GENERAL INFORMATION
INTRODUCTION This Body Repair Manual provides detailed repair procedures for repair of commonly damaged structural panels on the Hyundai Getz. To aid in the information of the damaged vehicle, body construction, replacement parts, body dimensions, body sealing locations, corrosion protection and body repair procedures are contained herein. The repair procedures specify locations where body members may be structurally sectioned.
CONTENTS GENERAL INFORMATION GENERAL GUIDELINES AND PRECAUTIONS .............................................................................................. 6 SRS AIR-BAG ................................................................................................................................................ 7 ELECTRONIC PARTS .................................................................................................................................... 8 CORROSION PROTECTION AND SEALING .......
GENERAL INFORMATION - General guide lines and precautions GENERAL GUIDE LINES AND PRECAUTIONS The Hyundai Getz is a completely new vehicle design. During its development, close attention has been given to safety, stability, weight and corrosion protection. Typical of unit body design, the Hyundai Getz is designed so that the front and rear compartments will absorb much of the collision energy so that the passengers are better protected.
GENERAL INFORMATION - SRS Air-bag SRS AIR-BAG SYSTEM COMPONENT PAB Clock spring BPT When it is deployed ERKB012A The Hyundai Getz is equipped with a Supplemental Restraint System AIR-BAG to provide the vehicle's driver and/ or the front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal impact of sufficient severity. When handling airbag components (removal, installation or inspection, etc.
GENERAL INFORMATION - Electronic parts ELECTRONIC PARTS Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse effects caused by overcurrent, 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.
GENERAL INFORMATION - Welding WELDING All repairs in this manual require the use of a Metal-Inert Gas (MIG) welder, Gas (oxyacetylene) welding must not be used. Both high strength steel and mild steel can be welded using the MIG welder. The I-CAR recommendations for welding should be followed. The shielding gas should be 75% Argon and 25% CO2. The recommended welding wire size is 0.23" and the wire should satisfy the American Welding Society standard code AWSER70S-6.
BODY CONSTRUCTION
BODY CONSTRUCTION - Body components BODY COMPONENTS 106 105 104 102 12 15 19 99 5 6 47 1 46 51 56 60 54 66 62 65 64 63 88 59 57 61 58 89 85 87 86 67 55 53 50 52 69 68 70 83 82 84 90 3 49 4 48 45 2 44 42 41 72 81 71 73 76 79 80 74 75 78 77 40 91 43 38 96 39 37 35 36 7 10 34 97 92 93 95 33 94 32 28 8 98 27 31 30 9 29 14 11 101 100 20 23 26 24 25 13 16 103 17 18 22 21 Body construction will sometimes differ depending o
BODY CONSTRUCTION - Body components 1. Plastic carrier 2. Radiator support upper center panel 3. Radiator support center panel 4. Radiator support center reinforcement 5. Dash panel 6. Brake booster reinforcement 7. Dash lower center reinforcement 8. Center floor panel 9. Rear floor extension 10. Front seat mounting rear side bracket 11. Rear floor front cross member 12. Rear floor panel 13. Towing hook bracket 14. Rear seat rear bracket 15. Rear floor center cross member 16.
BODY CONSTRUCTION - Zinc-galvanized steel panels ZINC-GALVANIZED STEEL PANELS 10 67 66 22 1 29 34 2 33 32 35 41 40 45 39 51 47 44 42 46 43 48 52 50 49 38 55 54 37 36 56 31 26 53 57 61 60 30 59 58 27 25 62 28 3 64 24 23 65 63 21 20 16 4 15 19 18 5 17 6 14 7 9 8 68 11 13 12 Because galvanized steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below.
BODY CONSTRUCTION - Zinc-galvanized steel panels 1. Radiator support upper center panel 2. Radiator support center reinforcement 3. Dash panel 4. Center floor panel 5. Rear floor extension 6. Rear floor front cross member 7. Rear floor panel 8. Towing hook bracket 9. Rear floor center cross member 10. Rear transverse member 11. Back panel 12. Tail gate inner panel 13. Tail gate outer panel 14. Rear door frame rear reinforcement 15. Rear door inner panel 16. Rear door outer panel 17.
BODY CONSTRUCTION - High-strength steel panels HIGH STRENGTH STEEL PANELS 3 2 19 26 31 29 28 33 32 34 41 36 38 40 42 39 64 44 43 47 45 63 61 60 62 46 37 35 49 48 50 59 58 65 1 30 27 23 52 57 51 53 56 54 55 24 22 25 20 21 66 17 18 68 4 16 67 15 11 69 14 13 12 7 5 10 70 8 71 6 72 73 9 Because High strength steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below.
BODY CONSTRUCTION - High-strength steel panels 1. Radiator support center panel 2. Brake booster reinforcement 3. Dash lower center reinforcement 4. Front seat mounting rear side bracket 5. Rear floor front cross member 6. Towing hook bracket 7. Rear seat rear bracket 8. Rear floor center cross member 9. Tail gate outer panel 10. Rear door reinforcement beam 11. Rear door outer panel 12. Rear floor side member extension 13. Rear floor side member reinforcement 14. Rear floor side member 15.
BODY CONSTRUCTION - Front body FRONT BODY 2 5 3 1 4 TB-60 No.
BODY CONSTRUCTION - Front body 1. RADIATOR SUPPORT PANEL 6 5 3 4 2 1 TB-70 No.
BODY CONSTRUCTION-Front body B Í D Í Í Í B' Í C C' A Í D' Í A' Í TB-80 Hood panel Front end module Head lamp Front bumper rail Front side complete member Front end module SECTION A-A' SECTION B-B' 80-1 Fender apron complete panel Fender panel 80-2 Hood panel Front end module Front end module SECTION C-C' SECTION D-D' 80-3 20 80-4
BODY CONSTRUCTION - Front body 2. FRONT SIDE MEMBER 5 4 8 3 7 11 9 1 10 2 12 13 6 17 22 21 23 18 15 19 14 20 16 TB-130 No. PART NAME No.
BODY CONSTRUCTION - Front body LH A Í A' Í TB-140A RH B Í C Í C' Í B' Í TB-140 Front side inner member Battery tray leg bracket Battery tray leg reinforcement Front towing hook mounting bracket Front side outer member Front side inner member SECTION A-A' SECTION B-B' 140-3 Front side inner member Engine mounting support Front side outer member SECTION C-C' 140-2 22 140-1
BODY CONSTRUCTION - Front body 3. FENDER APRON PANEL 9 8 4 3 7 10 2 6 11 1 5 TB-180 No.
BODY CONSTRUCTION - Front body BÍ A Í A' Í B' Í TB-190 Fender apron inner complete panel Cowl under cover extension Fender apron upper member Fender apron upper reinforcement Engine side mounting reinforcement Fender apron front complete panel Fender apron inner complete panel Fender apron front complete panel SECTION A-A' 190-1 24 SECTION B-B' 190-2
BODY CONSTRUCTION - Front body 4. DASH PANEL 1 14 2 12 3 8 6 9 10 15 13 4 11 5 7 TB-220 No. 1 2 3 4 5 6 7 8 PART NAME No.
BODY CONSTRUCTION - Front body Í D Í D' C Í B Í A B' Í Í A' C' Í Í TB-230 Dash lower center reinforcement Dash panel Foot rest bracket Dust cover panel Dash panel SECTION A-A' SECTION B-B' 230-1 Fuel filter mounting bracket Dash panel Heater lower mounting bracket SECTION C-C' Dash panel 230-3 26 230-2 Dash panel anti pad Dash lower center panel reinforcement SECTION D-D' 230-4
BODY CONSTRUCTION - Front body 5. COWL PANEL 4 5 2 6 12 13 14 7 8 9 15 10 11 1 3 TB-280 No.
BODY CONSTRUCTION - Front body C' D Í C Í Í Í B' Í Í Í A' B Í A D' TB-290 Cowl top outer panel Cowl top outer panel Wiper center mounting bracket Cowl under cover mounting bracket Cowl inner rear complete panel Cowl inner lower panel Cowl inner rear complete panel Cowl inner lower panel SECTION A-A' Cowl top outer panel Wiper center mounting bracket SECTION B-B' 290-1 290-2 Cowl top outer panel Cowl side outer panel Cowl inner rear complete pa
BODY CONSTRUCTION - Side body SIDE BODY 1 13 11 12 10 9 7 16 2 8 15 3 17 4 6 14 5 TB-340 No.
BODY CONSTRUCTION - Side body 1.
BODY CONSTRUCTION - Side body
2.BODY CONSTRUCTION - Side body 3.
BODY CONSTRUCTION - Side body 4.
BODY CONSTRUCTION - Side body Ó A Ó B' Ó A' Ó B Ó C Ó D' Ó Ó C' D TB-08 Side outer panel Side outer panel Side outer reinforcement Rear pillar panel SECTION A-A' 490-1 Fuel filler housing 490-2 Side outer panel Side outer panel SECTION C-C' SECTION B-B' Quarter outer rear lower extension 490-3 34 SECTION D-D' 490-4
BODY CONSTRUCTION - Side body 4-1.
BODY CONSTRUCTION - Side body Ð A Ð A' C Í Ð B Ð B D Í C' Í D' Í TB-809 Side outer panel Side outer panel Center pillar outer lower reinfocement Side outer reinforcement Front seat belt upper reinforcement assembly Side outer reinforcement SECTION A-A' SECTION B-B' 809-3A 809-4 Fuel filler housing Quarter outer rear lower extension Side outer reinforcement Side outer panel Mastic sealer SECTION C-C' 809-3 36 SECTION D-D' 809-1
BODY CONSTRUCTION - Center floor CENTER FLOOR PANEL 4 2 5 8 7 6 10 1 9 3 TB-539 No PART NAME 1 2 3 4 5 6 7 8 9 10 Center floor panel Center floor front reinforcement Parking brake aperture panel Front seat cross member TGS lever mounting bracket Front seat mounting rear inner bracket LH/RH Front seat mounting rear side bracket LH Front seat mounting rear side bracket RH Center floor side member LH/RH Center floor tunnel brace 37
BODY CONSTRUCTION - Rear floor & side member REAR FLOOR & SIDE MEMBER 13 16 17 15 14 10 16 11 12 19 4 5 3 21 5 18 4 1 11 6 7 20 2 2 3 22 1 10 6 22 25 23 24 7 9 8 TB-540 No 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NAME No Rear floor side member LH/RH Rear floor side front member LH/RH Rear floor side member extension LH/RH Rear floor side member reinforcement LH/RH Trailing arm mounting reinforcement LH/RH Rear suspension spring reinforcement LH/RH Trim & net mounting front bracket L
BODY CONSTRUCTION - Rear floor 1.
BODY CONSTRUCTION - Rear floor side member Ó Ó Ó D D' Ó A A' Ó Ó C B Ó Ó 2.
BODY CONSTRUCTION - Rear body < Back panel> REAR BODY BACK PANEL 4 3 2 1 TB-650 No 1 2 3 4 PART NAME Tail gate striker reinforcement assembly Rear transverse member Back panel Rear bumper cover lower mounting bracket 41
BODY CONSTRUCTION - Rear body Í A B B' Í Í A' Í TB-0660 Tail gate striker reinforcement Child restraint anchor reinforcement Back panel Rear transverse member Back panel SECTION A-A' Rear transverse member 660-1 42 SECTION B-B' 660-2
BODY CONSTRUCTION - Fender & Hood FENDER & HOOD 1 2 3 TB-690 No PART NAME 1 2 3 Hood panel Hinge hood side reinforcement LH/RH Fender panel LH/RH 43
BODY CONSTRUCTION - Roof ROOF 8 3 2 4 5 6 7 1 TB-700 NO 1 2 3 4 5 6 7 8 PART NAME Roof panel Roof center front rail Roof center side rail LH Roof center side rail RH Roof center rail Room lamp mounting bracket assembly Roof center rear rail Sunroof reinforcement ring assembly 44
BODY CONSTRUCTION - Door DOOR 1.
BODY CONSTRUCTION - Door 2.
BODY CONSTRUCTION - Tail gate TAIL GATE 1 2 TB-800A/B NO 1 2 PART TIME Tail gate outer panel Tail gate inner panel 47
REPLACEMENT PARTS
REPLACEMENT PARTS - Front body REPLACEMENT PARTS The following section illustrates 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 fit, safety and corrosion protection. For a more complete listing of service parts, refer to an authorized Hyundai dealership.
REPLACEMENT PARTS - Side body SIDE BODY G F D H C I B A E J TB-800C PART NAME A B FENDER MOUNTING BRACKET ASSEMBLY, FRONT PILLAR OUTER PANEL, LH/RH LH/RH C CENTER PILLAR OUTER ASSEMBLY, LH/RH D E QUARTER OUTER PANEL ASSEMBLY, LH/RH SIDE SILL OUTER PANEL, LH/RH F SIDE INNER PANEL ASSEMBLY, LH/RH G H QUARTER INNER PANEL ASSEMBLY, REAR PILLAR PANEL ASSEMBLY, LH/RH LH/RH I QUARTER OUTER REAR LOWER EXTENSION ASSEMBLY, LH/RH J QUARTER OUTER PANEL ASSEMBLY, 3DOOR LH/RH 51 (3 DOOR)
REPLACEMENT PARTS - Rear body REAR BODY F G E C F D A B H TB-830 PART NAME A REAR FLOOR FRONT MEMBER ASSEMBLY B REAR FLOOR FRONT EXTENSIOR ASSEMBLY C REAR FLOOR PANEL D E REAR FLOOR SIDE COMPLETE MEMBER ASSEMBLY, LH/RH F REAR FLOOR CENTER CROSS MEMBER ASSEMBLY GUSSET, LH/RH G REAR TOWING HOOK BRACKET ASSEMBLY H BACK PANEL ASSEMBLY 52
REPLACEMENT PARTS - Door DOOR A C B D TB-7112,113/TB-FRT E G H F TB-7113,7112/TB-RR PART NAME A FRONT DOOR PANEL ASSEMBLY, LH/RH B FRONT DOOR OUTER PANEL, LH/RH C FRONT DOOR UPPER HINGE ASSEMBLY, LH/RH D FRONT DOOR LOWER HINGE ASSEMBLY, LH/RH E REAR DOOR PANEL ASSEMBLY, LH/RH F G REAR DOOR OUTER PANEL, LH/RH REAR DOOR UPPER HINGE ASSEMBLY, LH/RH H REAR DOOR LOWER HINGE ASSEMBLY, LH/RH 53
BODY DIMENSIONS
BODY DIMENSIONS - General GENERAL 1. 2. 3. Basically, all measurements in this manual are taken with a tracking gauge. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual. MEASUREMENT METHOD PROJECTED DIMENSIONS 1. 2.
BODY DIMENSIONS - Upper body UPPER BODY A' B' D' C' E' F E A B C D TB-53 * These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Upper body A C B Ó Ó Ó Fender front mounting hole (Ø 6.6) Front shock absorber mounting hole (Ø 9) Fender center mounting hole (Ø 6.
BODY DIMENSIONS - Side body SIDE BODY C A E B D 55-A *These dimensions indicated in this figure are actual-measurement dimensions. G F L H I M K J TB-55B *These dimensions indicated in this figure are projected dimensions.
BODY DIMENSIONS - Side body A B C Ï Ñ Ñ 56-A Front door hinge upper mounting hole (Ø 12) D 56-C 56-B Front door hinge lower mounting hole (Ø 12) E Rear door hinge upper mounting hole (Ø 12) F Í Ï Í 56-D Rear door hinge lower mounting hole (Ø 12) G 56-E Rear door striker mounting hole (Ø 13) 56-F Tooling hole (Ø 25) I H Ô Ñ Ñ 56-G 54-C Front shock absorber mounting hole (Ø 89) Cross member mounting front hole (Ø 14.
BODY DIMENSIONS - Side body (3 Door) SIDE BODY (3 DOOR) D A E C B 3DOOR SIDE *These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Side body (3 Door) A B C Ñ Ñ Ï 56-A Front door hinge upper mounting hole (Ø 12) D 56-B Front door hinge lower mounting hole (Ø 12) E Í Í 3SC Side outer rear glass fixing hole ( 8 12 slot ) 3SD Rear bumper cover mounting hole ( 10 12) 62 3SB Front door switch hole (Ø 10)
BODY DIMENSIONS - Interior INTERIOR K' J' H' K J H I' I F' G' E' D' E C' A' B' G D F C A B 58 * These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Interior A C B Ó Ó Ó 59-A Front door checker mounting hole (Ø 14) Front seat belt mounting hole (Ø 16) Door scuff mounting hole (Ø 7) E F Ó Ï D 59-C 59-B Ò 59-D Rear seat belt lower mounting hole (Ø 13.2) Front door striker mounting hole (Ø 13) G H Ó Ð 59-H 59-G J Ñ Ñ 59-J 59-K Sun roof drain hose mounting hole (Ø 14) 64 59-I Front seat belt anchor mounting hole (Ø 15) Roof rack mounting hole (Ø 9) K Rear assist handle mounting hole (Ø 6.
BODY DIMENSIONS - Interior (3 Door) INTERIOR (3 DOOR) E' G' F' G F E D' A' C' B' D C B A 3DOOR INTERIOR * These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Interior (3 Door) C B A Ó Ó Ó 3IA 3IB Rear seat back mounting hole (Ø 13.
BODY DIMENSIONS - Under body UNDER BODY C' A' D' E' F' G' F G B' B A E D C TB-60A *These dimensions indicated in this figure are actual-measurement dimensions. C A B H G F D E TB-55B *These dimensions indicated in this figure are projected dimensions. Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' A-H Length (mm) 940 920 1066 880 914 1149 970 244 Point symbol B-H C-H D-H F-H G-H A-E B-E C-E Length (mm) 177 646 15 64 206.
BODY DIMENSIONS - Under body A B C Ï Ñ Ñ 56-F Cross member mounting front hole (Ø 14) Tooling hole (Ø 25) D Front shock absorber mounting hole (Ø 89) E F Ñ Ñ Ô 56-H 56-J 56-I Trailing arm mounting hole (Ø 13) Tooling hole (Ø 25) Cross member mounting rear hole (Ø 16) 54-C 56-G G Ñ 56-L Tooling hole (Ø 25) 68
BODY DIMENSIONS - Under body UNDER BODY A' B' C' D' E' A B C D E F' G' H' F G H 62 *These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Under body A B C Ï Ñ Ñ 56-F Cross member mounting front hole (Ø 14) Tooling hole (Ø 25) D 56-HI 56-G Cross member mounting rear hole (Ø 16) E F Ï Í Í 56-HI Tooling hole (Ø 25) Trail arm mounting hole (Ø 13) Tooling hole (Ø 18) G H Ô Ñ 56-L 56-K Rear suspension spring mounting hole (Ø 40) 56-J 63-E Tooling hole (Ø 25) 70
BODY DIMENSIONS - Engine compartment ENGINE COMPARTMENT E' C D' E D B' A' B 64 A * These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Engine compartment C B A Ó Ó Ó 65-B 65-B Cowl under cover mounting hole (Ø 11) Stay rod to paint hole (12 16 solt) Carrier mounting hole (Ø 12) E Ò D Ï 54-C Front shock absorber mounting hole (Ø 89) 54-C Front shock absorber mounting hole (Ø 9) 72 65-C
BODY DIMENSIONS - Luggage compartment LUGGAGE COMPARTMENT A' A B B' C C' D E E' 66 *These dimensions indicated in this figure are actual-measurement dimensions.
BODY DIMENSIONS - Luggage compartment A B C Ñ Ñ 67-A 67-B Rear combination lamp upper mounting hole ( 8.5 8.5) Tail gate hinge mounting hole (Ø 14) D Rear combination lamp lower mounting hole ( 8.5 8.
BODY PANEL REPAIR PROCEDURE
BODY PANEL REPAIR PROCEDURE - Fender apron panel (Partial) FENDER APRON PANEL (PARTIAL) WELDLING POINTS L/H 50mm 120 z MIG plug welding MIG butt welding xx MIG lap welding mm PRO-0030 PRO-0031 R/H 120 50mm PRO-0041 z MIG plug welding MIG butt welding xx MIG lap welding 76 mm PRO-0040
BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) FENDER APRON AND FRONT SIDE MEMBER (ASSEMBLY) WELDLING POINTS A Ô PRO-0050 z MIG plug welding PRO-0060 B Ô PRO-0070 C Ô PRO-0065 z MIG plug welding MIG butt welding xx MIG lap welding PRO-0071 77
BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) NOTE 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 you begin the repair procedure. PRO-0100 REMOVAL 1. Drill out all the spotwelds to separate cowl side upper outer panel from front side member.
BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) 4. 5. Using a spotweld cutter, drill out all the spotwelds attaching the fender apron to the dash panel and front side member. Remove the fender apron panel. PRO-0140 NOTE If collision damage requires replacement of fender apron and front side member together, remove both of them at the same time. PRO-0145 6. Using a spotweld cutter, remove the front side member by drilling out the spotwelds. PRO-0160 7.
BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) 8. Using a hammer and dolly, correct any flanges that become bent or deformed when spotwelds are broken. PRO-0180 INSTALLATION 1. 2. Drill 8 mm holes in the new fender apron and front side member for MIG plug welding. Remove paint from both sides of all portions that are to be welded such as peripheries of MIG plug weld holes. PRO-0190 PRO-0200 3. 4. Temporarily install new parts in place.
BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) 5. MIG plug weld all holes PRO-0220 6. Clean MIG welds with a disc grinder. PRO-0230 NOTE 1. Be careful not to grind welded portions too much. 2. The internal parts will be stronger if the weld traces are not ground. PRO-0070 7. Before welding the cowl side upper outer panel, apply the two part epoxy primer and anti-corrosion agent to the interior of the fender apron panel.
BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly) 8. 9. 10. 11. Install the cowl side upper outer panel in place. MIG plug weld all holes. Clean and prepare all welds, remove all residue. Apply the two part epoxy primer to the interior of the each panel. PRO-0260 12. Apply an anti-corrosion agent as required (Refer to the CORROSION PROTECTION). 13. Prepare the exterior surfaces for priming using wax and grease remover. 14. Apply metal conditioner and water rinse. 15.
BODY PANEL REPAIR PROCEDURE - Front side member (Partial) FRONT SIDE MEMBER (PARTIAL) WELDLING POINTS L/H 70mm PRO-0300 PRO-0310 z MIG plug welding MIG butt welding R/H 20mm 20mm PRO-0320 z MIG plug welding MIG butt welding 83 PRO-0330
BODY PANEL REPAIR PROCEDURE - Front side member (Partial) REMOVAL NOTE 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 side member. The following procedure illustrates a repair for the front left side member. The procedure may also be applied to the front right sidemember. 1. Measure and mark the vertical cutlines on front side member inner tooling hole center. PRO-0300 2.
BODY PANEL REPAIR PROCEDURE - Front side member (Partial) 3. Cut through the front side member inner and outer at cutlines. NOTE Take care not to cut through front side member inner reinforcement. 4. Prepare all surfaces to be welded. PRO-0380 INSTALLATION 1. 2. Transcribe the front side member inner and outer cutline to the new front side member, cut to length and chamfer butt end to improve weld surface. Drill 8mm holes in new front side member for MIG plug welding. PRO-0390 3. 4.
BODY PANEL REPAIR PROCEDURE - Front side member (Partial) 6. 7. Clean and prepare all welds, remove all residue. Apply the two-part epoxy primer to the interior of the front side member. PRO-0420 8. 9. 10. 11. 12. 13. 14. Apply an anti-corrosion agent as required (Refer to the CORROSION PROTECTION). Prepare the 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.
BODY PANEL REPAIR PROCEDURE - Front pillar FRONT PILLAR WELDLING POINTS B Ô A Ô PRO-0460 PRO-0450 A Î Ó Í C B Î D PRO-0470 D C Ô Ô PRO-0480 PRO-0481 z MIG plug welding MIG butt welding xx MIG lap welding 87
BODY PANEL REPAIR PROCEDURE - Front pillar REMOVAL m Measure and mark the each cutline on the front outer pillar at 150mm from the roof panel end line as indicated in the illustration. 80 m m 50 m m 15 0m 1. PRO-0490 2. Measure and mark the cutline on front side sill outer panel as shown in the illustration. 30mm PRO-0500 3. Depending on the extend of damaged area, it may be possible to determine the cutting range within indicated in the illustration. 130mm PRO-0510 4.
BODY PANEL REPAIR PROCEDURE - Front pillar 5. 6. Drill out all welds attaching the front pillar to dash and cowl top outer, cowl inner lower panels. Remove spotwelds and lap welds attaching cowl crossmember bar mounting upper bracket to remove front pillar. PRO-0530 7. Before cutting front pillar, be sure to support roof panel. PRO-0540 8. Cut the front pillar through each cutline, taking care not to damage the other panel as illustration.
BODY PANEL REPAIR PROCEDURE - Front pillar 10. Cut the side outer reinforcement as shown in the illustration. 11. Cut the side outer reinforcement vertical cutline and remove the front pillar. PRO-0570 12. Straighten all flanges as necessary, prepare all surfaces to be welded. PRO-0580 INSTALLATION 1. Transcribe the cutline to the new side inner panel, cut to length and chamfer butt end to improve weld surface. PRO-0590 2. 3.
BODY PANEL REPAIR PROCEDURE - Front pillar 4. 5. 6. 7. Transcribe the cutline to the new side inner panel, adding 30mm overlap to end and cut to length. Drill 8mm holes in the side inner panel for MIG plug welding. Fit and clamp the new side inner panel in place for welding. MIG plug weld all holes and MIG butt weld the seams. PRO-0610 8. 9. Temporarily install front pillar outer panel in place. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. 10.
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. The internal parts will be stronger if the weld traces are not ground. PRO-0460 18. Before welding the cowl side upper outer panel, apply the two part epoxy primer and anti-corrosion agent to the interior of the fender apron panel. PRO-0660 19. Install the cowl side upper outer panel in place. 20. MIG plug weld all holes. 21.
BODY PANEL REPAIR PROCEDURE - Front pillar 27. Apply the correct seam sealer to all joints carefully (Refer to the BODY SEALING LOCATIONS). 28. Reprime over the seam sealer to complete the repair.
BODY PANEL REPAIR PROCEDURE - Center pillar CENTER PILLAR WELDLING POINTS A Ô Ò 50mm PRO-0720 A B Ó B Ô PRO-0710 PRO-0730 z MIG plug welding MIG butt welding 94
BODY PANEL REPAIR PROCEDURE - Center pillar REMOVAL 1. Measure and mark the horizontal cutline on center outer pillar as indicated in the illustration. 150mm 30mm 120mm 30mm 30mm PRO-0740 2. Measure and mark the vertical cutline on side sill outer panel 30mm from the front door step trim mounting hole. 30mm 90mm PRO-0750 3. Before cutting center pillar, be sure to support roof panel. PRO-0760 4.
BODY PANEL REPAIR PROCEDURE - Center pillar 5. Cut through center outer pillar and side sill outer panel at cutlines. 6. NOTE When cutting side sill outer panel take care not to cut through mating flanges or side outer reinforcement. After cutting side outer panel (center outer pillar & side sill), cut 7. 8. PRO-0780 PRO-0790 PRO-0795 PRO-0800 the side outer reinforcement and center inner pillar. Remove the center pillar.
BODY PANEL REPAIR PROCEDURE - Center pillar 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. PRO-0840 2. Transcribe the center outer pillar cutlines to the new center outer pillar, adding 30mm overlap at center lower 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 5.
BODY PANEL REPAIR PROCEDURE - Center pillar 6. 7. Transcribe the cutline dimensions to the new side outer reinforcement, adding 30mm overlap to each end and cut to length. Drill 8mm holes in overlap areas on each end of new side outer reinforcement and clamp the new side outer reinforcement in place. Side outer reinforcement Center pillar outer panel PRO-0850 8. MIG plug weld all holes and MIG butt weld seams. NOTE The reinforcement will be stronger if the weld traces are not ground. PRO-0900 9.
BODY PANEL REPAIR PROCEDURE - Center pillar 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. 22. Apply the two-part epoxy primer. 23. Apply the correct seam sealer to all joints carefully (Refer to the BODY SEALING LOCATIONS). PRO-0930 24. Reprime over the seam sealer to complete the repair.
BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) SIDE SILL (ASSEMBLY) WELDLING POINTS z MIG plug welding MIG butt welding PRO-0950 REMOVAL 1. Measure and mark vertical cutline from the rear door step trim mounting hole on the rear side sill inner panel. 90mm PRO-0960 2. At the front and center pillar, measure and mark horizontal cutlines from the door hinge mounting hole on the side outer panel as shown in the illustration.
BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 3. 4. 5. Cut the side sill outer panel along cutlines. Be careful not to cut mating flanges. Drill out all spotwelds, attaching the side sill outer panel to side outer reinforcement. Remove the side sill outer panel. PRO-1020 6. 7. 8. 9. Determine if the side outer reinforcement is damaged and needs to be replaced, measure cutline on reinforcement as shown in the illustration. Cut side sill outer reinforcement along the cutline.
BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 6. Using service panel for replacement of side sill outer panel, drill 8mm holes in overlap areas and along upper and lower flanges. PRO-1050 7. Crimp flanges on the remaining portion of the side sill outer panel at all joint for overlap. 8. Fit and clamp the side sill outer panel in place. 9. MIG plug weld all holes and MIG butt weld seams. 10. Clean and prepare all welds and remove all residue. 11. Apply body filler to the side sill outer seams. 12.
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) WELDLING POINTS z MIG plug welding MIG butt welding PRO-1100 REMOVAL 1. Depending on the extent of damage, mark out the damaged portion of the side sill. 30mm 30mm PRO-0500 2. Drill out the spotwelds in upper and lower flanges of side sill between cutlines to remove side sill outer panel and cut the damaged portion of the side sill at the cutlines.
BODY PANEL REPAIR PROCEDURE - Side sill (partial) 3. 4. Determine if the side outer reinforcement is damaged and needs to be replaced. If replacing is necessary, mark out the damaged portion of the side outer reinforcement. Cut at cutlines and remove the damaged portion. Prepare all surfaces to be welded. PRO-1130 INSTALLATION 1. 2. Transcribe the cutline to the new front side outer reinforcement, adding 30 mm overlap to each end and cut to length.
BODY PANEL REPAIR PROCEDURE - Side sill (partial) 7. 8. 9. 10. 11. Fit and clamp the side sill in place. MIG plug weld all holes and MIG butt weld seams. Clean and prepare all welds, remove all residue. Apply body filler to the side sill outer seams. Apply the two-part epoxy primer to the interior of the side sill. PRO-1170 12. Apply an anti-corrosion agent to the welded parts and interior of the side sill (Refer to the CORROSION PROTECTION). 13.
BODY PANEL REPAIR PROCEDURE - Quarter panel QUARTER PANEL WELDLING POINTS A B Ô Ô PRO-1200 PRO-1201 ÍB ÍC PRO-1220 Í C A Ô PRO-1202 z MIG plug welding MIG butt welding 107
BODY PANEL REPAIR PROCEDURE - Quarter panel REMOVAL 1. Depending on the extent of damage, measure and mark cutlines on the quarter outer panel as indicated in the illustration. 480mm 0 20 420mm PRO-1250 2. 3. m m PRO-1260 Drill out all attaching spotwelds on the quarter outer panel, including the seam around the door lip opening. Cut the quarter outer panel at cutlines and remove the quarter outer panel as illustration.
BODY PANEL REPAIR PROCEDURE - Quarter panel 6. Apply body filler to the welded seam. Sand and finish. Apply the two-part epoxy primer to the interior of the quarter outer panel. PRO-1310 7. Apply an anti-corrosion agent to the welded parts and interior of the quarter outer panel (Refer to the CORROSION PROTECTION). 8. Prepare exterior surfaces for priming, using wax and grease remover. 9. Apply metal conditioner and water rinse. 10. Apply conversion coating and water rinse. 11.
BODY PANEL REPAIR PROCEDURE - Rear floor REAR FLOOR WELDLING POINTS A Ô PRO-1520 A Ô PRO-1503 z MIG plug welding MIG butt welding 110
BODY PANEL REPAIR PROCEDURE - Rear side member (assembly) REAR SIDE MEMBER (ASSEMBLY) WELDLING POINTS A B Ô Ô PRO-1500 PRO-1501 Ô A D Ô B Ô C Ô PRO-1520 C D Ô z MIG plug welding MIG butt welding Ô PRO-1503 PRO-1502 111
BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) NOTE Because the rear side members are desigened to absorb energy during a rear collision, care must be taken when deciding to use this repair method. This repair is recommended only for moderate damage to vehicle, where distortions do not extend forward of the trunk region. If the damage is more severe, then the entire side member assembly should be replaced at factory seams without employing this sectioning procedure.
BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) 4. Remove the rear floor panel and rear side member from the rear body. PRO-1580 PRO-1590 INSTALLATION 1. Transcribe the cutline to the new rear side members. Drill out the spotwelds attaching the inner reinforcements. Remove remaining portions of side members. PRO-1600 2. Temporarily fit and clamp the rear side members in place.
BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) 5. 6. 7. MIG plug weld the rear side members and MIG butt weld seams. Prepare the welds and surfaces to which the rear floor will attach. Transcribe the cutline to the new rear floor panel, adding 30mm for overlap at the old joint. PRO-1620 8. 9. Drill 8mm holes in overlap area and production locations of the new rear floor panel for MIG plug welding.
BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly) 17. Apply an anti-corrosion to the interior of the rear side members (Refer to the CORROSION PROTECTION). 18. Prepare exterior surfaces for priming, using wax and grease remover. 19. Apply metal conditioner and water rinse. 20. Apply the two-part epoxy primer. PRO-1660 21. Apply the correct seam sealer to all joints (Refer to the BODY SEALING LOCATIONS). 22. Reprime over the seam sealer to complete the repair. PRO-1670 23.
BODY PANEL REPAIR PROCEDURE - Rear side member (Partial) REAR SIDE MEMBER (PARTIAL) WELDLING POINTS z MIG plug welding MIG butt welding PRO-1690 REMOVAL NOTE Because the rear side members are designed to absorb energy during a rear collision, care must be used when deciding to use this repair method. This repair is recommended only for moderate damage to the vehicle, where distortions do not extend forward of the trunk region.
BODY PANEL REPAIR PROCEDURE - Rear side member (Partial) 1. Depending on the extent of damage, if the right side member is to be replaced it should be measured and marked 30mm from the rear floor side member tooling hole center. NOTE The flowing procedure illustrates a repair for the right rear side member. The procedure may also be applied the left rear side member. 30m m PRO-1690 2. 3. 4. Cut through rear side member at cutline being careful not to cut rear side member reinforcement.
BODY PANEL REPAIR PROCEDURE - Rear side member (Partial) 6. Apply an anti-corrosion to the interior of the rear side member (Refer to the CORROSION PROTECTION). 7. Prepare exterior surfaces for priming, using wax and grease remover. 8. Apply metal conditioner and water rinse. 9. Apply conversion coating and water rinse. 10. Apply the two-part epoxy primer. PRO-1660 11. Apply the correct seam sealer to all joints (Refer to the BODY SEALING LOCATIONS). 12.
BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels FRONT AND REAR DOOR OUTER PANELS WELDLING POINTS FRONT DOOR A Ô Ô A CON-0752 CON-0750 REAR DOOR CON-0800 z MIG plug welding xx MIG lap welding 119
BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels REMOVAL 1. 2. Cut door outer panel hem with a sander. After grinding off the hemming location, remove the outer panel. PRO-1830/PRO1831 3. Dress rusty part with a sander and prepare surface to be hemmed. PRO-1840 INSTALLATION 1. 2. Apply adhesive or equivalent to outer panel hem. Apply mastic sealer or equivalent to the door upper member and door reinforcement beam as shown in the figure.
BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels 3. Bend the flange hem with a hammer and dolly, then fasten tightly with a hemming tool. NOTE 1. Hemming work should be done in three steps as illustration. 2. If a hemming tool cannot be used, hem with a hammer and dolly. PRO-1870 PRO-1880 PRO-1900 4. 5. 6. After completing the hemming work, make MIG spot welds at 50 mm intervals on the inside. Clean and prepare all welds, remove all residue.
BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels 7. Apply an anti-corrosion agent to the welded parts and lower inside of the door panel (Refer to the CORROSION PROTECTION). 8. Prepare exterior surfaces for priming, using wax and grease remover. 9. Apply metal conditioner and water rinse. 10. Apply conversion coating and water rinse. 11. Apply the two-part epoxy primer. 12. Apply the correct seam sealer to whole panel edge. PRO-2010 13. Reprime over the seam sealer to complete the repair.
BODY SEALING LOCATIONS
BODY SEALING LOCATIONS - Floor FLOOR Ï 7 14/15 Ñ Ï 3 4Ò Î Ñ2 8 11 Î Ï 6 10 Ï Ï Ò Í 1 Ï 5 Ï 12 9 13 SEA-0010 2 1 SEA-0020 3 SEA-0030 4 SEA-0035 124 SEA-0040
BODY SEALING LOCATIONS - Floor 6 5 SEA-0050 7 SEA-0060 8 SEA-0080 SEA-0070 10 9 SEA-0100 SEA-0090 12 11 SEA-0110 125 SEA-0120
BODY SEALING LOCATIONS - Floor 13 14 SEA-0130 15 SEA-0150 126 SEA-0140
BODY SEALING LOCATIONS - Upper and side body UPPER AND SIDE BODY 3 Ð 1Ò 5Ò 2 Î 4 6 Ð Ô 12 Î 11 Ð Í13 Ï Ï 7 10 Í Ï 9 8 SEA-0160, 0170 2 1 SEA-0200 127 SEA-0210
BODY SEALING SEALING LOCATIONS and side body BODDY LOCATIONS -- Upper Upper and side body 3 4 SEA-0230 SEA-0220 5 6 SEA-0240 7 SEA-0250 8 SEA-0120 SEA-0260 10 9 SEA-0090 128 SEA-0130
BODY SEALING LOCATIONS - Upper and side body 11 12 SEA-0300 13 SEA-0320 129 SEA-0310
CORROSION PROTECTION
BODY CONSTRUCTION - Zinc-galvanized steel panels ZINC-GALVANIZED STEEL PANELS 10 67 22 2 34 32 35 45 39 51 47 50 49 41 40 38 55 44 42 46 43 48 61 52 54 37 36 56 31 53 57 60 30 33 1 29 27 26 59 58 25 62 28 3 64 24 23 65 63 21 20 16 4 66 15 19 18 5 17 6 14 9 7 8 68 11 13 12 Because galvanized steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below.
BODY CONSTRUCTION - Zinc-galvanized steel panels 1. Radiator support upper center panel 2. Radiator support center reinforcement 3. Dash panel 4. Center floor panel 5. Rear floor extension 6. Rear floor front cross member 7. Rear floor panel 8. Towing hook bracket 9. Rear floor center cross member 10. Rear transverse member 11. Back panel 12. Tail gate inner panel 13. Tail gate outer panel 14. Rear door frame rear reinforcement 15. Rear door inner panel 16. Rear door outer panel 17.
CORROSION PROTECTION - Zinc-phosphate coat & cationic eletrodeposition primer ZINC-PHOSPHA TE CO A T & CA TIONIC ELECTR ODEPOSITION PRIMER ZINC-PHOSPHATE COA CATIONIC ELECTRODEPOSITION In order to improve the adhesion of the paint coat on the steel panel, and also to improve the corrosion resistance, the entire body is coated with a film of Zinc-phosphate and a cationic electrodeposition primer.
CORROSION PROTECTION - Anti-corrosion primer ANTI-CORROSION PRIMER An anti-corrosion primer has been applied to the side sill outer panel for the purposes of corrosion prevention and abrasion protection. If this panel is replaced, apply an anti-corrosion primer between the undercoat and the intermediate coat, as shown in the following illustrations.
CORROSION PROTECTION - Antivibration pads ANTIVIBRATION PADS-LOCATION & SECTION 84156-1C000 84152-1C000 84186-1C000 C B' B A Ï A' Ï Ï Ï 84187-1C000 Í C' Í D D' Ï Ï 84155-1C000 84151-1C000 84185-1C000 ANT-0001 Front seat cross member Dash lower reinforcement 84155/56-1C000 84151/52-1C000 84151/52-1C000 15mm 3mm 15mm Dash panel Center floor panel SECTION A-A' Center floor panel 84156/55-1C000 7mm SECTION B-B' ANT-0002 Side sill inner panel ANT-0003 44.
CORROSION PROTECTION - Attachment of antivibration pads ATTACHMENT OF ANTIVIBRATION PADS Antivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat. If these antivibration pads are peeled off in the course of replacement or repair of a welded panel, cut and attach replacement material (in the shape shown in the figure). 84152-1C000 84151-1C000 1.
CORROSION PROTECTION - Under body coat UNDER BOD Y CO AT BODY COA In order to provide corrosion, stone chipping and vibration resistance, under body coat is applied to the under sides of the floor and wheel house. Therefore, when such panel is replaced or repaired, apply under body coat to that part. FLOOR AÍ A' Í Í Í D' Í C' Í BÍ C D B' Í Because parts are to be mounted in these locations, mask the location, before applying the under body coat. Under body coating (Thickness 0.8 mm - 2.
CORROSION PROTECTION - Under body coat SIDE BOD Y BODY B' Î Î Î A' B Î A Because parts are to be mounted in these locations, mask the location before applying the under body coat. Under body coating (Thickness 1.0 mm - 2.
CORROSION PROTECTION - Cavity wax injection CAVITY WAX INJECTION In order to provide greater corrosion resistance, cavity wax injection has been performed for the lower areas of the vehicle, such as the sidemember, the side sill and the inside of other panels which are a hollow construction. When replacing these parts, be such to apply cavity wax to the appropriate areas of the new parts. "C" Ï A Ï A' Ï Ï "B" Wax injection must be done through access holess marked.
CORROSION PROTECTION - Cavity wax injection 200mm 250mm Í Í 150mm (MIN) B B' 200mm 250mm HOOD TAIL GATE Wax injection must be done through access holes marked.
A' Í Í A' Í FRONT DOOR REAR DOOR Wax injection must be done through access holes marked.
CORROSION PROTECTION - Under body anti-corrosion agent UNDER BOD Y ANTI-CORR OSION A GENT BODY ANTI-CORROSION AG The undersides of the floor and wheel house are undercoated to provide greater corrosion resistance. Therefore, when such panel is replaced or repaired, apply under body anti-corrosion agent to that part. NOTE Do not apply the under body anti-corrosion agent to come in contact with tires, muffler and exhaust pipe. Under body anti-corrosion agent (Thickness 0.8 ~ 2.
