Hyundai Coupe Workshop Manual

CONTENTS

GENERAL INFORMATION

GENERAL GUIDELINES AND PRECAUTIONS.. 6

SRSAIRBAG 7

ELECTRONIC PARTS 8

CORROSION PROTECTION AND SEALING 8

SIDE BODY PANELS.... 8

WELDING ....9

BODY CONSTRUCTION

BODY COMPONENTS 12

ZINC-GALVANIZED STEEL PANELS 14

HIGH-STRENGTH STEEL PANELS 16

FRONT BODY 18

SIDE BODY .....29

UNDER BODY..... 34

REAR BODY 39

FENDER & HOOD 43

ROOF 44

DOOR 45

REPLACEMENT PARTS

FRONT BODY .48

SIDE BODY. 49

REAR BODY ."' 50

DOOR 51

BODY DIMENSIONS

GENERAL... 52

UPPER BODY 53

SIDE BODY 55

INTERIOR 58

UNDER BODY 60

ENGINE COMPARTMENT 64

LUGGAGE COMPARTMENT 66

BODY PANEL REPAIR PROCEDURE

RADIATOR SUPPORT PANEL 72

FENDER APRON AND FRONT SIDEMEMBER (ASSEMBLY) 73

FRONT SIDEMEMBER (PARTIAL). 79

FRONT PILLAR 83

SIDESILL (ASSEMBLY) 90

SIDE SILL (PARTIAL) 94

QUARTER PANEL 97

REAR FLOOR 100

REAR SIDEMEMBER (ASSEMBLY) 101

REAR SIDEMEMBER (PARTIAL) 106

DOOR 109

BODY SEALING LOCATIONS

FLOOR 114

UPPER & SIDE BODY 118

CORROSION PROTECTION

ZINC-GALVANIZED STEEL PANELS 122

ZINC-PHOSPHATE COAT&CATIONICELECTODEPOSITION PRIMER 124

ANTI-CORROSION PRIMER 125

ANTIVIBRATION PADS-LOCATION & SECTION 126

ATTACHMENT OF ANTIVIBRATION PADS 127

UNDER BODY COAT 128

SIDE BODY 129

CAVITY WAX INJECTION 130

UNDER BODY ANTI-CORROSION AGENT 134

GENERAL

m

GENERAL INFORMATION » General guide lines and precautions

GENERAL GUIDE LINES AMD PRECAUTIONS

The Hyundai TIBURON/COUPE 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 TIBURON/

COUPE is designed so that the front and rear compartments will absorb much of the collision energy so that the passengers are better protected. During collisions, these front and rear energy absorbing systems may be severely damaged. During repair, these damaged areas must be returned to their original strength and geometry.

If this is not properly done, the vehicle will not provide the intended level of protection to its occupants in the event of another collision.

The repairs described in this manual were performed 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 be 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 returned 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 responsibility of the repair technician, based upon the extent of damage, to determine which location and procedure is suitable for the particular damaged vehicle.

During the repair of a collision damaged automobile, it is impossible to fully duplicate the methods used in the factory during the vehicle manufacture. Therefore, auto body repair techniques have been developed to provide a repair that has strength properties equivalent to those of the original design and manufacture.

Certain guidelines and precaution are noted as follows.

SRS AIRBAG

SYSTEM COMPONENT

GENERAL INFORMATION - SRS Airbag

ERKB012A

The Hyundai TIBURON/COUPE is equipped with a Supplemental Restraint System (AIRBAG) 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 or lateral impact of sufficient severity.

When handling airbag components (removal, installation or inspection, etc.), always follow the directions given in the repair manual for the relevant model to prevent the occurrence of accidents and airbag malfunction.

Also take the following precautions when repairing the body:

1. Work must be started after approximately 30 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-up power source so that if work is started within 30 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 before starting work, make a record of the contents memorized by the audio memory system. Then when work is finished, reset the audio system as before and adjust the clock.

2. When using electric welding, first disconnect the SRSCM connectors under the lower crash pad center.

3. Store the airbag module where the ambient temperature remains below 80°C (176°F), without high humidity and away from electrical noise.

4. WARNING/CAUTION labels are attached to the periphery of the airbag components.

Refer to the TIBURON/COUPE SHOP MANUAL.

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 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. Before removing and inspecting the electrical parts or before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.

2. Do not expose the CONTROL MODULES to ambient temperatures above 80°C (176°F).

MOTE :

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.

3. Be careful not to drop the CONTROL MODULES and not to apply physical shocks to them.

CORROSION PROTECTION AND SEALING

Proper corrosion protection and sealing is an important part of any repair. When reviewing these repair procedures, it is important to recognize the need for corrosion restoration to provide for 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.

After the corrosion restoration process for the closed sections are completed, then the process can be applied to all exterior sections. For exterior surfaces, both metal conditioner and conversion coating treatments are applied to the exterior surface prior to application of the epoxy primer. The procedure in applying the corrosion restoration process is important in order to insure that moisture, due to the water rinsing of the metal conditioner and conversion coating 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 to all joints. Follow manufacturer's recommendations for the appropriate type of seam sealer to be used at each seam or joint.

SIDE BODY PANELS

The side body panel for TIBURON/COUPE 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 part.

Service part line

GK-0030

8

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 l-CAR recommendations for welding should be followed. The shielding gas should be 75% Argon and 25% C0

2

.

The recommended welding wire size is 0.23" and the wire should satisfy the American Welding Society Standard code AWSER70S-6.

During the repair process, plug welds are used to duplicate original factory spot welds. All plug welds should be done with the MIG welder. An 8 mm (5/16") hole is placed in the top (welding side) sheet metal.

You then begin welding along the edges and the spiral towards the center (see illustration). This is important so that weld penetration between the two metal pieces may take place along the circumference of the circle.

Weld around edges first working in towards the center

////////////////^^^^

8mm or 5/16" dia. hole illustration-Welding in collision Repair

SAFETY FACTORS

Disconnect the negative(-) battery cable before performing any work on the vehicle.

Protect yourself by wearing goggles, earplugs, respirators, gloves, safety shoes, caps, etc. when working on a vehicle.

Safely support the vehicle before any work is done. Block the front or rear wheels if the vehicle is not lifted off of the ground.

Cap or remove the fuel tank when working on the rear section of the car.

Insure proper ventilation of your working area. Some paint and sealant can generate toxic gases when heated.

Use an air chisel or saw to remove damaged panels instead of a gas torch.

Observe all local and national safety regulations when performing any work.

Cover interior with heat-resistant cover to insure safety when welding.

Take care when using gas or cutting torches so as not to burn body sealer or interior. Extinguish immediately if they should catch fire.

30DY

: ! •

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.

12

1. Radiator support upper center member

2. Radiator support center member

3. Radiator upper mounting bracket

4. Radiator support upper side member

5. Head lamp support panel

6. Head lamp support gusset

7. Front shipping hook bracket

8. Radiator support lower inner member

9. Radiator support lower outer member

10. Dash panel

11. Dash panel reinforcement

12. Dash lower member

13. 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 shock absorber housing panel

18. Front shock absorber housing upper panel

19. Fender apron inner front panel

20. Front side inner member

21. Front side member inner gusset

22. Engine mounting reinforcement

23. Transmission mounting reinforcement

24. Front side outer member

25. Front side rear lower member

26. Front side rear upper member

27. Front side member rear lower extension

28. Front side member lower reinforcement

29. Center floor panel

30. Muffler hanger mounting bracket

31. Center floor reinforcement

32. Front seat cross member

33. Front seat cross No.2 member

34. Center floor side member

35. Center floor side member reinforcement

36. Side sili inner panel

37. Parking brake lever rear mounting reinforcement

38. Rear floor panel

39. Rear floor side panel

40. Rear floor center cross upper

41. Rear floor side member

42. Rear bumper mounting reinforcement

43. Rear floor side member center reinforcement

44. Side sill inner rear panel

45. Rear floor center cross member

46. Rear floor side member front reinforcement

47. Rear floor front extension

48. Rear floor front cross member

49. Jack up cross center member

50. Jack up cross rear member

BODY CONSTRUCTION - Body components

5 1 . Fender panel

52. Cowl side upper panel

53. Cowl inner lower panel

54. Cowl inner lower reinforcement

55. Cowl side upper inner panel

56. Hood hinge mounting reinforcement

57. Cowl top outer panel

58. Roof panel

59. Roof panel(sun roof)

60. Roof front lower

61. Roof rear upper rail

62. Tail gate hinge mounting reinforcement

63. Roof rear lower rail

64. Roof center rail

65. Roof center rail No.2

66. Sun roof ring reinforcement

67. Sun roof rear lower reinforcement

68. Back panel

69. Rear transverse member

70. Rear transverse side extension

7 1 . Front inner lower pillar

72. Front inner upper pillar

73. Center pillar inner panel

74. Front seat belt upper mounting bracket

75. Wheel housing inner panel

76. Wheel housing inner front extension

77. Rear spring housing cover

78. Wheel housing inner rear cover

79. Quarter inner panel

80. Quarter inner reinforcement

81. Quarter inner upper panel

82. Side outer panel

83. Side outer 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 panel

89. Hood outer panel

90. Hood inner rail

91. Door outer panel

92. Door belt outer rait

93. Door reinforcement beam

94. Door upper member

95. Door inner panel

96. Door belt inner rail

97. Tail gate outer panel

98. Tail gate inner panel

99. Tail gate side reinforcement

13

BODY CONSTRUCTION - 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

14

BODY CONSTRUCTION - Zinc-galvanized steel panels









9. Dash panel
















25. Side sill inner panel





30.

31.

32.

33.

34.

35.

36.

37.

48.

Rear floor side member center reinforcement

Side sill inner rear panel

Rear floor center cross member

Rear floor side member front reinforcement

Rear floor front cross member

Jack up cross center member

Jack up cross rear member

Fender panel






43. Back panel

44. Front inner lower pillar




Quarter inner panel






54. Hood inner rail





15

BODY CONSTRUCTION - High - strength steel panels

HIGH STRENGTH STEEL PANELS

Because High strength steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below

16







7. Engine mounting reinforcement

8. Transmission mounting reinforcement

9. Front side rear lower member

10. Front side rear upper member


12. Front side member lower reinforcement

13. Front seat cross member

14. Front seat cross No. 2 member





19. Rear floor side member center reinforcment



22. Fender panel

BODY CONSTRUCTION - High-strength steel panels



25. Roof front lower

26. Tail gate hinge mounting reinforcement

27. Roof rear lower rail

28. Roof center rail

29. Back panel


31. Front inner upper pillar

32. Center pillar inner panel


34. Front door striker reinforcement

35. Front door striker upper reinforcement


37. Door belt outer rail

38. Door upper member

39. Door belt inner rail


41. Tail gate side reinforcement

17

FRONT BODY

BODY CONSTRUCTION - Front body

No. PART NAME

Radiator support panel complete

Radiator support center complete member assembly

Fender apron panel assembly,

Front side member assembly,

Cowl side outer panel assembly

Cowl panel inner lower panel assembly

Dash panel cower side outer upper panel,

Cowl cross bar assembly

LH/RH

LH/RH

LH/RH

18

CON-0090

BODY CONSTRUCTION - Front body <Radiator support paneS>

1. RADIATOR SUPPORT PANEL

No.

1

2

3

4

5

6

7

8

9

10

11

PART NAME

Radiator support upper center member

Radiator support center member

Radiator upper mounting bracket

Radiator support upper side member

Head lamp support panel

Head lamp support gusset

Radiator lower mounting bracket

Front shipping hook bracket

Radiator support lower inner member

Radiator lower mounting reinforcement

Radiator support lower outer member

19

CON-0110

BODY CONSTRUCTION-Front body <Radiator support panel>

<Cross-Sectior»a! Views>

CON-0120

Front bumper mounting reinforcement Radiator support lower^ outer member

/T

Front bumper stay

Front side member inner front extension

Front side member inner gusset



SECTION A-A"

Radiator support center member

CON-0130

Antinoise pad

I

SECTION B-B

1 m

CON-0140



/ *


\

SECTION D-D' SECTION C-C

CON-0150 CON-0160

20

BODY CONSTRUCTION - Front body <Fender apron panel>

2. FENDER APRON PANEL

No.

1

2

7

8

9

10

3

4

5

6

PART NAME

Fender apron upper outer panel

Fender apron inner rear upper extension

Fender apron inner rear lower extension

Fender apron upper inner panel

Front shock absorber housing panel

Front shock absorber housing upper panel

Fender apron inner front panel

Engine stay mounting bracket

Fender mounting bracket

ABS module mounting bracket

21

CON-0170

BODY CONSTRUCTION - Front body <Fender apron panei>

<Cross-Sectional Views>

A'

B"

Shock absorber housing complete panel

Fender apron inner complete panel

SECTION A-A'


Front shock absorber housing panel

CON-0190

Fender apron inner complete panel

Front side member-

SECTION B-B'

CON-0200

22

BODY CONSTRUCTION - Front body <Front side member>

3. FRONT SIDE MEMBER

No.

10

11

12

13

6

7

8

9

1

2

3

4

5

PART NAME

Front side inner member

Front side member inner gusset

Subframe mounting front plate

Subframe mounting front support

Engine mounting reinforcement

Engine mounting front bracket

Engine mounting rear bracket

Transmission mounting reinforcement

Transmission mounting front bracket

Transmission mounting rear bracket

Front side outer member

Subframe mounting stud bolt

Brake hose mounting bracket

No.

14

15

16

17

18

19

20

21

22

23

24

25

26

CON-0210

PART NAME

Front side rear lower member

Front side rear upper member

Front side member rear lower extension

Front side member lower reinforcement

Front back beam mounting bracket

Subframe rear mounting bracket

Subframe rear mounting reinforcement

Subframe rear mounting support

Subframe front mounting bracket

Front side member inner front extension

Front side member outer front extension

Front tie down hook

Undercover mounting bracket

23

BODY CONSTRUCTION - Front body :<Rront side member, LH/RH>

<Cross-SectionaI Views>

Front side complete member

ABS module mounting bracket


SECTION A-A'

CON-0230

Fender apron complete panel r^m


CON-0220

SECTION B-B'

CON-0231

SECTION C-C

CON-0232

24

4. DASH PANEL

BODY CONSTRUCTION - Front body <Dash panel>

No. PART NAME

Dash panel

Dash panel reinforcement

Dash lower member

Clutch pedal mounting bracket(RHD ONLY)

Blower lower mounting bracket

Foot rest bracket

E.C.U. mounting bracket

25

CON-0260

BODY CONSTRUCTION - Front body <Dash panel>


CON-0270

— Cowl complete panel

Dash panel

Dash panel center antipad

Dash reinforcement

Dash lower member

SECTION A-A'

CON-0280

Dash panel

Dash panel center anti pad

Dash panel side deadening sheet

Dash reinforcement

SECTION B-B'

CON-290

Dash reinforcement

Dash panel rest bracket

Dash panel

SECTION D-D'

CON-0310

SECTION C-C

CON-0300

26

5. COWL PANEL

BODY CONSTRUCTION - Front body <CowI panel>

No.

7

8

9

10

1

2

3

4

5

6

PART NAME

Plenum chamber guide panel

Cowl inner lower panel

Cowl inner lower reinforcement

Wiper pivot side mounting bracket

Cowl inner lower center reinforcement

Cowl side upper inner panel

Hood hinge mounting reinforcement

Hood hinge mounting support

Side column upper support extension

Side column lower support extension

No,

11

12

13

14

15

16

PART NAME

Clutch pedal mounting bracket

Cowl top outer panel

Wiper mounting side reinforcement

Wiper motor mounting bracket

Wiper pivot center mounting bracket

Cowl side upper inner panel

27

BODY CONSTRUCTION - Front body <Cowl panel>


Cowl inner lower center reinforcement


Cowl inner lower panel Cowl top outer panel


SECTION A-A'

Side column support extension

CON-0340

Cow! inner lower reinforcement


SECTION C-C

CON-0360

28

Cowl inner lower pane!

Cowl inner lower reinforcement

SECTION B-B'

CON-0350


Wiper pivot side mounting bracket

SECTION D-D'

E.C.U. mounting upper bracket

CON-0370

SIDE BODY

BODY CONSTRUCTION - Side body

No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

PART NAME

Front inner lower pillar

Cowl center member mounting front bracket

Cowl center member mounting rear bracket

Cowl center member mounting bracket

Front inner upper pillar

Center pillar inner panel

Front seat belt upper mounting bracket

Seat belt upper mounting reinforcement

Side outer panel

Fender mounting bracket

Side outer reinforcement

Front pillar outer upper reinforcement

Front door hinge mounting lower reinforcement

Front pillar lower gusset

Front door lower hinge extension

Front door hinge mounting upper reinforcement

Front door checker reinforcement

CON-0380

No.

28

29

30

31

32

33

34

35

36

18

19

20

21

22

23

24

25

26

27

PART NAME

Front door upper hinge extension

Front door striker reinforcement

Front door striker upper reinforcement

Side outer rear upper feinforcement

Side outer rear filler

Side outer rear upper extension

Quarter outer front reinforcement

Quarter outer upper filler

Quarter outer lower reinforcement

Quarter outer upper reinforcement

Tail gate gas lift mounting bracket

Fuel filler housing mounting plate

Fuel filler housing catch mounting bracket

Rearcombi lamp housing panel

Connector mounting bracket

Rear bumper side mounting bracket

Rear bumper mounting bracket

Side outer rear extension

Tail gate guide bumper mounting bracket

29

BODY CONSTRUCTION - Side body <Front pil!ar>

1. FRONT PILLAR



Front pillar outer panel

Front door hinge mounting reinforcement

Front side outer panel


Front inner upper pillar

SECTION A-A'


CON-0390


Side sill in


Side inner complete fornt panel

SECTION B-B'

CON-0400

Side outer panel

Side inner compiete frant panel

SECTION C-C

CON-0410

Center floor panel Side outer reinforcement

SECTION D-D'

CON-0420

30

2, SIDE SILL


BODY CONSTRUCTION - Side body <Side sili>

A' B

1

Side inner complete front panel

SECTION A-A*

SIDE-2

Side outer panel

Side outer complete panel assembly

Side sill inner

Cente floor panel

>J

SECTION B-B'


CON-0420 CON-0470

31

BODY CONSTRUCTION - Side body <Quarter panel>

3. QUARTER PANEL

Ho.

11

12

13

14

15

16

1

2

3

4

5

6

7

8

9

10

17

PART NAME

Quarter panel

Wheel housing inner panel

Wheel housing inner front extension

Wheel housing inner rear extension

Rear seat back side bracket

Rear seat back upper bracket

Rear seat 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

Wheel housing inner upper rear reinforcment

Wheel housing inner upper gusset

Wheel housing inner front reinforcement

Luggage net mounting bracket

No.

18

19

20

21

22

32

PART NAME

Quarter inner panel

Quarter inner reinforcement

Quarter inner upper panel

Quarter antipad mounting bracket

Jack mounting bracket

CON-0540

BODY CONSTRUCTION - Side body <Quarter panel>

<Cross-SeetionaI Views>


Side outer panel Side outer panel

Front door striker reinforcement

Side outer reinfrocement

Center inner pillar

SECTION A-A'

Side sill inner

CON-0550

Center inner pillar

Center pillar inner panel

SECTION B-B'

Quarter outer panel

Quarter inner & wheel house complete panel

Center floor panel


SECTION C-C SECTION D-D

1

CON-0571

CON-0551

33

UNDER BODY

1. CENTER FLOOR

BODY CONSTRUCTION - Under body<Center f!oor>

No.

9

10

11

12

13

14

5

6

7

8

1

2

3

4

15

16

17

PART NAME

Center floor panel

Muffler hanger mounting bracket

Muffler hanger mounting bar

Center floor reinforcement

Center support mounting reinforcement

T.G.S. lever mounting reinforcement

Parking brake lever mounting reinforcement

Parking brake cable guide pipe

Parking brake cable mounting reinforcement

Front seat cross member

Front seat cross No. 2 member

Center floor side member

Center floor side member reinforcement

Side sill inner panel

Parking brake lever rear mounting reinforcement

Front seat mounting bracket

Wiring protector mounting bracket

34

CON-0590

BODY CONSTRUCTION - Under body<Rear floor & side member>

2. REAR FLOOR & SIDE MEMBER

35

B O D Y C O N S T R U C T I O N - U n d e r b o d y < R e a r floor & side m e m b e r >

2. REAR FLOOR & SIDE MEMBER

1. Rear floor panel

2. Spare tire mounting bracket


4. Rear floor center cross upper

5. Rear seat side mounting bracket

6. Rear seat isofix mounting bar

7. Rear seat mounting bracket

8. Rear seat belt center mounting bracket

9. Rear seat belt center mounting reinforcement

10. Rear seat center mounting bracket

11. Rear seat back side protector

12. Rear seat cushion protector

13. Floor to wheel housing inner reinforcement




17. Brake hose mounting front bracket

18. Side sill inner rear reinforcement


20. Rear seat belt mounting side bracket

21. Trailing arm mounting bracket

22. Rear floor center cross extension

23. Muffler hanger front pipe

24. Rear cross member mounting pipe


26. Fuel tank mounting rear bracket


28. Rear floor front extension


30. Rear floor front side extension

3 1 . Parking cable mounting center bracket

32. Fuel tank mounting front bracket

33. Center floor side member rear extension

34. Rear floor side member front extension

35. Rear tie down reinforcement


37. Canister mounting front bracket


39. Jack up cross rear extension

40. Canister mounting rear bracket

41. Rear towing hook bracket

42. Muffler hanger rear pipe

43. Rear towing hook

44. Parking cable mounting side bracket

45. Trailing arm mounting plate

46. Rear tie down support

36

BODY CONSTRUCTION - Under body < Rear floor>

1.REAR FLOOR

<Cross»sectional views>

O'

Rear floor panel

Rear floor complete member

SECTION A-A'

Rear floor center cross

Rear floor panel upper member

CON-0600

Rear floor pane!

RRF-1100


SECTION B-B'

Rear floor panel

CON-0610

Rear seat mounting bracket


SECTION C-C

CON-0620

37


SECTION D-D'

CON-0630

BODY CONSTRUCTION - Under body <Rear side member>

2. REAR SIDE MEMBER

A'

«• •« i

B !<•

=minrn wsh

Rear floor side member

Trailing arm mounting bracket r~


Rear floor center cross extension

CON-0640

Rear floor side memeber

Rear floor side memeber front reinforcement

SECTION A-A'

Rear floor side memeber center reinforcement

SECTION B-B'

CON-0660

CON-0650

38

REAR BODY

1. BACK PANEL

BODY CONSTRUCTION - Rear body <Back panel>

No. PART NAME

Back panel

Tail gate striker support

Rear transverse member

Rear transverse side extension

Trunk net rear mounting bracket

Rear transverse upper extension

License plate mounting bracket

Rear bumper upper side mounting bracket

39

CON-0690

BODY CONSTRUCTION - Rear body <Back panel>

<Cross-sectionaI views>

Back panel


Back panel

SECTION A-A'


CON-0710

Rear bumper side mounting bracket

Back panel

SECTION B-B'

CON-0700

Rear transverse upper extension

CON-0711

SECTION C-C

CON-0720

40

CON-0721

2. TAIL GATE

BODY CONSTRUCTION - Rear body<Tail gate>

No. PART NAME

Tail gate outer panel

Tail gate inner panel

Tail gate latch reinforcement

Tail gate high mounting stop lamp mounting bracket

Tail gate side reinforcement

Tail gate wiper motor mounting reinforcement

Tail gate inside handle housing bracket

41

TG-1090

BODY CONSTRUCTION - Rear body<TaiS gate>

TAIL GATE PANEL

<Cross-seeti©tiaI views>


TG-1100




SECTION A-A'


TG-1101

Mastic sealer


SECTION B-B'


TG-1102

Tail gate side reinforcement


Tail gate wiper motor mounting reinforcement

SECTION C-C

TG-1103

SECTION D-D' TG-1104

42

FENDER & HOOD

BODY CONSTRUCTION - Fender & Hood

Tn^rnniiiFmiTMiiiiiiiiiiiiiiiii iniiwiMniirirgTrriffrmmirff'" • • • isaaiaiiasSE^ls

No PART NAME

Hood panel assembly

Hood hinge assembly

Fender panel

43

CON-0730-2

ROOF

BODY CONSTRUCTION - Roof

No. PART NAME

1 Roof panel

2 Roof panel(sun roof)

3 Roof front lower

4 Over head console mounting bracket

5 Roof rear upper rail

6 Tail gate hinge mounting reinforcement

7 Roof rear lower rail

8 Roof center rail

9 Roof center rail No. 2

10 Sun roof ring reinforcement

11 Sun roof rear side reinforcement

12 Sun roof rear lower reinforcement

13 Sun roof side mounting bracket

44

CON-0740

DOOR

1. FRONT DOOR


BODY CONSTRUCTION - Door <Front door>

Door outer pane!

CON-0750

No solvent sealer Door inner panel Door outer panel

No solvent sealer

Door belt inner rai

Door upper member

SECTION A-A

1

CON-0760

Door outer panel

Door reinforcement beam

No solvent sealer

Door inner panel

Door regulator mounting lower reinforcement

Door inner pane

Door outer panel

No solvent sealer reinforcement beam assembly

SECTION B-B'

CON-0770

Door inner panel

SECTION C-C SECTION D-D' CON-0790

CON-0780

45

PARTS

is

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.

FRONT BODY

PART NAME

RADIATOR SUPPORT PANEL COMPLETE

RADIATOR SUPPORT CENTER COMPLETE MEMBER ASSEMBLY

FRONT SIDEMEMBER ASSEMBLY,

FENDER APRON PANEL ASSEMBLY,

COWL TOP OUTER PANEL ASSEMBLY

COWL INNER LOWER PANEL ASSEMBLY

COWL SIDE OUTER UPPER PANEL,

COWL CROSS BAR ASSEMBLY

LH/RH

LH/RH

LH/RH

48

SIDE BODY

REPLACEMENT PARTS - Side body

I I I M I I I I W B I M M I ^ ^ iiliiiiiiiiiHiiHiiHI

PART NAME

FRONT INNER PILLAR ASSEMBBLY, LH/RH

CENTER INNER PILLAR ASSEMBLY, LH/RH

STDE OUTER REINFORCEMENT ASSEMBLY, LH/RH

PILLAR OUTER PANER ASSEMBLY, LH/RH

SIDE SILL OUTER PANEL, LH/RH

QUARTER INNER PANEL ASSEMBLY, LH/RH

REAR COMBI LAMP HOUSING PANEL ASSEMBLY, LH/RH

SIDE OUTER REAR EXTENSION ASSEMBLY, LH/RH

QUARTER OUTER PANEL ASSEMBLY, LH/RH

49

CON-0381

REAR BODY

REPLACEMENT PARTS - Rear body

PART NAME

REAR FLOOR PANEL

REAR FLOOR 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 FLOOR SIDE PANEL, RH

REAR SEAT MOUNTING BRACKET ASSEMBLY, LH

REAR FLOOR SIDE PANEL, LH

REAR FLOOR CROSSEMBER ASSEMBLY

SPARE TIRE MOUNTING BRACKET ASSEMBLY

BACK PANEL ASSEMBLY

50

CON-0860

DOOR

REPLACEMENT PARTS - Door

CON-0870-1

PART NAME

DOOR PANEL ASSEMBLY, LH/RH

DOOR OUTER PANEL, LH/RH

DOOR UPPER HINGE ASSEMBLY, LH/RH

DOOR LOWER HINGE ASSEMBLY, LH/RH

51

CON-0750-1

worn

GENERAL

'.;;~.':;:;,:"T™n

G E N E R A L

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.

M E A S U R E M E N T M E T H O D

PROJECTED DIMENSIONS

1. These are the dimensions measured when the measurement points are projected into the reference plane, and are the reference dimensions used for body alterations.

2. If the 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 two surfaces.

ACTUAL-MEASUREMENT DIMENSIONS

1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement.

2. Measure by first adjusting both probes to the same length

(A=A').

NOTE

Check the probes and gauge itself to make sure there is no free play.

MEASUREMENT POINT

1. Measurements should be taken at the hole center.

L] V S .

if \ i \

y^ v__ J) 1 X r

~\

N s

^——'

\

J

^ 1 1

DIM0020

Hole center

mS^M-inzznznzn

A

DIM0030

54

UPPER BODY

BODY DIMENSIONS - Upper body

These dimensions indicated in this figure are actual-measurement dimensions. j Point symbol

1 Length (mm)

Point symbol

Length (mm)

Point symbol

Length (mm)

A-A'

1304

F-G'

1380

K-H

1489

A'-D

954

G-G

1

1032

K-H'

1503

B-B'

1372

G-H

915

L-E'

1490

B-D

785

H-G'

1376

C-C

998

H-H*

1032

D-L

944

H-J'

1663

E-E

1

1498

i-r

1084

F-F'

1305

J-J'

1184

55

A

/ 0

[a

1° IS / /

I (f AR /

1 ° \ / /

i N

fel

Fender mounting hole (08)

BODY DIMENSIONS - Upper body

B

I ^--.r^^N

0

rOr^/

^S-//

/ \ /

/ 9 / /

/a / /

/ ° A / /

/ y ° /

1

//

°

UPPER-B J

Fender mounting hole (06.6) Front suspension mouning hoie(011)

E

\ \

5

^C^pl

Tooling hole(015)

\ L V UPPER-E |

Cowl top cover mounting hole

(07)

Front edge of side outer panel

Corner of side outer panel

Rear edge of side outer panel

Tail gate striker mounting hole

(014)

Hood hinge mounting hole

(013)

I' k^

\\i feK

Pt^&

0

W W

UPPER4

Rear seat belt reel mounting hole(012)

I L v JlycY^>/

\° \T j/'ff

l O l j M

^s^l XJ X j \ k \ \ V /UPPER-L

Member side mounting hole

(06)

56

SIDE BODY

BODY DIMENSIONS - Side body

• H H H H H B I

* These dimensions indicated in this figure are actual-measurement dimensions.

SIDE-2

* These dimensions indicated in this figure are projected dimensions.

Point symbol

Length (mm)

Point symbol

Length (mm)

Point s y m b o l

Length (mm)

Point s y m b o l

Length (mm)

A-B

805

C-F

1494

J-Z

635

J-L

455

A-C

872

C-G

1763

K-Z

68

K-L

223

B-C

372

D-E

726

M-Z

67

L-M

1325

B-E

1220

E-F

586

N-Z

772

L-N

2074

B-F

1340

E-G

662

O-Z

127

L-0

2950

B-G

1646

F-G

338

P-Z

238

L-P

2666

C-D

1218

H-Z

142

H-L

1159

C-E

1224 l-Z

229

I-L

850

SIDE-1

57

BODY DIMENSIONS - Side body

LAJ

?

I M P I M

SIDE-A J

Tooling & hood cable passage hole(015)

Door hinge mounting hoie(013) Door hinge mounting hole

(013)

Retainer mounting hole

( • 6.7x6.7)

G

Hi f!

[I. ^J ^ r r ^ S ^

\i\

\

V

SIDE-G |

Fixed glass mounting hole

( 9 x 7 slot)

J

< S T ^ l l

0 J

2S;

H\ fvT—*—1—l

1 ® ^ l / /

O 1

V\ \ ^ _ l o |

• P P

MP *-

" / SIDE-J |

Front suspension passage hole

(051)

Door switch mounting hole

(09)

SIDE-E

Fixed glass mounting hlole

( 9 x 7 slot)

11

€S-

/ * / ^

S

^ s \

' I

0

// I

! Jv v ' /^0/J

///°/l s^/

^^

%

\/° 1'Js^

/0 /{[ \

UNDER-C J

Tooling ho!e(025) Front tie down hook mounting hole(012)

I L

^vv

Y—\\\

I N / / ° V'

I P?v ° \ o /

V7§// j%Q ypy\

I <P~--P\ /

^ S ^

\1T,

^p-3j

p>^?

UNDER-F

Tooling hole (028) Sub-frame mounting hole

(020)

58

BODY DIMENSIONS - Side body

Trailing arm mounting hole

(013)

Rear suspension passage hole

(034)

X \

\ UNDER-K

Rear cross member mounting hole(014)

Bumper stay mounting hole

(013)

59

INTERIOR

BODY DIMENSIONS -Interior

INTER

These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol

Length (mm)

Point symbol

Length (mm)

A-A'

1480

i-r

1021

B-B'

1348 l-J'

1063

C-C

1164

J-J'

1013

D-D'

1387

E-E'

1122

F-F'

1507

G-G'

1153

H-H'

1053

60

B O D Y D I M E N S I O N S - Interior

Front door checker mounting hole(011)

Floor wiring mounting hole

( 7 x 1 2 slot)

Seat mounting hole(011

Seat belt reel mounting hole

(012.2)

Front seat belt mounting hole

(015)

Rear seat belt side lower mounting hole(015.7)

IH

Vs^ffr)°°

SIR

\ \ %

INT-H

Rear suspension mounting hole

( 0 9)

Door striker mounting hole

(013)

Sun roof side bracket mounting hole(06.6)

Sun roof side bracket mounting hole(06.6)

61

UNDER BODY

BODY DIMENSIONS - Under body


UND-ASSY

* These dimensions indicated in this figure are projected dimensions.

Point symbol

Length ( m m )

Point symbol

Length ( m m )

Point symbol

Length ( m m )

A-A'

960

A-Z

102

B-E

850

B-B'

960

B-Z

229 c-e

455

C-C

1136

C-Z

635

D-E

223

D-D'

560

D-Z

68

E-P

1325

E-E'

754

F-Z

67

E-G

2074

F-F

1192

G-Z

772

E-H

2666

G-G'

1136

H-Z

238

H-H'

970

A-E

1078

62

A

' ' / //

/ ° / A\.

* ( o //> ) y "

0 /ff (

UNDER-B

Sub-frame mounting hoie(024)

BODY DIMENSIONS - Under body

|B

fo>

/['/ ' \ ° // 1

• ^ / O L J A

\ J / < /fjy^

1 y\ /

Tooling hoie(025)

UNDER-C |

Front suspension passage hole

(0102)

ID

/ \

0

| fr\)Y\ i\\\g/

7*- / D

—Â / " &v

UNDER-E

Sub-frame mounting hole(02O)

<=;

E

Tooling hole(028)

2M

UNDER-F j


(013)

Rear suspension passage hole(034)


(013)

63

UNDER BODY


ACT-ASSY


Point symbol

Length (mm)

Point symbol

Length (mm)

Point symbol

Length (mm)

Point symbol

Length (mm)

A-D

957

E-E'

580

i-r

1192

M-l'

1731

B-B'

960

E-F'

707

I-J'

1175

M-K

1153

B-C

994

F-F'

754

J-J'

1126

N-K

656

C-C

960

F-G'

866

J-K'

1170

C-D'

1046

G-G'

754

K-K'

959

D-D'

956

G-l-T

1012

K-L

1

995

D-B

1

1165

H-H'

754

L-L

1

961

D-E'

817

H-r

1002

M-M'

970

64

A

if

te^

: w = \

/ ^

^Jêô

UNDER-A |

Air dam mounting ho!e(06)


B

/ H / ^ * ^ ? l t i / /jr

/ o / / \

1 s (

UNDER-B J

Sub-frame mounting hole(024)

0 o \ ^ \

%J^

/ *f / ^^^?l

Jv

/ o / jf\<

' } ° / / )J

> s sl/^ /

^k/^

/o/ij

UNDER-C J

Tooling hole(025)

E

//rim t

YA) \Y\

\\^C

\v/-

^ f S * .

* \ V o o

1'——^? D

^/J^sr^

r

V

. — i

UNDER-E

Sub-frame mounting hole(02O) Tooling hole(028) Tooling hole(015)

Tooling hole(015)


(013)

Tooling & paint drain hole(027) Tooling hole(025)

Rear cross momber mounting hole(014)

65

I L

^ \ \ < &

J>\G

V I

r—)-~-V^

~ ^

Tooling hole(013)

I

UNDER-L

|M

A U

\

^ ^ ^ ^ \ ^^^Jj^fea^jV i "*~**^

0

/ nh

/ j

HI

ff

^

UNDEB-M |


(013)


Tooling & paint drain hole(02O)

66

BODY DIMENSIONS - Engine compartment

ENGINE COMPARTMENT

ENGINE


1 Point symbol

Length (mm)

Point symbol

Length (mm)

A-A'

1070

F-H'

1213

B-B'

980

G-G

1

1498

C-C

778

H-H'

1305

D-D'

1310

H-D'

1593

D-E'

1377

D-F

1269

E-E'

1372

F-F'

998

67

BODY DIMENSIONS - Engine compartment

|B W I

/O^

^

(2k \ . / v^C^-—

T^m

\y\/X^^ ><

\ o S J

\ \ o NT 1 TV

Passage bumper stay hole

(016)

|D

/of \ 1

/° l"""/ r

1° 1/ 1

1° rf As

J

^niw

>

s

>^=^%

=

=

=

^^

£

^

: f

wT^.

Fender mounting hole(08)

Tooling hole(08)

ENG-B J

Front bumper mounting hole

(012)

|E ^ r î ° r ^ /

\ / v

/ ° 7

> 7

/o I /

°° A /

/ y o

[A

UPPER-B I

Fender mounting hole(06.6)

IF

Aj

I / / \ ® /

1 / / ° ^s/

B o I 6 ^ ^

0

or>

UPPER-C

Front suspension mounting hole(011)

Tooling hole(015) Hood hinge mounting hole

(013)

68

BODY DIMENSIONS - Luggage compartment

LUGGAGE COMPARTMENT

LUGG


Point symbol

Length (mm)

Point symbol

Length (mm)

A-A

1

1128

F-F'

625

B-B'

1390

F-G

1410

C-C

1176

G-F'

1421

D-D'

1179

G-E'

1273

D-E'

1456

G-D'

668

E-E'

1119

69

A

JAX lv n V

^ ^ - ^ C ^

o

1

^ ^ = ^ @

L^L

I

REAR-A

Cover mounting hole

(•8.5x8.5)

BODY DIMENSIONS - Luggage compartment

Combi lamp mounting hole

(08)

Rear combi lamp mounting hole(08)

D

^y^

(3

REAR-D

Tail gate guide bumper mounting hole(09)

Tail gate lift mounting hole

(012.5)

Tail gate hinge mounting hole

(014)

Tail gate striker mounting hole

(014)

70

REPAIR

m A

BODY PANEL REPAIR PROCEDUER - Radiator support panel

RADIATOR SUPPORT PANEL

WELDLING POINTS

PRO-0020

MIG plug welding

PRO-0320

72

PRO-0040

BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly)

FENDER APRON AND FRONT SIDE MEMBER (ASSEMBLY)

WELDLING POINTS

A ^

PRO-0050

• MIG plug welding

PRO-0060

PRO0070

# MIG plug welding jJU- MIG butt welding xx MIG lap welding

PRO-0071

73

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.

REMOVAL

1. Drill out ail the spotwelds to separate radiator support panel from front side member.

NOTE

When spotwelded portions are not apparent, remove paint with a rotary wire brush.

2. Remove the radiator support panel.

• \^MI?~ „ ——-"

— "31 » r^S

PRO-0110

3. Drill out all the spotwelds attaching the cowl side upper outer panel.

NOTE

If it is possible that the cowl side upper outer panel is reusable, be careful not to damage it while removing.

74


4. Using a spotweld cutter, drill out all the spotwelds attaching the fender apron to the dash panel and front side member.

5. 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, removethe front side member by drilling out the spotwelds.

PRO-0160

7. 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.

75


8. Using a hammer and dolly, correct any flanges that become bent or deformed when spotwelds are broken.

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.

3. Temporarily install new parts in place.

4. Measure each measurement point (Refer to the BODY DIMEN

SIONS) and corrcet the installation position.

76

PRO-0200

PRO-0210

BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly)

5. MIG plug weld all holes

" " " " " C - - ^ ^ I ^ ^ ^ ^ ^ " ^ X ^ iPJ^^^hi^^N*^ vC_o, * — J - J

H = " \ v v x / 1 r

PRO-0220

6. Clean MIG 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.

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.

77

BODY PANEL REPAIR PROCEDURE - Fender apron and front side member (Assembly)

8. Install the cowl side upper outer panel in place.

9. MIG plug weld all holes.

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

11. Apply the two part epoxy primer to the interior of the each panel.

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. Apply conversion coating and water rinse.

16. Apply the two-part epoxy primer.

17. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATION).

18. Reprime over the seam sealer to complete the repair.

19. After completing body repairs, carefully apply under coating to the front sidemember and fender apron (Refer to the CORRO-

SION PROTECTION).

20. In order to improve corrosion resistance, if necessary, apply an under body anti-corrosion agent to the panel which is repaired or replaced (Refer to the CORROSION PROTECTION).

78

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

FRONT SIDE MEMBER (PARTIAL)

WELDLING POINTS

L/H

60mm

PRO-0310

© MIG plug welding fflf MIG butt welding

R/H

PRO-0300

60mm


|f}f MIG butt welding

PRO-0320

79

77mm

PRO-0330

BODY PANEL REPAIR PROCEDURE - F r o n t 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 outlines on front side member outer and inner from rear edge of front side member gusset.

PRO-0300 PRO-0310

2. Drill out all the spotwelds to separate radiator support panel from front side member.

NOTE

1. When spotweSded portions are not apparent, remove paint with a rotary wire brush.

In order to perform cutting and separation of spotwelded 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.

^p^^-Ôr

3^85

""\^v^r4J/

\ * •» V f

PRO-0370

80

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

3. Cut through the front side member inner and outer at outlines.

NOTE

Take care not to cut through front side member inner reinforcement.

4. Prepare all surfaces to be welded.

INSTALLATION

1. 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.

2. Drill 8mm holes in new front side member for MIG plug welding.

3. Fit and clamp the front side member inner and outer in place.

4. MIG plug weld all holes and MIG butt weld all seams.

7 / \ r^

7^4

—c~L^-^7

^-^dk i q

°

° o

1 | 0

\ °

1 ^ M«_

PRO-0390

PRO0400

5. Measure each measurement point (Refer to the BODY DIMEN-

SIONS) and correct the installation position.

PRO-0410

81

BODY PANEL REPAIR PROCEDURE - Front side member (Partial)

6. Fit and clamp the radiator support panel in place.



9. Apply the two-part epoxy primer to the interior of the front side member.

10. Apply an anti-corrosion agent as required


11. Prepare the exterior surfaces for priming using wax and grease remover.




OJ

PffSI foe: vf\


(Refer to the BODY SEALING LOCATIONS).


PRO-0430

82

FRONT PILLAR

WELDLING POINTS

BODY PANEL REPAIR PROCEDURE - Front pillar

PRO-0460

$ MIG plug welding

| f MIG butt welding xx MIG lap welding

PRO-0450

83

B

PRO-0480

BODY PANEL REPAIR PROCEDURE - Front pillar

REMOVAL

1. Measure and mark the each outline on the front outer pillar, front outer upper pillar and front inner upper pillar from the windshild glass moulding mounting hole indicated in the illustration.

2. Measure and mark the outline on front side sill outer panel as shown in the illustration.

PRO-0490

3. Depending on the extent of damaged area, it may be possible to determine the cutting range within indicated in the illustration.

4. To remove the front pillar, grind away and drill out all welds attaching the cowl side upper outer panel as illustration.

NOTE if it is possible that the cowl side upper outer panel is reusable, be careful not to damage it while removing.

84

PRO-0510

PRO-0520

BODY PANEL REPAIR PROCEDURE - Front pillar

5. Drill out ail welds attaching the front pillar to dash, cowl top outer and cowl inner lower panel.

6. Remove spotwelds and lap welds attaching cowl crossmember bar mounting upper bracket to remove front pillar.

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.

9. Before cutting the front side sill outer panel, make a rough cut the front side sill outer panel only.

NOTE

When cutting the front side sill outer panel, he careful not to cut side sill outer front reinforcement.

Front pillar outer panel 11



Front pillar inner panel

PRO-0550

PRO-0560

85


10. Cut the side sill outer front reinforcement as illustration.

11. Cut the front side sill outer panel vertical cutiine and remove the front pillar.

12. Straighten all flanges as necessary, prepare all surfaces to be welded.

""^-^£5^^^.,

""o*]j. '•jj-^^*"^ feffl

T^XldS'^^

—f A\ lin) ° pu mm

¥""'

/^T\__

PRO-0580

INSTALLATION

1. Transcribe the cutiine to the new front inner upper pillar, cut to length and chamfer butt end to improve weld surface.

2. Transcribe the cutiine to the new front side sill outer panel and new front pillar, adding 30mm overlap to end and cut to length.

3. Drill 8mm holes along outer panel flanges in production location for attachment to other panels.

V » «, J V " " " " "

PRO-0600

86


4. Transcribe the cutline to the new side sill outer front reinforcement panel, adding 30mm overlap to end and cut to length.

5. Drill 8mm holes in the side sill outer front reinforcement for MIG plug welding.

6. Fit and clamp the new side sill outer front reinforcement panel in place for welding.

7. MIG plug weld all holes and MIG butt weld the seams.

8. Temporarily install front inner pillar and front side outer panel in place.

9. Measure and each measurement point (Refer to the BODY

DIMENSIONS) and correct the installation position.

10. If necessary, make temporary welds, and then check to confirm that the closing and fit for windshield glass, door and fender are correct.

11. MIG butt weld front outer pillar and front side outer panel seams.

12. Reattach the cut away front inner pillar section, then MIG butt weld.

^ ^ ^ ^ ^ ^ J $ \ ^ ^ J ^ - ^ t-H

\x^f\

In,'I

\s sZr Front outer / f

^y/sf pillar s e c t i o n ^ / / k^

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{((f^^^^r

\ A

PRO-0630

13. MIG plug weld all holes and MIG butt weld ail seams in the front side sill outer panel.


15. Apply body filler to joints and sand as needed.

16. Apply the two-part epoxy primer to the interior of the front pillar.

87


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.

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. ^ S S

^ ^

_ / / /

S2S3%

Pff

^4

^

â^

PRO-0660

19. Install the cowl side upper outer panel in place.



22. Apply an anti-corrosion agent to the welded parts and inside of front pillar (Refer to the CORROSION PROTECTION).

23. Prepare exterior surfaces for priming, using wax and grease remover.




Ml ^ o ,[) ///

^ S _ - ^ ^ ^ S » ^ ^

\V_J ^x>s\

iftfCC

PRO-0680 PRO-0690

88



(Refer to the BODY SEALING LOCATIONS).


89

BODY PANEL REPAIR PROCEDURE - Side sill (Assembly)

SIDE SILL (ASSEMBLY)

WELDLING POINTS

Jjl7°~ ~ ="

5

~~~ ~~^ °~ "


§ MIG butt welding

REMOVAL

1. Measure and mark vertical cutline from the rear door scuff trim mounting hole on the rear side sill outer panel.

PRO-0950

PRO-0960

2. At the front and side sill, measure and mark horizontal outlines from the door hinge mounting hole on the side outer panel as illustration.

PRO-0970

90

BODY PANEL REPAIR PROCEDURE - Side sill (Assembly)

3. Cut the side sill outer panel along outlines. 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 if the side outer reinforcement is damaged and needs to be replaced, measure outline on reinforcement as illustration.

7. Cut side outer reinforcement along the outline.

8. Drill out spotwelds attaching the side outer reinforcement to the body and remove side sill outer reinforcement.


INSTALLATION

1. Transcribe outline dimension to side outer reinforcement, adding 30mm overlap to rear end and cut to length.

2. Drill 8mm holes in overlap area on rear end and along front flange.

3. Fit and clamp the side outer reinforcement in place.

4. MiG plug weld all holes and MIG butt weld seams.

Before welding the side sill outer panel, apply the two-part epoxy primer and anti-corrosion agent to the welded parts.

NOTE

The reinforcement will be stronger if the weld traces are not ground.

91


6. Using service panel for replacement of side sill outer panel, drill

8mm holes in overlap areas and along upper and lower flanges.

7. Crimpflanges on the remaining portion of the side siil 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. Apply the two-part epoxy primer to the interior of the side sill.

V o Q O O O O p r f O O 0 O O P . _P Q U Q fl, fl, .0 9 _ f l

PRO-1050

13. Apply an anti-corrosion agent to welded parts and interior of the side sill (Refer to the CORROSION PROTECTION).

14. Prepare the exterior surfaces for priming, using wax and grease remover.




I \°°o i o a

Nsfl

l i

EE^S

PRO-1060

PRO-1180

18. Apply the correct seam sealer to all joints (Refer to the BODY

SEALING LOCATIONS).

19. Reprime over the seam sealer.

92


20. Appiy the anti-corrosion primer to the side sill outer pane! to complete the repair(Refertothe CORROSION PROTECTION).

93

BODY PANEL REPAIR PROCEDURE - Side sill (partial)

SIDE SILL (PARTIAL)

WELDLING POINTS

• MIG plug welding f-MIG butt welding

REMOVAL

1. Depending on the extent of damage, mark out the damaged portion of the side sill.

PRO-0955

150mm

2. Drill out the spotwelds in upper and lower flanges of side sill between outlines to remove side sill outer panel and cut the damaged portion of the side sill at the outlines.

PRO-0500 PRO-0960

94

BODY PANEL REPAIR PROCEDURE - Side sill (partial)

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 outlines and remove the damaged portion.

Prepare all surfaces to be welded.

INSTALLATION

1. Transcribe the cutline to the new side outer reinforcement, adding

30 mm overlap to each end and cut to length.

2. Drill 8 mm holes in overlap areas on each end and upper flange of new side outer reinforcement and clamp the new side outer reinforcement in place.

3. MIG plug weld all holes and MIG butt weld all seams.

NOTE

The reinforcement will be stronger if the weld traces are not ground.

4. Before welding the side sill outer panel, apply the two part epoxy primer and anti-corrosion agent to the welded parts.

Transcribe the side sill outer panel cutline to the new side sill, adding 30 mm overlap to each end, cut and chamfer butt end to improve weld surface.

Drill 8 mm holes in overlap areas on each end and along upper and lower flanges of the new side sill outer panel for MIG plug welding.

PRO-1040 o — - ' " Q "

a

° """""

PRO-1160

95

BODY PANEL REPAIR PROCEDURE - Side sill (partial)

7. Fit and clamp the side sill in place.

8. MIG plug weld all holes and MIG butt weld seams.


10. Apply body filler to the side sill outer seams.

11. Apply the two-part epoxy primer to the interior of the side si

12. Apply an anti-corrosion agent to the welded parts and interior of the side sill (Refer to the CORROSION PROTECTION).

13. Prepare the exterior surfaces for priming, using wax and grease remover.




17. Apply the anti-corrosion primer to the side sill outer panel to complete the repair (Referto the CORROSION PROTECTION).

PRO-1180

PRO-1190

96

QUARTER PANEL

BODY PANEL REPAIR PROCEDURE - Quarter panel

WELDLING POINTS

A

[ri

^'

PRO-1200

PRO-1201

m MIG plug welding fljf MIG butt welding xx MIG lap welding

97

PRO-1230

PRO-1203

BODY PANEL REPAIR PROCEDURE - Quarter pane!

REMOVAL

1. Depending on the extent of damage, measure and mark outlines on the quarter outer panel as illustration.

70mm

PRO-1250 PRO-1260

2. Drill out ail attaching welds on the quarter outer panel, including the seam around the door lip opening.

3. Cut the quarter outer panel at outlines and remove the quarter outer panel as illustration.

NOTE

When cutting the quarter outer panel, be careful not to cut quarter inner panel.


INSTALLATION

1. Transcribe the outline to the new quarter outer panel, adding 30 mm for overlap at the old joint.

2. Drill 8 mm holes in overlap areas and along upper and lower flanges of the new quarter outer panel for MIG plug welding.

3. Fit and clamp the quarter outer panel in place.

4. MIG plug weld all holes and MIG butt weld seams. At the wheel well the edge 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 applied to the joint before or after crimping.


98

PRO-1270

PRO-1300

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.

7.

8.

9.

10.

11.

Apply an anti-corrosion agent to the welded parts and interior of the quarter outer panel (Refer to the CORROSION PROTEC-

TION).

Prepare 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.

12. Apply the correct seam sealers to all joints.


14. In order to improve corrosion resistance, if necessary, apply an under body anti-corrosion agent to the wheel well (Refer to the

CORROSION PROTECTION).

99

REAR FLOOR

WELDLING POINTS

BODY PANEL REPAIR PROCEDURE - Rear floor

• MIG plug welding jflf MIG butt welding xx MIG lap welding

100

PRO-1521

BODY PANEL REPAIR PROCEDURE - Rear side member (assembly)

REAR SIDE MEMBER (ASSEMBLY)

WELDLING POINTS

PRO-1501


{fff MIG butt welding

101

PRO-1503

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.

Refer to the body dimension chart and measure the vehicle to determine straigthening and alignment requirements. The body must be returned to its original dimension before beginning the repair procedure.

R E M O V A L

2.

Drill out all the spotwelds attaching the rear floor pane! to the wheel housings and rear side members.

Make a rough cutting of the rear floor panel as shown in the figure.

3. Remove the rear floor panel (front section),

4. Remove the back panel by drilling out all attaching spotwelds.

102

BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly)

5. Remove the rear floor panel (rear section) and rear side member from the rear body.

INSTALLATION

1. Transcribe the outline to the new rear side members. Drill out the spotwelds attaching the inner reinforcements.

Remove remaining portions of side members.

!°: '• \<Lsy ^

T^r-^ -i-i/

-ê—~

PRO-1600

Temporarily fit and clamp the rear side members in place.

NOTE

When installing the rear floor side member, temporarily

install the back panel to measure each measurement point.

Measure each measurement point (Refer to BODY DIMEN-

SIONS) and correct the installation position.

If necessary, maketemporarity welds, andthenchecktoconfirm that the fit of rear floor panel is correct.

* 1 o' bft — ^- •£

IV&Hhil V U ^ ^ ^-vLJ-L/

JUL w

PRO-1610

103

BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly)

5. MIG plug weld the rear side members and MIG butt weld seams.

6. Prepare the welds and surfaces to which the rearfioor will attach.

7. Transcribe the outline to the new rear floor panel, adding 30mm for overlap at the old joint.

8. Drill 8mm holes in overlap area and production locations of the new rear floor panel for M!G plug welding.

9. Fit and clamp the rearfioor panel and attach the rearfioor panel to the rear side members and other panels.

10. MIG plug weld all holes and MIG butt weld the seams.

11. Clean all welded surfaces.

12. Drill 8 mm holes on the flange attaching the back panel to the rear floor and side member ends.

13. Fit and clamp the back panel in place.

14. MIG plug weld the back panel.

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

16. Apply the two-part epoxy primer to the interior of the rear side members.

PRO-1640

PRO-1650

104

BODY PANEL REPAIR PROCEDURE - Rear floor and rear side member (assembly)

17. Apply an anti-corrosion to the interior of the rear side members





21. Apply the correct seam sealer to all joints (Refer to the BODY

SEALING LOCATIONS).


23. After completing body repairs, carefully apply under coating to the under body (Refer to the CORROSION PROTECTION).

24. In order to improve corrosion resistance, if necessary, apply an under body anti-corrosion agent to the panel which is repaired or replaced (Refer to the CORROSION PROTECTION).

105

BODY PANEL REPAIR PROCEDURE - Rear side member (Partial)

m^

: mm^^^¥^ww^W);^ww^

REAR SIDE MEMBER (PARTIAL)

WELDLING POINTS

m MIG plug welding

HH-MIG butt welding

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. 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 both side members are damaged and need to be replaced, then the procedure of Rear Side members

And Rear Floor 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 before beginning the repair procedure.

106

PRO-1690

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 21 Omm 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. Cut through rear side member at outline being careful not to cut rear side member reinforcement.

3. Remove the rear floor side member by drilling out all attaching spotwelds.


INSTALLATION

1. Transcribe the cutline to the new rear side member. Cut at line and drill out the spotwelds attaching the inner reinforcement and separate it.

2. Fit and clamp the new rear side member in place for welding.

Measure to ensure dimensions are accurate as given in the body dimension charts.

3. 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 ail residue.

5. Apply the two-part epoxy primer to the interior of the rear side member.

107

BODY PANEL REPAIR PROCEDURE - Rear side member (Partial)

6. Apply an anti-corrosion to the interior of the rear side member






11. Apply the correct seam sealer to ail joints (Refer to the BODY

SEALING LOCATIONS).


13.

14.

After completing body repairs, carefully apply under coating to the under body (Refer to the CORROSION PROTECTION).

In order to improve corrosion resistance, if necessary, apply an under body anti-corrosion agent to the panel which is repaired or replaced (Refer to the CORROSION PROTECTION).

108

DOOR

WELDLING POINTS

BODY PANEL REPAIR PROCEDURE - Door

PRO-1800

>e«MIG lap welding

109

CON-0751

BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels

R E M O V A L

1. Cut door outer panel hem with a sander.

2. After grinding off the hemming location, remove the outer panel.

3. Dress rusty part with a sander and prepare surface to be hemmed.

I N S T A L L A T I O N

1. Apply adhesive or equivalent to outer panel hem.

2. Apply mastic sealer or equivalent to the door upper member and door reinforcement beam as shown in the figure.

W 'J

110

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Y@x

<£ ;)Vv

^ ^ M E §

=jD

PRO-1800

BODY PANEL REPAIR PROCEDURE - Door

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.

4. After completing the hemming work, make MIG spot welds at 50 mm intervals on the inside.


6. Apply the two-part epoxy primer to the interior of the door panel.

111

BODY PANEL REPAIR PROCEDURE - Door

7. Apply an anti-corrosion agent to the welded parts and lower inside of the door panel (Refer to the CORROSION PROTEC-

TION).





12. Apply the correct seam sealer to whole panel edge.


112

BODY SEALING

LOCATIONS

FLOOR

BODY SEALING LOCATIONS - Floor

Sealer

Center floor reinforcemet

SEA-0010

Rear floor front extension Rear floor panel

Parking cable mounting bracket

11

Dash lower member

Center floor panel

SECTION A-A'


Rear floor panel

SEA-0011

12 i t

Center floor panel

Rear floor front cross member


SECTION B-B'

SEA-0012

Back panel

Rear floor panel

Rear floor side member front extension

Rear floor side extension

SECTION C-C'

SEA-0013

114

SECTION D-D

1

SEA-0014

FLOOR

BODY SEALING LOCATIONS - Floor

^ 1 4

^•15

SEA-0010

SEA-0030

115

SEA-0040

BODY SEALING LOCATIONS - Floor

0050

SEA-0060

,-0080

12

SEA-0100

116

SEA-0051

0070

SEA-0090

SEA-0110

BODY SEALING LOCATIONS - Floor

117

BODY SEALING LOCATIONS • Upper and side body

UPPER AND SIDE BODY

SEA-0200

118

4" 16

SEA-0160, SEA-0170

9

BODY SEALING LOCATIONS - Upper and side body

L U T J R

8

SEA-0260

10

SEA-0280

119

SEA-0250

SEA-0270

SEA-0290

11

BODY SEALING LOCATIONS - Upper and side body

,-,!

i „ W -

SEA-0300

14

SEA-0310

SEA-0070

15

SEA-0110

16

SEA-0130

SEA-0120

17

SEA-0140

120

CORROSION

PROTECTION

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.

122

GK-0050

CORROSION PROTECTION - Zinc-galvanized steel panels









9. Dash panel




























37. Fender panel






43. Back panel





48. Quarter inner panel






54. Hood inner rail





123

CORROSION PROTECTION - Zinc-phosphate coat & cationic eletrodeposition primer

i^^^^^sm^mmammammmmmmmmmasmmmm i • iiiiiiiiiiii • mmmummmmmmmammHmmmmmmmmm^Mmmt

ZINC-PHOSPHATE COAT & CATIONIC ELECTR0DEP0S1T10N 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

COR-0020

124

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.

Door inner panel

SECTION A-A'

Rock panel primer (Thickness 180 ~ 200^n)

125

Door outer panel

COR-0030

Side outer panel

COR-0040

CORROSION PROTECTION - Antivibration pads

ANTIVIBRATION PADS-LOCATION & SECTION

84151-2D000



84113/23-2 D000

Support mounting bracket

ANT-1100


Center floor panel

84110/30-2C000

Center floor panel

SECTION A-A'


ANT-1101

84151-2D000


ANT-1102

SECTION B-B'

84149-2C000 Spare tire mounting bracket

Center floor panel

SECTION C-C

ANT-1103

Rear floor panel

SECTION D-D'

126

ANT-1104

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). For detailed information concerning the location where antivibration pads are to be attached for individual models, refer to the figure below.

84123-2D000 84125-2C000

84126-2C000 84171-2C000

84159-2C000

84113-2D000 -2C000

84116-2C000

84157-2C000

2C000 \ 84149-2C000

84171-2C000

ANT-1100

1. Heat the "antivibration pad" with a blow drier to soften it.

2. Align the antivibration pad layer in the position where it is to be installed, and then press it down with a roller or a block of wood so that it adheres well.

NOTE

An infrared lamp can also be used to heat both the antivibration pad layer and the body panels(be sure to wear gloves).

127

CORROSION PROTECTSON - Under body coat

UNDER BODY COAT

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

* 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 - 2,0 mm)

Dash panel

Subframe mounting rear bracket

-Dash lower member

Center floor panel



Side outer panel jf 80 Masking £

SECTION A-A'

£- *30 Masking

COR-0060

Rear floor center cross member

Rear floor panel

Center floor panel


55mm

Rear floor panel-

SECTION B-B'

COR-0070

Rear floor side member j* 40 Masking

Rear floor side member-

Jack up cross center member

Rear towing hook bracket assembly


SECTION C-C

COR-0080

SECTION D-D'

COR-0050

COR-0090

128

SIDE BODY

CORROSION PROTECTION - Under body coat

COR-0100

-k 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 - 2.0 mm)

Rear floor panel

Shock absorber housing upper panel

Shock absorber housing panel

Front side inner member



Fender panel


Rear floor side member front extension


• 40x60 Masking

SECTION A-A'

COR-0110

SECTION B-B"

COR-0120

Rear spring house cover

Rear floor panel — b s u 1

Quarter inner reinforcement

Quarter outer panel

Wheel house inner panel

SECTION C-C'

90x90 Masking

(LH side only)

COR-0130

Wheel house inner panel(LH)

Wheel house inner pad cover

Side outer panel

Quarter inner panel

Wheel house inner panel(RH)

SECTION D-D'

COR-0140

129

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.

COR-0030

I Cavity wax injection (Thickness 40 u\ - 50 $)

130

ACT-ASSY

G

CORROSION PROTECTION - Cavity wax injection

B

COR-0160

PRO-0480

COR-0190

PRO-1800

COR-0200 COR-0210

COR-0230

COR-0220

131


132

Q


R

T

U

COR-0360

V

COR-0370

133

CORROSION PROTECTION - Under body anti-corrosion agent

UNDER BODY ANTI-CORROSION AGENT

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.

I Under body anti-corrosion agent (Thickness 2.0mm)

134

COR-0050

No results