired or roplaced (Reler to the CORROSION PROTECTION) 108 DOOR BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels REMOVAL 1. Cut door outer panel hem with a sander 2, _Affergrinding of the hemming location, remove the outer panel 3. Dress rusty part with a sander and prepare surface to be hemmed. INSTALLATION 1. Apply adhesive or equivalent to outer panel hem, 2. Apply mastiesealerorequivalentiothe door upper member and door reinforcement lheam as shown in the figure. 110 BODY PANEL REPAIR PROCEDURE - Door 3. Bandthe flange hem wth ahammer and dolly, then fasten tightly sn a. hemming took, NOTE ) 4. Hemming wrork should be dene in three steps as illus- tration. 2. Fa homming tool cannot be used, hem with a hammer and dolly. 4. Aftercompleting the hemming work, make MIG:spotwelds at'50 . ‘mm intervals on the inside. 5. Clean and prepare all welds, remove all residue 6. Apply the two-part epoxy primerto the interior of the door panel a BODY PANEL REPAIR PROCEDURE - Door 10. in 12, 13. ‘Apply an anti-corresion agant to the welded parts and lower inside of the docr panel (Refer to the CORROSION PROTEC: TION), Prapare exterior surfaces for priming, using wax and grease remover. Apply metal conditioner and water rinse. Apply conversion coating and water rinse. Apply the two-part epoxy primer. Apply the correct seam sealer ta whole pans! sdge. Floprime over the seam sealer to complete tha repair. 112 BODY SEALING LOCATIONS BODY SEALING LOCATIONS - Floor FLOOR cle Centr Nob rirtorcament conte oor part SECTION A-A’ BAGH SECTION B-B' enone i ‘Sido ail Inver ear panel Fear far panel Sark rama ete ee FP fear tor side member front! extension * Rar Tae sie atnsion SECTION D-D’ owns SECTION C-C* EAA 14 FLOOR BODY SEALING LOCATIONS - Floor IN) A 44 ae = eis ud BODY SEALING LOCATIONS - Floor 116 BODY SEALING LOCATIONS - Floor "7 BODY SEALING LOCATIONS - Upper and side body UPPER AND SIDE BODY sennen sear 118 BODY SEALING LOCATIONS - Upper and side body 119 BODY SEALING LOCATIONS - Upper and side body CORROSION PROTECTION (CORROSION PROTECTION - Zinc - galvanized steel panels ZINC - GALVANIZED STEEL PANELS Because galvanized steel panei has excellent resistance, it is used in areas which have a high possibilty of painting deficlancy below. 122 CORROSION PROTECTION - Zinc-galvanized steel panels 1, Radiator support upper center member 2, Radiator support center member 8. Radiator support upper side member 4, Head lamp support panel 5, Head lamp support gusset 6: Front shipping hook bracket 7. Radiator support lower inner member 8. Radiator support lower outer member 8. Dash pane! 10. Dash lower member 11, Fender apron upper outer panel 112, Fender apron inner rear upper extension 18, Fender apron inner rear lower extension 114, Fender apron upper inner panel 18, Front shock absorber housing panel 116, Front shock absorber housing upper panel 17. Fender apron inner front pane! 18. Front side inner member 18, Front side member inner gusset 20, Front side member rear Inver extension 21. Center floor panel 22, Muller hanger mounting bracket 23, Center floor side member 24, Center floor sige member reinforcement 25, Side sil inner panel 26, Rear tloor panel 27. Flearttloor side pane! 28, Rear floor side member 29. Rear bumper mounting reinforcement 30, Rear floor side mamber center reinforcement 31, Skdo sill inner rear panel 32, Rear floor center cross member ‘98. Rear floor side member front reinforcement 24, Rear floor front eross member 35, Jack up cross center member 96. Jack up cross rear member 37. Fender panel 98, Cowl side upper panel 39. Cowl inner lewer panel 40, Cowl sida upper inner paral 41, Hood hinge mounting reinforcement 42, Cowl top cuter panat 43, Back panel 44, Front inner lower pillar 48, Whee! housing inner panel 46, Whee! housing inner front extension 47. Flear spring housing cover 48, Quarter inner panel 49, Side outer panel 50. Side outer reinforcement 81, Side outer rear upper extension 52, Flear combination lamp housing panel 58, Hood outer pane! 54. Hood inner rail 85, Door outer panel 56, Door inner panel 57, Tail gate outer panel 58, Tail gate inner pane! 1239 CORROSION PROTECTION - Zinc-phosphate coat & cationic eletradeposition primer ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER Inorder to improve the adhesion of the paint coat on the steel panel, and also to improve the carrosion resistance, the ‘entire body is coated with a film of Zinc-phosphate and a cationic electradeposition primer. ‘Cationic electrodeposition primer Zine phosphate film Body stee! panel ‘CORROSION PROTECTION - Anti - coro: fn primer ANTI - CORROSION PRIMER ‘An anti

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