Hyundai H-1 Repair Manual
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INTRODUCTION
This Body Repair Manual provides detailed repair procedures for repair of commonly
damaged structural panels on the Hyundai H-1. To aid in the information of the damaged
vehicle, body construction, replacement parts, body dimensions, body sealing locations,
corrosion protection and body repair procedures service are contained herein.
The repair procedures specify locations where body members may be structurally sectioned.
All of the repair procedures have been performed on Hyundai H-1 body shells and that
is currently available in most auto body repair shops. Each repair procedure was subjected
to testing and evaluation to insure that the structural integrity of the vehicle was maintained
as a result of the repair procedure.
The repair procedures illustrated in this manual were developed to simplify body repair
in order to reduce insurance costs, and indirectly, cost of ownership.
The vehicle should not be sectioned in locations other than those illustrated in this repair
manual. Furthermore, these repair procedures DO NOT apply to any other vehicle. The
individuals performing the work must assume full responsibility for the quality of their
workmanship.
We believe this manual to be helpful for Hyundai dealers, and anticipate it to be effectively
used for Hyundai vehicle bodies.
For the services of other than collision-damaged body parts of the Hyundai H-1, refer
to the H-1 shop manual.
The illustrations and descriptive text in this manual were correct at the time of printing.
It is the policy of HYUNDAI MOTOR COMPANY to continuously improve its products.
Specifications and procedures are subject to change at any time without notice.
Aug, 1997, Printed Korea

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Summary of Contents for Hyundai H-1

  • Page 1 INTRODUCTION This Body Repair Manual provides detailed repair procedures for repair of commonly damaged structural panels on the Hyundai H-1. To aid in the information of the damaged vehicle, body construction, replacement parts, body dimensions, body sealing locations, corrosion protection and body repair procedures service are contained herein.
  • Page 2: Table Of Contents

    CONTENTS GENERAL INFORMATION GENERAL GUIDELINES AND PRECAUTIONS ....................SRSCM ..............................7 ELECTRONIC PARTS..........................8 CORROSION PROTECTION AND SEALING ....................8 WELDING ..............................9 BODY CONSTRUCTION BODY COMPONENTS ..........................12 FRONT BODY ............................14 SIDE BODY ..............................29 UNDER BODY ............................39 DOOR ...............................
  • Page 3: General Information

    GENERAL INFORMATION...
  • Page 4: General Guidelines And Precautions

    GENERAL GUIDE LINES AND PRECAUTIONS The Hyundai H-1 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 H-1 is designed so that the front and rear compartments will absorb much of the collision energy so that the passengers are better protected.
  • Page 5: Srscm

    DTC codes using Scan tool just after repairing or replacing the troubled parts including fuse. 9. Especially in case of welding the body, never fail to disconnect the battery negative (-) terminal. 10. WARNING/CAUTION labels are attached to the periphery of the air-bag components. Refer to the H-1 SHOP MANUAL.
  • Page 6: Electronic Parts

    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.
  • Page 7: Welding

    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.
  • Page 8 BODY CONSTRUCTION...
  • Page 9: Body Construction Body Components

    BODY CONSTRUCTION - Body components BODY COMPONENTS Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destination. AAAC0050...
  • Page 10 BODY CONSTRUCTION - Body components PART NAME PART NAME Front end crossmember. Gusset panel (RH). Front sidemember. "B" outer pillar (RH). Rear side member. Rear door side outer rail. Crossmember No.1. "C" pillar lower reinforcement (RH). Crossmember No.2. Quarter inner panel (RH). Crossmember No.3.
  • Page 11 BODY CONSTRUCTION - Front body FRONT BODY RADIATOR SUPPORT COMPLETE CRAR 1100 PART NAME Radiator support upper member center. Radiator support upper member (LH). Radiator upper mounting reinforcement. Radiator support center member. Head lamp support reinforcement. Head lamp support panel. Head lamp support cover (A) extension.
  • Page 12 BODY CONSTRUCTION - Front body FRONT APRON INNER COMPLETE CFAA1100...
  • Page 13 BODY CONSTRUCTION - Front body PART NAME Fender mounting (D) bracket. Front apron outer panel. Front apron support. Deck member mounting reinforcement. Quarter glass defrost bracket. Front apron inner panel. Tube bracket. Fender mounting (A) bracket. Deck member mounting bracket. Deck member mounting lower bracket.
  • Page 14 BODY CONSTRUCTION - Front body COWL COMPLETE CFAC1100...
  • Page 15 BODY CONSTRUCTION - Front body PART NAME Bar upper bracket. Bar mounting bracket upper. Bar mounting bracket lower. Steering column mounting plate. Bar mounting lower plate. Cowl crossmember mounting bracket. Cowl cross bar. Bar mounting bracket (RH). Blower mounting bracket. Evaporator mounting bracket.
  • Page 16 BODY CONSTRUCTION - Front body DASH COMPLETE CFAD1100 PART NAME PART NAME Brake tube, No.4 bracket. Blower mounting bracket. Brake tube, No.3 bracket. Heater mounting bracket (RH). Brake tube, No.2 Bracket. Heater mounting bracket (LH). Dash panel reinforcement. Brake tube, No.5 bracket. Brake tube, No.6 bracket.
  • Page 17 BODY CONSTRUCTION - Front body FRONT END CROSSMEMBER DIAE0010 Cover panel Front end cross outer member Front end cross Front end cross inner member outer member Front side member lower reinforcement Front side extension SECTION B - B' SECTION A - A' CFAF1100 CFAF1110 Front end cross inner...
  • Page 18 BODY CONSTRUCTION - Front body FRONT SIDEMEMBER COMPLETE (2WD) 19, 26 CFAF1300...
  • Page 19 BODY CONSTRUCTION-Front body PART NAME Front end crossmember outer. Front end crossmember inner. No.1 crossmember. No.2 crossmember. No.3 crossmember. No.3 crossmember support (LH). No.3 crossmember support (LH). Seat anchor (D) reinforcement (LH). Seat anchor (D) reinforcement (RH). Fuel tank mounting reinforcement. Heater protector mounting bracket.
  • Page 20 BODY CONSTRUCTION - Front body FRONT END CROSSMEMBER (Cross - Sectional Views) CFAF1200 Cover panel (A) Upper arm mounting bracket Front sidemember Front sidemember reinforcement Front sidemember CFAF1210 CFAF1220 SECTION B - B' SECTION A - A' Front sidemember reinforcement (B) Front sidemember Front sidemember No.1 crossmember...
  • Page 21 BODY CONSTRUCTION - Front body FRONT SIDEMEMBER COMPLETE (4WD) CFAF1500...
  • Page 22 BODY CONSTRUCTION - Front body PART NAME Front end crossmember. Front end cross innermember. No.1 crossmember. No.2 crossmember. No.3 crossmember. Front sidemember outer. Front sidemember inner. Front sidemember outer extension (LH). Cover panel. Front sidemember front (A) reinforcement. Front sidemember front (B) reinforcement. Front sidemember lower (A) reinforcement.
  • Page 23 BODY CONSTRUCTION - Front body FRONT SIDEMEMBER (4WD) (Cross - Sectional Views) CFAF1400 Cover panel Cover panel Front side inner Front side member front member reinforcement Front side outer member Front side inner member Front side member outer extension Front side member Front side member lower Front side extension Front side member...
  • Page 24 BODY CONSTRUCTION - Side body SIDE BODY FRONT PILLAR COMPLETE CFAP1200 PART NAME PART NAME Front outer panel. Front sill side outer reinforcement. Front pillar inner reinforcement. Fender mounting bracket (B). Front inner panel. Fender mounting bracket (C). Front pillar inner extension. Fender mounting bracket (E).
  • Page 25 BODY CONSTRUCTION - Side body FRONT PILLAR AND APRON PANEL (Cross - Sectional Views) CFAP1100 Front outer panel Front apron panel Front outer panel Front inner panel Fender panel Front piller inner reinforcement SECTION A - A' SECTION B - B' CFAP1110 CFAP1120 Fender panel...
  • Page 26 BODY CONSTRUCTION - Side body REAR END STRUCTURE (SHORT BODY) CRAS1300...
  • Page 27 BODY CONSTRUCTION - Side body REAR END STRUCTURE PART NAME Quarter outer panel. Roof side outer panel. Fuel filler neck braket. Quarter outer rear upper extension. Quarter outer rear lower extension. Rear gusset panel. Quarter inner panel. Roof side inner reinforcement. "C"...
  • Page 28 BODY CONSTRUCTION - Side body REAR END STRUCTURE (LONG BODY) CRAS1400...
  • Page 29 BODY CONSTRUCTION - Side body REAR END STRUCTURE PART NAME Quarter outer panel. Roof side outer panel. Fuel filler neck braket. Quarter outer rear upper extension. Quarter outer rear lower extension. Rear gusset panel. Quarter inner panel. Roof side inner reinforcement. "C"...
  • Page 30 BODY CONSTRUCTION - Side body REAR END STRUCTURE (LH) (Cross - Sectional Views) CRAS1100 Front inner complete pillar Quarter inner panel Quarter outer panel Quarter outer panel CRAS1110 CRAS1120 SECTION A - A' SECTION B - B' Quarter inner panel Quarter inner panel Quarter outer panel Quarter outer panel...
  • Page 31 BODY CONSTRUCTION - Side body REAR END STRUCTURE (RH) (Cross - Sectional Views) CRAS1200 Front inner complete pillar Quarter inner panel Quarter outer panel Quarter inner panel CRAS1210 CRAS1220 SECTION A - A' SECTION B - B' Quarter outer panel Quarter outer panel Quarter inner panel Quarter inner panel...
  • Page 32 BODY CONSTRUCTION - Side body REAR STEP PANEL (Cross - Sectional Views) CRAS1400 Rear floor panel "B" pillar inner lower panel Rear step panel Rear step panel Rear side sill inner CRAS1250 SECTION A - A' SECTION B - B' CRAS1260 "C"...
  • Page 33 BODY CONSTRUCTION - Under body REAR FLOOR COMPLTE (SHORT BODY) CUAF1400 PART NAME Rear floor panel. Rear step panel. Rear side sill inner (RH). Rear step panel extension. Quart inner lower front panel (LH). "B" pillar inner lower panel (LH). "B"...
  • Page 34 BODY CONSTRUCTION - Under body REAR FLOOK COMPLETE (LONG BODY) CUAF1500 PART NAME Rear floor panel. Rear step panel. Rear side sill inner (RH). Rear step panel extension. Quarter inner lower front panel (LH). "B" pillar inner lower panel (LH). "B"...
  • Page 35 BODY CONSTRUCTION - Under body REAR SIDEMEMBER COMPLETE (SHORT BODY, 2WD) CRAS2100...
  • Page 36 BODY CONSTRUCTION - Under body PART NAME PART NAME Rear sidemember. Fuel tank rear plate. Hitch member reinforcement. No.6 Crossmember. Brack stopper bracket. No.6 Crossmember reinforcement. Brack stopper bracket support. No.6 Crossmember support. Rear side (A) brace. Upper arm mounting bracket. Rear side (B) brace.
  • Page 37 REPLACEMENT PARTS...
  • Page 38: Front Body

    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.
  • Page 39: Side Body

    REPLACEMENT PARTS - Side body SIDE BODY BC02 PART NAME FRONT INNER PILLAR ASSEMBLY LH/RH FRONT PILLAR OUTER PANEL LH/RH SIDE SILL OUTER PANEL LH/RH CENTER OUTER PILLAR ASSEMBLY LH/RH QUARTER INNER PANEL ASSEMBLY LH/RH QUARTER OUTER PANEL ASSEMBLY LH/RH CON-0400, 0545, PRO-1430...
  • Page 40: Rear Body

    REPLACEMENT PARTS - Rear body REAR BODY BC03 PART NAME REAR FLOOR PANEL REAR FLOOR SIDEMEMBER ASSEMBLY LH/RH REAR FLOOR SIDE PANEL LH/RH REAR FLOOR CENTER CROSSMEMBER ASSEMBLY BACK PANEL ASSEMBLY...
  • Page 41 REPLACEMENT PARTS - Door DOOR BC04 PART NAME FRONT DOOR PANEL ASSEMBLY LH/RH FRONT DOOR OUTER PANEL LH/RH DOOR HINGE ASSEMBLY LH/RH REP-1770,0010,0020, PRO-1800...
  • Page 42: Body Dimensions

    BODY DIMENSIONS...
  • Page 43: General

    GENERAL GENERAL Basically, all measurements in this manual are taken with a tacking 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 ac- tual-measurement dimension are used in this manual. MEASUREMENT METHOD PROJECTED DIMENSIONS These are the dimensions measured when the measurement...
  • Page 44 BODY DIMENSIONS -Under body (2WD Short Body) UNDER BODY (ACTUAL-MEASUREMENT DIMENSIONS) SHORT BODY (2WD) SHORT2 < > < < > > < > < > < < > > SHORT1 * These dimensions indicated in this figure are actual-measurement dimensions. (SHORT BODY : 2WD) Point symbol A-A'...
  • Page 45 BODY DIMENSIONS -Under body (2WD Short body) DIAA0071 DIAA0070 DIAA0070 Location hole Engine mounting crossmember Front upper arm mounting (∅20) (∅16) (∅15) DIAA0090 DIAA0100 DIAA0080 Axle mounting hole Strut bar mounting hole Manual transmission mounting (∅18) (∅16) hole (∅14) DIAA0110 DIAB0060 DIAB0060 Tooling hole...
  • Page 46 BODY DIMENSIONS -Under body (2WD Long Body) LONG BODY (2WD) D' E' LONG2 > < < < > > < > > < < < > > LONG1 * These dimensions indicated in this figure are actual-measurement dimensions. (LONG BODY : 2WD) Point symbol A-A' B-B'...
  • Page 47 BODY DIMENSIONS -Under body (2WD Long body) DIAA0071 DIAA0070 DIAA0070 Location hole Engine mounting crossmember Front upper arm mounting (∅20) (∅16) (∅15) DIAA0080 DIAA0090 DIAA0100 Axle mounting hole Strut bar mounting hole Manual transmission mounting (∅18) (∅16) hole (∅14) DIAA0110 DIAB0060 DIAA140 Tooling hole...
  • Page 48 BODY DIMENSIONS -Under body (4WD Short Body) SHORT BODY (4WD) A' B' 4WD-2 < > < > < > < >< > < >< > 4WD-1 * These dimensions indicated in this figure are actual-measurement dimensions. (SHORT BODY : 4WD) Point symbol A-A' B-B'...
  • Page 49 BODY DIMENSIONS -Under body (4WD Short body) DIAB0030 DIAB0020 DIAB0020 Location hole Engine crossmember mounting Upper arm mounting hole (∅20) hole (∅16) (∅15) DIAB0030 DIAB0040 DIAB0050 Front suspension mounting Manual transmission mounting Tooling hole crossmember (∅16) crossmember (∅13) (∅25) DIAB0060 DIAB0060 DIAB0070 Rear leaf spring mounting...
  • Page 50: Side Body

    BODY DIMENSIONS - Side body (RH) SIDE BODY (RH) DIAC0010 * These dimensions indicated in this figure are actual-measurement dimensions. (SHORT BODY) Point symbol Length (mm) 1014 1289 1562 1506 Point symbol 1289 Length (mm) 1212 1428 1026 1255 1490 Point symbol Length (mm) 1880...
  • Page 51 BODY DIMENSIONS - Side body (RH) DIAC0020 DIAC0030 DIAC0040 Fender mounting hole Location hole Front door hinge mounting hole (∅9) (∅15) (∅11) DIAC0060 DIAC0070 DIAC0050 Tooling hole Front pillar outer position notch Front pillar outer position notch (∅12) DIAC0080 DIAC0090 DIAC100 Center pillar outer position Door switch mounting hole...
  • Page 52 BODY DIMENSIONS - Side body (RH) DIAC0130 DIAC0140 DIAC0150 Center rail mounting hole Quarter outer and roor side Rear bumper mounting hole (∅9) outer matching (∅8) DIAC0160 Rear bumper mounting (∅8)
  • Page 53 BODY DIMENSIONS -Side body (LH) SIDE BODY (RH) DIAC0210 * These dimensions indicated in this figure are actual-measurement dimensions. (SHORT BODY) Point symbol Length (mm) 1014 1289 1562 1407 1289 Point symbol Length (mm) 1212 1644 2279 1376 1261 1769 1038 Point symbol Length (mm)
  • Page 54 BODY DIMENSIONS -Side body (LH) DIAC0220 DIAC0230 DIAC0240 Location hole Fender mounting hole Front door hinge mounting hole (∅15) (∅9) (∅11) DIAC0250 DIAC0270 DIAC0260 Tooling hole Front pillar outer position notch Front pillar outer position notch (∅12) DIAC0290 DIAC0300 DIAC0280 Rear glass hinge mounting hole Door switch mounting hole Quarter outer panel (LH)
  • Page 55 BODY DIMENSIONS -Side body (LH) DIAC0330 Rear bumper mounting hole (∅8)
  • Page 56: Upper Body

    BODY DIMENSIONS -Upper body UPPER BODY SHORT BODY DIAD0010 LONG BODY DIAD0020 * These dimensions indicated in this figure are actual-measurement dimensions. (SHORT BODY) B-C' B'-D Point symbol A-A' B-B' C-C' C-E' 1539 Length (mm) 1492 1464 1632 F-F' Point symbol C'-E' F'-C F'-G...
  • Page 57 BODY DIMENSIONS -Upper body DIAD0040 DIAD0030 DIAD0050 Headlamp support complete Fender mounting hole Hood hinge mounting hole mounting (∅9) (∅6.6) (∅11) DIAD0070 DIAD0080 DIAD0060 Wiper pivot mounting Roof side outer end line Roof side outer panel (∅9) DIAD0090 Roof side outer panel...
  • Page 58: Interior

    BODY DIMENSIONS - Interior INTERIOR DIBD0010 * These dimensions indicated in this figure are actual-measurement dimensions. (SHORT BODY) Point symbol B-B' D-D' E-F' A-A' C-C' E-E' F-F' F-G' Length (mm) 1450 1470 1602 1648 2111 1630 1786 1943 Point symbol G-G' I-I' J-J'...
  • Page 59 BODY DIMENSIONS - Interior DIBD0030 DIBD0040 DIBD0020 Wheel guard mounting hole Front step fixing cover Front door checker mounting ( 9) ( 8.5) hole (∅11) DIBD0060 DIBD0070 DIBD0050 Front door striker mounting Center floor step mounting edge Rear floor and rear wheel house hole (∅10) front edge DIBD0090...
  • Page 60 BODY DIMENSIONS - Interior DIBD0150 DIBD0160 DIBD0140 Roof bow mounting Roof bow mounting Head lining mounting hole (∅9.8) (Long body) (∅9.8) (Long body) (∅8.5)
  • Page 61: Front Body

    BODY DIMENSIONS - Front body FRONT BODY DIAE0010 * These dimensions indicated in this figure are actual-measurement dimensions. A-A' A-B' B-B' Point symbol D-D' C-C' E-E' F-F' 1400 1490 1490 Length (mm) J-I' J-J' H-H' Point symbol G-G' I-I' 1333 1556 1450 1492...
  • Page 62 BODY DIMENSIONS - Front body DIAE0020 DIAE0030 DIAE0040 Thermo sensor mounting Head lamp mounting Location hole (∅7) (∅7) (∅10) DIAE0060 DIAE0070 DIAE0050 Front bumper upper rail Location hole (2WD) Shock absorer mounting (2WD) mounting (∅7) (∅8) (∅15) DIAE0080 DIAE0090 DIAE0100 Location hole (4WD) Wheel guard mounting hole Fender mounting hole...
  • Page 63: Rear Body

    BODY DIMENSIONS -Rear body REAR BODY DIAF0010 * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol B-B' A-A' A-C' B-A' B'-C' Length (mm) 1379 1782 1405 1596 1628 Point symbol C-B' C-C' 1400 Length (mm) 1565...
  • Page 64 BODY DIMENSIONS -Rear body DIAF0020 DIAF0030 DIAF0040 Quarter outer panel Gas Spring mounting Rear bumper mouting hole (∅10) ( 8x8.5) DIAF0050 Trim cargo step mounting hole ( 8)
  • Page 65: Body Panel Repair Procedure

    BODY PANEL REPAIR PROCEDURE...
  • Page 66: Radiator Support Panel & Front Sidemember

    BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember RADIATOR SUPPORT PANEL & FRONT SIDEMEMBER WELDING POINTS MIG plug welding MIG butt welding MIG lap welding RFAC4010~4040...
  • Page 67: Body Panel Repair Procedure

    BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember REMOVAL Radiator support upper center member Remove the radiator upper mounting reinforcement. Remove the radiator support upper center member. NOTE NOTE Radiator upper mounting reinforcement and the radiator support upper center member are mounted with 10 mm (Head side) bolts.
  • Page 68: Body Panel Repair Procedure

    BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember Drill out all spotwelds and MIG plug welds to separate front end crossmember inner and outer panel. RFAC4020 RFAC4030 Remove the front end crossmember. NOTE NOTE This procedure is to be used only for repair of minor damage on to the front sidemember and front end crossmember when it is impossible to straighten the damage on them.
  • Page 69 BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember (4WD) 20 mm 120 mm RFAC4120 15. Remove the front sidemember partial. <2WD> 1) Drill out all spotweld and MIG lap welds to separate cover panel from front sidemember. 2) Cut the front sidemember at 80 mm apart from the air conditioning discharge pipe hole.
  • Page 70: Body Panel Repair Procedure

    BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember INSTALLATION 1. Transcribe the cutlines to the new front sidemember, cut to length and chamfer butt end to improve weld surfaces. <2WD> 80mm 1) Cut the new front sidemenber at 45 mm from the air 60 mm conditioning discharge pipe hole .
  • Page 71: Body Panel Repair Procedure

    BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember RFAC4180 2) Temporarily install front sidemember outer panel and rein- Cover panel forcement. NOTE If necessary, make temporary welds so as not to twist. RFAC4190 3) Temporarily install front sidemember inner panel and cover panel.
  • Page 72: Body Panel Repair Procedure

    BODY PANEL REPAIR PROCEDURE - Radiator support panel & front sidemember 5. MIG plug weld all holes and MIG butt weld at the front apron panel and front wheelhouse. 6. Fit and clamp the front end crossmember and radiator support panels.
  • Page 73: Front Pillar And Apron Panel

    BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel FRONT PILLAR AND APRON PANEL MIG plug welding or spot welding MIG butt welding MIG lap welding FAAA0010~0040 This book has been described on the basis of MIG plug weldings to the points which were spot-welded in production line. But, if necessary, either the MIG plug weldings or the spotweldings are able to be applied.
  • Page 74 BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel REMOVAL Before cutting front pillar, be sure to support roof panel. FAAA0050 Measure and mark each cutline on the front pillar inner, front pillar outer and front pillar inner reinforcement from the location 95 mm hole indicated in the illustration.
  • Page 75 BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel Drill out all spotwelds attaching the front pillar outer panel and reinforcement. NOTE Depending on the extent of damaged area, it may be possible to determine the cutting range within indicated in the illustration.
  • Page 76 BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel Cut the front pillar through each cutline, taking care not to damage the other panel as illustration. FAAA0120 10. Using a hammer and dolly correct the flanges if they are bent or deformed when spotwelds are broken.
  • Page 77 BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel Tamporarily install front apron panel. FAAA0160 Tamporarily install front pillar inner panel and front pillar inner Front pillar inner panel reinforcement. 60 mm Front pillar inner reinforcement FAAA0170 Perform MIG plug welding the front apron panel and MIG butt welding to the front pillar inner reinforcement.
  • Page 78 BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel Cinfirm the installation status of front pillar inner panel and outer panel by checking the hole center at "A". Confirm the installation status of front pillar inner reinforcement and front pillar outer panel by checking the hole center at "B".
  • Page 79 BODY PANEL REPAIR PROCEDURE - Front pillar and apron panel 11. Apply body sealer to joints and sand as needed. 12. Apply the two-part epoxy primer to the interior of the front pillar. 13. Apply an anti-corrosion agent to the welded parts and inside of front pillar (Refer to the CORROSION PROTECTION).
  • Page 80: Center Pillar

    BODY PANEL REPAIR PROCEDURE - Center pillar CENTER PILLAR WELDING POINTS MIG plug welding or spot welding MIG butt welding MIG lap welding CPAC1010~1030 REMOVAL Measure and mark the horizontal cutline on center outer pillar. 220 mm Center outer pillar CPAC1040...
  • Page 81 BODY PANEL REPAIR PROCEDURE - Center pillar Drill out spotwelds attaching the center pillar inner panel from the center pillar inner lower panel. Center pillar inner lower panel CPAC1050 Drill out all spotwelds from the center pillar panel below the cutline.
  • Page 82 BODY PANEL REPAIR PROCEDURE - Center pillar CPAC1090...
  • Page 83 BODY PANEL REPAIR PROCEDURE - Center pillar INSTALLATION Cut the center pillar outer at 160 mm on the center pillar inner and reinforcement at 190 mm. CPAC1100 Attach the center pillar inner lower panel and the center pillar inner reinforcement to the center pillar inner panel with vice grips.
  • Page 84 BODY PANEL REPAIR PROCEDURE - Center pillar Temporarily install center pillar outer panel. CPAC1140 Measure each measurement point (Refer to the BODY DIMEN- SIONS) and correct the installation position. If necessary, make temporary welds, and then check to confirm that the closing and fit for front door and rear door are correct. CPAC1150 MIG plug weld and spotweld all holes.
  • Page 85 BODY PANEL REPAIR PROCEDURE - Center pillar 12. Apply an anti-corrosion agent to the welded parts and inside of the center pillar. 13. Prepare exterior surfaces for priming, using wax and grease remover. 14. Apply metal conditioner and water rinse. 15.
  • Page 86: Center Floor

    BODY PANEL REPAIR PROCEDURE - Center floor CENTER FLOOR WELDING POINTS MIG plug welding or spot welding MIG butt welding MIG lap welding RFAF2010~2013...
  • Page 87 BODY PANEL REPAIR PROCEDURE - Center floor REMOVAL Before drilling out spotwelds, remove body sealant and silencer pad from the center floor. RFAF2020 Drill out all spotwelds attaching the center floor to the body. NOTE Drill the outer panel with a spot cuttor so as not to damage the members.
  • Page 88 BODY PANEL REPAIR PROCEDURE - Center floor INSTALLATION Drill 8 mm holes in production location of the new center floor panel for MIG plug welding. New center floor panel RFAF2060 Overlap the center floor panel and the rear floor panel as shown Center floor panel in the illustration.
  • Page 89 BODY PANEL REPAIR PROCEDURE - Center floor Apply the two-part epoxy primer to the interior of the front sidemember and other parts. Apply an anti-corrosion to the interior of the welded front sidemember and other parts (Refer to the CORROSION PRO- TECTION).
  • Page 90: Rear Step Panel

    BODY PANEL REPAIR PROCEDURE - Rear step panel REAR STEP PANEL WELDING POINTS MIG plug welding or spot welding MIG butt welding MIG lap welding PSAS0010~0040...
  • Page 91 BODY PANEL REPAIR PROCEDURE - Rear step panel REMOVAL Drill out all spotwelds attaching the center pillar outer panel below cutline. Cutline NOTE It is convenient to install if remove welding points only from the outer panel with a spot cutter without puncturing the inner panel.
  • Page 92 BODY PANEL REPAIR PROCEDURE - Rear step panel Remove the rear step panel. PSAS0080 Grind and smooth any weld traces which might be left on the body surface by using an air grinder or similar tool, being careful not to damage any of the panels which is not to be replaced. Hammer Using a hammer and a dolly, correct any flanges that become bent or deformed when spotwelds are broken.
  • Page 93 BODY PANEL REPAIR PROCEDURE - Rear step panel INSTALLATION Fit and clamp the rear step panel in place for temporary welding. PSAS0081 Fit and clamp the rear side sill inner panel in place for welding Rear side sill inner panel PSAS0091 If necessary, make temporary welds to the rear side sill outer panel and center pillar outer panel, and then check to confirm...
  • Page 94 BODY PANEL REPAIR PROCEDURE - Rear step panel Apply an anti-corrosion agent as required. Prepare exterior surfaces for priming, using wax and grease remover. Apply metal conditioner and water rinse. 10. Apply conversion coating and water rinse. 11. Apply the two-part epoxy primer. PSAS0120 12.
  • Page 95: Quarter Outer Panel

    BODY PANEL REPAIR PROCEDURE - Quarter outer panel QUARTER OUTER PANEL SHORT BODY (LH) WELDING POINTS QSAQ2010 Spot welding or MIG plug welding MIG butt weldling QSAQ2020 QSAQ2030...
  • Page 96 BODY PANEL REPAIR PROCEDURE - Quarter outer panel QUARTER OUTER PANEL LONG BODY (LH) WELDING POINTS QSAQ2040 QSAQ2020 QSAQ2030 Spot welding or MIG plug welding MIG butt weldling...
  • Page 97 BODY PANEL REPAIR PROCEDURE - Quarter outer panel REMOVAL Depending on the extent of damage, measure and mark cutline on the quarter outer panel 170 mm downward from the rear window LH glass upper line as illustration. 170 mm Quarter outer panel QSAQ2050 Measure and mark cutline on the quarter outer panel 160 mm downward from the quarter window LH glass upper line as...
  • Page 98 BODY PANEL REPAIR PROCEDURE - Quarter outer panel Cut quarter outer panel along cutlines to remove quarter outer panel. NOTE 1) Becareful not to cut quarter inner panel. QSAQ2090 2) When cutting "C" outer pillar (Left side), be careful not to cut reinforcement panel as illustration.
  • Page 99 BODY PANEL REPAIR PROCEDURE - Quarter outer panel INSTALLATION Measure and mark guide lines 30 mm upward and downward from "B" pillar outer panel, "C" pillar outer panel and "D" pillar outer panel cutlines. Drill 8 mm holes where the insertion panel to be installed. Make an insertion panel with 60 mm width from unused portion Insertion of the panel.
  • Page 100 BODY PANEL REPAIR PROCEDURE - Quarter outer panel Apply a coating of silicon rubber sealer and body sealant at places indicated in the illustration. QSAQ2111 Fit and clamp the quarter outer panel in place. 10. MIG plug weld all holes and MIG butt weld seams. Spot weld at the wheel well.
  • Page 101 BODY PANEL REPAIR PROCEDURE - Quarter outer panel 19. Apply the correct seam sealer to all joints. 20. Reprime over the seam sealer to complete the repair. (Refer to the BODY SEALING LOCATIONS). QSAQ2210 21. After completing body repairs, carefully apply under coating to the wheel well (Refer to the CORROSION PROTECTION).
  • Page 102 BODY PANEL REPAIR PROCEDURE - Quarter outer panel QUARTER OUTER PANEL SHORT BODY (RH) WELDING POINTS QSAQ2230 QSAQ2240 QSAQ2250...
  • Page 103 BODY PANEL REPAIR PROCEDURE - Quarter outer panel QUARTER OUTER PANEL LONG BODY (RH) WELDING POINTS QSAQ2260 QSAQ2250 QSAQ2240...
  • Page 104 BODY PANEL REPAIR PROCEDURE - Quarter outer panel REMOVAL Depending on the extent of damage, measure and mark cutline on the quarter outer panel 205 mm downward from the quarter window RH glass upper line as illustration. 205 mm QSAQ2270 Measure and mark cutline on the quarter outer panel 150 mm upward from the quarter window glass RH lower line as illustra- tion.
  • Page 105 BODY PANEL REPAIR PROCEDURE - Quarter outer panel 2) When cutting "C" outer pillar (Right side), be careful not to cut reinforcement panel as illustration. QSAQ2310 Remove quarter outer panel. QSAQ2320 Prepare all surfaces to be welded. QSAQ2330...
  • Page 106 BODY PANEL REPAIR PROCEDURE - Quarter outer panel INSTALLATION Measure and mark guide lines 30 mm upward and downward from "C" pillar outer panel and "D" pillar outer panel cutlines. Drill 8 mm holes where the insertion panel to be installed. Insertion panel Make an insertion panel with 60 mm width from unused portion...
  • Page 107 BODY PANEL REPAIR PROCEDURE - Quarter outer panel Fit and clamp the quarter outer panel in place. 10. MIG plug weld all holes and MIG butt weld seams. Spot weld at the wheel well. NOTE Insertion In order to prevent distortion caused by the welding heat, panel make the welds alternately at regular intervals.
  • Page 108 BODY PANEL REPAIR PROCEDURE - Quarter outer panel 21. After completing body repairs, carefully apply under coating to the wheel well (Refer to the CORROSION PROTECTION). 22. In order to improve corrosion resistance, if necessary, apply a under body anti-corrosion agent to the wheel well (Refer to the CORROSION PROTECTION).
  • Page 109: Rear Floor

    BODY PANEL REPAIR PROCEDURE - Rear floor REAR FLOOR (SHORT BODY) WELDING POINTS RRAF3010 RRAF3023 RRAF3012 MIG plug welding MIG batt welding...
  • Page 110 BODY PANEL REPAIR PROCEDURE - Rear floor REAR FLOOR (LONG BODY) WELDING POINTS RRAF3020 RRAF3024 RRAF3022 MIG plug welding MIG batt welding...
  • Page 111 BODY PANEL REPAIR PROCEDURE - Rear floor REAR END CORSSMEMBER (PARTIAL) WELDING POINTS RRAF3150 REMOVAL 1. Cut the rear end crossmember outer and lower simultaneously at 50 mm apart from the hole marked in the illustration. 50mm RRAF3160 2. Cut the rear end crossmember inner at 30 mm apart from the rear end crossmember outer.
  • Page 112 BODY PANEL REPAIR PROCEDURE - Rear floor REMOVAL Refer to the body dimension chart and measure the vehicle to determine straigthtening and alignment requirments. NOTE The body must be returned to its original dimension before beginning the repair procedure. Measure and mark the cutline on the rear floor from the rear edge of rear floor as shown in the figure.
  • Page 113 BODY PANEL REPAIR PROCEDURE - Rear floor Drill out all spotwelds attaching the rear floor panel to the body. NOTE Drill the outer panel with a spot cutter so as not to damage the members. RRAF3060, AAAA9000 Cut the rear floor panel between No.7 crossmember welding points.
  • Page 114 BODY PANEL REPAIR PROCEDURE - Rear floor 3. Fit and clamp the rear floor panel and attach the rear floor panel to the rear sidemembers and other panels. 4. MIG plug weld all holes and MIG butt weld the seam. RRAF3100 5.
  • Page 115: Door Panel

    BODY PANEL REPAIR PROCEDURE - Door panel DOOR PANEL FRONT DOOR WELDING POINTS <Outer panel> <Inner panel> D0AF0010 D0AF0030 REAR DOOR <Outer panel> <Inner panel> D0AF0020 DOAF0040 MIG plug welding or spot welding MIG batt welding MIG lap weldling...
  • Page 116 BODY PANEL REPAIR PROCEDURE - Door panel TAIL GATE PANEL WELDING POINTS (Outer panel) DOAT0010 (Inner panel) MIG plug welding or spot welding MIG batt welding MIG lap weldling DOAT0020...
  • Page 117 BODY PANEL REPAIR PROCEDURE - Door panel REMOVAL Drill out the spotweld to separate door outer panel from front and rear door. DOOR0010 Cut door outer panel. DOOR0020 After grinding off the hemming location with a sander, remove the outer panel. DOOR0030 Dress rusty part with a sander and prepare surface to be hemmed.
  • Page 118 BODY PANEL REPAIR PROCEDURE - Door panel INSTALLATION Mastic sealer DOAI0010 DOAI0020 (Rear door) (Front door) SECTION A-A' Adhesive DOAI0040 (Tail gate panel) DOAI0030 QSAQ2030...
  • Page 119 BODY PANEL REPAIR PROCEDURE - Door panel Apply adhesive (3M 08531) or equivalent to outer panel hem. Apply mastic sealer (3M 08105) or equivalent to the door member as shown in the figure. DOAI0050 Bend the flange hem with a hammer and dolly, then fasten tightly with a hemming tool.
  • Page 120 BODY PANEL REPAIR PROCEDURE - Door panel Apply an anti-corrosion agent to the welded parts and lower inside of the door panel, (Refer to the CORROSION PROTEC- TION). Prepare exterior surfaces for priming, using wax and grease remover. Apply metal conditioner and water rinse. 10.
  • Page 121: Body Sealing Locations

    BODY SEALING LOCATION...
  • Page 122: Upper And Side Body

    BODY SEALING LOCATIONS - Upper and side body UPPER AND SIDE BODY SEAA0010 SEAA0020 SEAA0030 SEAA0040...
  • Page 123 BODY SEALING LOCATIONS - Upper and side body SEAA0050 SEAA0060 SEAA0070 SEAA0080 SEAA0090 SEAA0100 SEAA0110 SEAA0120...
  • Page 124 BODY SEALING LOCATIONS - Upper and side body SEAA0130 SEAA0140 SEAA0150 SEAA0160 SEAA0170...
  • Page 125: Rear Body

    BODY SEALING LOCATIONS - Rear body REAR BODY SEAB0010 SEAB0050 SEAB0020 SEAB0030 SEAB0040...
  • Page 126: Floor

    BODY SEALING LOCATIONS - Floor FLOOR SEAC0010 SEAC0020 SEAC0030 SEAC0040 SEAC0050...
  • Page 127 BODY SEALING LOCATIONS - Floor SEAC0060 SEAC0070 SEAC0080 SEAC0090 SEAC0100 SEAC0110 SEAC0120 SEAC0130...
  • Page 128 BODY SEALING LOCATIONS - Floor SEAC0140 SEAC0150 SEAC0160 SEAC0170 SEAC0180...
  • Page 129: Corrosion Protection

    CORROSION PROTECTION...
  • Page 130: Zinc-Galvanized Steel Panels

    CORROSION PROTECTION - Zinc - Galvanized steel panels ZINC - GALVANIZED STEEL PANELS Because galvanized steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below. AAAC0050...
  • Page 131 CORROSION PROTECTION - Zinc - galvanized steel panel PART NAME PART NAME Front end crossmember. (**) Wheel house outer rear panel (LH). (**) Front sidemember. (**) Quarter outer panel (RH). (**) Rear side member. Roof side outer panel (RH). (**) Crossmember No.1.
  • Page 132: Zinc-Phosphate Coat & Cationic Electrodeposition Primer

    CORROSION PROTECTION - Zinc-phosphate coat & cationic eletrodeposition primer ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER 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. Cationic electrodeposition primer Zinc-phosphate film Body steel panel...
  • Page 133: Under Body Coat

    CORROSION PROTECTION - Under body coat UNDER BODY COAT In order to provide corrosion, resistance 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 Before applying the under body, mask the location where parts are to be mounted.
  • Page 134 CORROSION PROTECTION - Under body coat SIDE BOD SIDE BOD SIDE BODY Y Y Y Y SIDE BOD SIDE BOD Before applying the under body, mask the location where parts are to be mounted. Underbody coating (more than 0.8mm thinkness) Underbody coating (more than 1.2mm thinkness) CPAS0010 Quarter outer panel...
  • Page 135: Cavity Wax Injection

    CORROSION PROTECTION - Cavity wax injection C AVITY VITY VITY VITY W W W W W AX INJECTION AX INJECTION AX INJECTION AX INJECTION VITY AX 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 in an hollow construction.
  • Page 136 CORROSION PROTECTION - Cavity wax injection 15 mm 15 mm 15 mm 15 mm D0AF0040 D0AF0030 50 mm 50 mm D0AT0010 SEAA0030 Cavity wax injection (Thickness 60 µ - 70 µ ). 10 mm 10 mm SECTION A-A' CCAS0060 SECTION B-B' CCAS0070 15 mm 15 mm...
  • Page 137: Under Body Anti-Corrosion Agent

    CORROSION PROTECTION - Under body anti-corrosion agent UNDER BOD UNDER BOD UNDER BODY ANTI-CORR UNDER BOD UNDER BOD Y ANTI-CORR Y ANTI-CORR Y ANTI-CORROSION A Y ANTI-CORR OSION A OSION A OSION AG E N T OSION A G E N T G E N T G E N T G E N T...

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