Manual de Chapisteria Del Hyundai Accent 2006

INTRODUCTION
This Body Repair Manual provides detailed repair procedures for repair of commonly dam-
aged structural panels on the Hyundai 2006 ACCENT(MC). To aid in the information of the
damaged vehicle, body construction, replacement parts, body dimensions, body sealing
locations, corrosion protection, body modification tools, plastic parts and body repair proce-
dures 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 ACCENT body shells and that
is currently available in most auto body repair shops.
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 ACCENT, refer
to the ACCENT 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.
July 2005, Printed in Korea
All rights reserved. No part of this publication may be reproduced, stored in any
retrieval system or transmitted in any form or by any means without the prior
written permission of Hyundai Motor Company.
CONTENTS
GENERAL INFORMATION
GENERAL GUIDELINES AND PRECAUTIONS ..................................................................................... GI-2
SRS AIR-BAG ....................................................................................................................................... GI-3
ELECTRONIC PARTS ........................................................................................................................... GI-4
CORROSION PROTECTION AND SEALING ........................................................................................ GI-4
SIDE BODY PANELS ............................................................................................................................ GI-4
WELDING .............................................................................................................................................. GI-5
BODY CONSTRUCTION
BODY COMPONENTS ........................................................................................................................ BC-2
ZINC-GALVANIZED STEEL PANELS ................................................................................................. BC-4
HIGH-STRENGTH STEEL PANELS .................................................................................................... BC-6
FRONT BODY ..................................................................................................................................... BC-8
SIDE BODY ........................................................................................................................................ BC-17
FLOOR ............................................................................................................................................... BC-20
REAR BODY ...................................................................................................................................... BC-22
FENDER & HOOD .............................................................................................................................. BC-26
ROOF ................................................................................................................................................. BC-27
DOOR ................................................................................................................................................. BC-28
TRUNK LID ......................................................................................................................................... BC-30 GI
REPLACEMENT PARTS
FRONT BODY ..................................................................................................................................... RP-2 BC
SIDE BODY ......................................................................................................................................... RP-2
CENTER FLOOR PANEL ASSEMBLY ................................................................................................ RP-2
REAR FLOOR PANEL ASSEMBLY ..................................................................................................... RP-2 RP
DOOR .................................................................................................................................................. RP-2
BODY DIMENSIONS
BD
GENERAL ........................................................................................................................................... BD-2
MEASUREMENT METHOD ................................................................................................................. BD-2 BP
FRONT BODY ..................................................................................................................................... BD-4
SIDE BODY ......................................................................................................................................... BD-6
INTERIOR A ........................................................................................................................................ BD-8 BS
INTERIOR B ....................................................................................................................................... BD-10
INTERIOR C ....................................................................................................................................... BD-12
REAR BODY ...................................................................................................................................... BD-14 CP
UNDER BODY .................................................................................................................................... BD-16
BODY PANEL REPAIR PROCEDURE BT

FENDER APRON PANEL(PARTIAL) ................................................................................................... BP-2
FENDER APRON PANEL AND FRONT SIDE MEMBER(PARTIAL) .................................................... BP-3
FRONT SIDE MEMBER(PARTIAL) ..................................................................................................... BP-9 PP
FRONT PILLAR .................................................................................................................................. BP-13
CENTER PILLAR ................................................................................................................................ BP-19
SIDE SILL(ASSEMBLY) ..................................................................................................................... BP-24
SIDE SILL(PARTIAL) .......................................................................................................................... BP-27
QUARTER PANEL .............................................................................................................................. BP-30
REAR FLOOR SIDE MEMBER(PARTIAL) .......................................................................................... BP-33
FRONT AND REAR DOOR OUTER PANELS ..................................................................................... BP-36
BODY SEALING LOCATION

FLOOR ................................................................................................................................................ BS-2
UPPER AND SIDE BODY ................................................................................................................... BS-4
UNDER BODY ..................................................................................................................................... BS-7
CORROSION PROTECTION
ZINC-GALVANIZED STEEL PANELS ................................................................................................. CP-2
ZINC-PHOSPHATE COATNIC ELECTRODEPOSITION PRIMER ....................................................... CP-4
ANTIVIBRATION PADS-LOCATION & SECTION ............................................................................... CP-5
ATTACHMENT OF ANTIVIBRATION PADS ....................................................................................... CP-7
UNDER BODY COAT .......................................................................................................................... CP-8
SIDE BODY ......................................................................................................................................... CP-9
CAVITY WAX INJECTION .................................................................................................................. CP-11
UNDER BODY ANTI-CORROSION AGENT ........................................................................................ CP-14
BODY MODIFICATION TOOLS

MODIFICATION TOOLS ....................................................................................................................... BT-2
CUT AND DISASSEMBLY TOOLS ....................................................................................................... BT-3
ASSEMBLY TOOLS ............................................................................................................................. BT-4
WELDING MACHINE ............................................................................................................................ BT-5
BUFFING AND GRINDING TOOLS ...................................................................................................... BT-6
HANDHELD TOOLS ............................................................................................................................. BT-8
PLASTIC PARTS
POLYPROPYLENE(PP) BUMPER REPAIRABILITY ........................................................................... PP-2
BUMPER REPAIR PROCEDURE ........................................................................................................ PP-2
REPAIR METHOD FOR PP BUMPER ................................................................................................. PP-3
GENERAL
INFORMATION
GI
BC
RP
BD
BP
BS
CP
BT
PP
GI-2 GENERAL INFORMATION
GENERAL GUIDE LINES AND PRECAUTIONS

The Hyundai ACCENT 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 ACCENT 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 ACCENT 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 follow.
BMCGI6010
GENERAL INFORMATION GI-3
SRS AIR-BAG
SYSTEM COMPONENT
Clock spring
Front impact sensor PAB
Side impact sensor

Buckle pretentioner
BPT When it is deployed
ERKB012A
The Hyundai ACCENT is equipped with a Supplemental Restraint System AIR-BAG to provide the vehicle's driver and/or the
front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal impact of
sufficient severity.
When handling airbag components (removal, installation or inspection, etc.), 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 air-bag connectors under the steering column near the MULTI-FUNCTION
SWITCH and the passenger's side crash pad before starting work.
3. Store the air-bag modules where the ambient temperature remains below 93 C(200 F), without high humidity and away
from electrical noise.
4. WARNING/CAUTION labels are attached to the periphery of the air-bag components.
Refer to the ACCENT SHOP MANUAL
GI-4 GENERAL INFORMATION
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.
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).
NOTE
If it is possible the ambient temperatures may reach 80 C(176 F) or more, remove the CONTROL MODULES from the
vehicle before starting work.
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 in
followed by an application of an oil or wax based 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 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 ACCENT is designed and stamped from a 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
TG-0008
GENERAL INFORMATION GI-5
WELDING
All repairs in this manual require the use of a Metal-Inert Gas (MIG) welder, Gas (oxyacetylene) welding must not be used.
Both high strength steel and mild steel can be welded using the MIG welder. The I-CAR recommendations for welding should
be followed. The shielding gas should be 75% Argon and 25% CO2.
The recommended welding wire size is 0.23" and the wire should satisfy the American Welding Society standard code
AWSER70S-6.
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) sheetmetal.
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 takes place along the circumference of the circle.
Weld around
edges first
working in to
wards the
center
(Top wiew)
PLUG WELDING
8mm or 5/16" dia. hole
Illustration-Welding in collision repair
CON-0040
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.
BODY
CONSTRUCTION
GI
BC
RP
BD
BP
BS
CP
BT
PP
BC-2 BODY CONSTRUCTION
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.
118
117
80
116
97
114
115
113
96
112
98
111
79
95
94
45
78
93
77
44
92
76
106
43
46
110
91
108
42
109
74
75
107
104
105
73
41
40
71
38
39
102
72
103
70
89
69
31
101
36
68
86
87
37
100
67
33
90
88
99
29
32
30
65
64
66
28
82
84
35
85
34
26
16
83
27
62
15
63
25
61
14
81
12
60
7
13
59
24
56
11
23
53 54
55
6
58
51
52
5
50
22
57
9
1
10
4
49
20
21
48
3
47
19
2
18
17
BMCBC6001
BODY CONSTRUCTION BC-3
1. Roof panel 60. Center member rear bracket

2. Roof front rail assembly 61. Front side rear lower extension
3. Sunroof rear lower reinforcement 62. Front side rear upper member
4. Roof center No.1 rail 63. Front side rear lower reinforcement
5. Roof rear rail 64. Front side rear upper member
6. Roof rear rail 65. Center floor side reinforcement, LH/RH
7. Sunroof reinforcement ring 66. Side sill inner bracket assembly
8. Fender panel 67. Center floor front reinforcement assembly
9. Front outer lower pillar, LH/RH 68. Center floor tunnel brace assembly
10. Front door upper mounting bracket, LH/RH 69. Front seat cross member assembly
11, Roof side outer reinforcement, LH/RH 70. Center floor side member, LH/RH
12. Side outer panel, LH/RH 71. Center floor rear reinforcement assembly
13. Side sill outer reinforcement, LH/RH 72. Side sill inner rear panel, LH/RH
14. Side outer rear upper extension 73. Rear floor side rear member assembly, LH/RH
15. Rear combination lamp housing panel, LH/RH 74. Rear floor side reinforcement assembly, LH/RH
16. Fuel filler housing 75. Rear floor side extension assembly, LH/RH
17. Cowl top outer panel 76. Spring seat bracket assembly, LH/RH
18. Cowl top front pillar gusset, LH/RH 77. Rear floor side front member assembly, LH/RH
19. Brake tube mounting bracket 78. Rear seatbelt center mounting reinforcement assembly
20. Fender apron upper reinforcement 79. Back panel assembly
21. Cowl inner lower panel 80. Rear transverse member assembly
22. Cowl side outer member 81. Hood outer panel
23. Side inner panel assembly LH/RH 82. Hood inner panel
24. Front seatbelt upper mounting bracket assembly, LH/RH 83. Dash lower member
25. Center outer pillar, LH/RH 84. Dust cover panel
26. Center pillar outer reinforcement, LH/RH 85. Dash panel
27. Rear door lower mounting bracket, LH/RH 86. Dash cross member
28. Quarter inner reinforcement, LH/RH 87. Dash cross side member
29. Quarter inner upper panel assembly, LH/RH 88. Dash lower center reinforcement
30. Quarter inner panel assembly, LH/RH 89. Dash panel reinforcement
31. Package tray side rear panel assembly, LH/RH 90. Dash cross center member
32. Rear spring house reinforcement assembly, LH/RH 91. Center floor panel assembly
33. Rear suspesion mounting bracket assembly, LH/RH 92. Rear floor front cross member assembly
34. Rear back lower bracket assembly, LH/RH 93. Rear floor front extension assembly
35. Wheel house inner front extension, LH/RH 94. Rear floor front panel assembly
36. Wheel house inner panel assembly, LH/RH 95. Rear floor center cross member assembly
37. Package tray side extension, LH/RH 96. Rear floor rear panel assembly
38. Package tray side inner extension, LH/RH 97. Rear towing hook reinforcement
39. Package tray side front panel assembly, LH/RH 98. Rear towing hook bracket
40. Trunk lid hinge mounting reinforcement assembly, LH/RH 99. Front door quadrant reinforcement, LH/RH
41. Package tray front lower member 100. Front door upper frame, LH/RH
42. Package tray center panel 101. Front door rear inner frame, LH/RH
43. Rear window opening outer frame 102. Front door belt inner rail, LH/RH
44. Trunk lid inner panel 103. Front door quadrant channel, LH/RH
45. Trunk lid outer panel 104. Front door rear outer frame, LH/RH
46. Package tray center rear reinforcement 105. Front door latch reinforcement, LH/RH
47. Front end module assembly 106. Front door inner panel, LH/RH
48. Fender and bumper mounting bracket 107. Front door reinforcement beam assembly, LH/RH
49. Transaxle mounting side bracket 108. Front door belt outer rail, LH/RH
50. Battery tray leg bracket 109. Front door outer panel, LH/RH
51. Fender apron inner front panel 110. Front door member, LH/RH
52. Engine mounting reinforcement 111. Rear door inner panel, LH/RH
53. Engine mounting front bracket 112. Rear door reinforcement beam assembly, LH/RH
54. Engine mounting rear bracket 113. Rear door belt outer rail, LH/RH
55. Carrier mounting bracket 114. Rear door outer panel, LH/RH
56. Fender apron inner panel 115. Rear door front outer frame, LH/RH
57. Fender apron upper member 116. Rear door front inner frame, LH/RH
58. Front absorber cover panel 117. Rear door upper frame, LH/RH
59. Battery tray leg reinforcement 118. Rear door latch Reinforcement, LH/RH
ZINC-GALVANIZED STEEL PANELS

Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency
below.
97
114
96
98
111
79
95
94
45
93
77
44
92
76
106
43
91
109
74
75
73
71
72
70
36
68
33
32
30
64
66
82
84
85
26
16
83
27
62
15
63
25
61
14
81
12
60
59
56
23
53 54
55
58
51
52
50
57
9
1
10
49
21
48
47
19
8
18
17
BMCBC6002

HIGH STRENGTH STEEL PANELS

Because high strength steel panel has excellent resistance, it is used in areas which have a high posibility of painting
deficiency below.
80
114
113
96
98
79
95
94
45
78
93
77
76
43
46
91
108
42
109
74
75
73
41
40
71
38
39
102
72
70
89
69
31
86
87
37
67
33
90
88
29
32
65
64
66
28
35
34
26
83
27
62
63
25
61
81
60
7
13
59
24
11
23
53 54
55
6
58
51
52
5
50
22
57
9
10
4
49
20
21
48
3
18
17
BMCBC6003

FRONT BODY
1
4
BMCBC6004
No. PART NAME
1 Front side member assembly LH/RH

2 Fender apron panel assembly LH/RH
3 Cowl panel assembly
4 Dash panel complete assembly
1. FRONT SIDE MEMBER
14 18
4 19
4 20
3
13
9 2
12
21
6
8 23
7
22
1
15
16
11 24
10
25
17
BMCBC6005
No. PART NAME No. PART NAME
1 Front side inner member 14 Side sill inner front extension

2 Front side member inner front reinforcement 15 Hook tie down reinforcement
3 Engine mounting front support 16 Front sub frame mounting front support
4 Engine mounting rear support 17 Front side member outer front extension
5 Engine mounting reinforcement 18 Front side outer extension
6 Front end module mounting reinforcement 19 Front tie down reinforcement
7 Front end module mounting bracket 20 Front side rear upper member
8 Sub frame mounting center support 21 Front side rear upper reinforcement
9 Sub frame mounting center reinforcement 22 Front side rear upper extension
10 Transmission mounting reinforcement 23 Sub frame mounting rear bracket
11 Transmission mounting rear support 24 Sub frame mounting rear reinforcement
12 Fender apron front lower reinforcement 25 Front side member rear lower member
13 Front side outer member
< Cross-Sectional Views >
B'
A'
A B
BMCBC6006
Fender apron
upper member
Fender apron
inner panel
Fender apron
upper reinforcement
Front side
memeber assembly
A - A' BMCBC6007 B - B' BMCBC6008

2. FENDER APRON PANEL
8
3
6
5
BMCBC6009
No. PART NAME
1 Fender apron upper reinforcement LH/RH

2 Fender and bumper mounting bracket assembly LH/RH
3 Fedner apron inner front panel LH/RH
4 Transaxle side mounting bracket assembly LH/RH
5 Front end module bracket assembly LH/RH
6 Fender apron upper member LH/RH
7 Shock absorber cover panel assembly LH/RH
8 Fender apron rear bracket LH/RH
9 Fender apron inner panel assembly LH/RH
B'
A'
BMCBC6010
Fender apron
upper member
Front shock absorber

cover panel assembly
Fender apron inner

front panel assembly
Fender
apron upper
reinforcement
Fender apron
upper reinforcement Fender apron
upper member
Fender apron
inner panel
Fender apron
inner panel

3. DASH PANEL
1
2
5
10
11
BMCBC6013
1 Dash panel assembly 7 Dash lower member assembly

2 Dash panel assembly reinforcement 8 Dash cross member assembly
3 Foot rest bracket 9 Accel pedal mounting assembly
4 Dash cross side member assembly 10 Dash cross center member assembly
5 Dash lower center reinforcement assembly 11 Dash panel pad
6 Dust cover panel
A'
B'
A B
BMCBC6014
Cowl panel
Cowl panel
Dash panel
assembly
Brake pedal
mounting
Dash lower center bracket assembly
reinforcement assembly
Dash cross
member assembly
Dash panel
Dash lower
member assembly

4. COWL PANEL
BMCBC6017
No. PART NAME
1 Cowl inner lower panel assembly

2 Cowl top panel
3 Cowl side panel
4 Cowl side upper reinforcement assembly
D' C' B' A'
D C B A
BMCBC6018
Hood Cowl top cover Cowl top

assembly outer panel
Cowl top
panel
Cowl inner
lower panel Dash
assembly isolation pad
Cowl inner
Dash insulator Dash panel
lower panel Pedal mounting
assembly
assembly bracket assembly
Cowl top Cowl inner lower

outer panel panel assembly
Cowl top
Fender mounting outer panel
Fender mounting
bracket assembly
bracket assembly
C - C' BMCBC6021 D - D' BMCBC6022

SIDE BODY
BMCRP6002
PART NAME
A Side inner panel assembly LH/RH

B Quarter panel assembly LH/RH
C Side outer panel LH/RH
D Side outer rear extension assembly LH/RH
E Rear combination lamp housing panel complete LH/RH
1. FRONT PILLAR
D
R
C D'
R'
L
C'
P
P'
H
B B' E E' G
G'
A A'
H'
F L'
N
F' N'
BMCBC6023
A B
Side outer panel Side outer panel
Side inner panel Side inner panel
C D
Side outer panel
Side outer
complete panel
Side inner
assembly
complete panel
assembly
Quarter inner
complete panel
assembly
Side inner panel

E F
Side outer panel
Side outer
panel
Side sill
inner panel
Side inner panel
E - E' BMCBC6028 F - F' BMCBC6029
G H
Side outer panel Wheel house
inner panel Side outer
panel
Quarter inner panel Quarter

inner panel
G - G' BMCBC6030 H - H' BMCBC6031
L N
Wheel house Quarter inner panel
inner panel
Fuel filler
housing asembly
Side
outer panel
Quarter Side outer panel

inner panel
L - L' BMCBC6032 N - N' BMCBC6033
P R
Side outer panel Side outer panel
Side inner
Side inner panel panel
P - P' BMCBC6034 R - R' BMCBC6035

CENTER FLOOR PANEL
BMCRP6003
PART NAME
A Center floor panel

B Side sill inner panel assembly LH/RH
C Center floor reinforcement assembly
D Front seat cross member assembly LH/RH
E Center pillar rear reinforcement assembly
REAR FLOOR & SIDE MEMBER
BMCRP6004
PART NAME
A Rear floor panel

B Rear floor front extension assembly
C Rear floor rear panel assembly
D Rear towing hook bracket assembly
E Rear floor front cross member
F Rear floor center cross member assembly
G Rear floor side member assembly LH/RH
1. REAR BODY
B B'
A A'
C C'
BMCBC6036
Rear floor complete

panel assembly Rear floor
Rear floor extension extension
panel assembly panel assembly
Rear under
floor complete
Rear under member assembly
floor complete
member assembly
Spare tire mounting bracket assembly Rear floor rear panel assembly
Rear towing hook bracket assembly
C - C' BMCBC6039
2. REAR FLOOR SIDE MEMBER
8
13
12
11
22 29 15
21 31
28 25 10
24 12
16
23 9 11
27 25
21
19 24
23
18 22
26
21
14 20
17 3
19 15
1 18
7
17
28 31
2
27
30
6
14
5 16
26
4
BMCBC6040
1 Rear floor front cross member 17 Trailing arm mounting bracket

2 Rear floor front cross filler 18 Rear suspension mounting reinforcement
3 Rear floor front cross center reinforcement 19 Rear suspension rear support
4 Deflector mounting bracket 20 Suspension mounting center bracket
5 Center floor side member rear extension 21 Rear suspension front upper reinforcement
6 Parking cable mounting bracket 22 LPI bombe mounting rear bracket
7 Fuel tank mounting front bracket 23 Rear suspension rear upper reinforcement
8 Rear floor center cross member 24 Rear bumper mounting bracket
9 LPI bombe mounting front bracket 25 Rear bumper mounting reinforcement
10 Fuel tank mounting rear bracket 26 Rear tie down reinforcement
11 Rear suspension spring mounting sheet 27 Child seat side mounting reinforcement
12 Rear floor center cross side reinforcement 28 Rear suspension spring sheet reinforcement
13 Rear floor center cross center reinforcement 29 Auto level sensor mounting bracket
14 Rear floor side front member 30 ABS wheel sensor mounting bracket
15 Rear floor side rear member 31 Brake hose rear bracket
16 Side sill inner rear panel
3. REAR PACKAGE TRAY PANEL
5
1
BMCBC6041
No. PART NAME
1 Rear package tray lower member

2 Rear package tray center panel
3 Rear package tray center rear reinforcement
4 Rear window opening outer frame
5 Rear seat belt center mounting reinforcement assembly

B'
B'
C' A'
C A
BMCBC6042
Rear package tray center Rear window opening

panel assembly outer frame
Rear window opening

outer frame
A - A' BMCBC6043
Rear package tray center Rear window opening

panel assembly outer frame Rear package tray center
panel assembly
C - C' BMCBC6044 B - B' BMCBC6045

FENDER & HOOD
BMCBC6046
No. PART NAME
1 Hood panel
2 Hood hinge assembly LH/RH
3 Fender panel LH/RH
ROOF
BMCBC6047
No. PART NAME
1 Roof panel
2 Sun roof reinforcement ring
3 Roof center rail
4 Roof center No.1 rail assembly
DOOR
1. FRONT DOOR
C
C'
B'
A'
D'
BMCBC6048
Front door outer panel

Front door frame
and inner rail
Front door
outer panel
Front door
Front door inner panel
Front door inner
reinforcement
panel Front door
beam assembly
belt outer rail
Front door frame

and inner rail
Front door
Front door inner panel
inner panel

2. REAR DOOR
C C'
B
B'
B
B'
D
D'
BMCBC6053
Rear door outer panel Rear door outer panel
Rear door belt outer rail
Rear door frame

and inner rail Rear door
inner panel
Rear door
reinforcement
Rear door inner panel beam
Rear door outer panel Rear door outer panel
Rear door
Rear door belt outer rail inner panel
Rear door
reinforcement
Rear door frame
beam
and inner rail Rear door inner panel

TRUNK LID
BMCBC6058
No. PART NAME
1 Trunk lid outer panel

2 Trunk lid inner panel
3 Trunk lid hinge assembly LH/RH
REPLACEMENT
PARTS
GI
BC
RP
BD
BP
BS
CP
BT
PP
RP-2 REPLACEMENT PARTS
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
A
D
BMCRP6001
PART NAME
A Front side member assembly LH/RH

B Fender apron panel assembly LH/RH
C Cowl panel assembly
D Dash panel complete assembly
REPLACEMENT PARTS RP-3
SIDE BODY
BMCRP6002
PART NAME
A Side inner panel assembly LH/RH

B Quarter panel assembly LH/RH
C Side outer panel LH/RH
D Side outer rear extension assembly LH/RH
E Rear combination lamp housing panel complete LH/RH
CENTER FLOOR PANEL ASSEMBLY
BMCRP6003
PART NAME
A Center floor panel

B Side sill inner panel assembly LH/RH
C Center floor reinforcement assembly
D Front seat cross member assembly LH/RH
E Center pillar rear reinforcement assembly
REPLACEMENT PARTS RP-5
REAR FLOOR PANEL ASSEMBLY
BMCRP6004
PART NAME
A Rear floor panel

B Rear floor front extension assembly
C Rear floor rear panel assembly
D Rear towing hook bracket assembly
E Rear floor front cross member
F Rear floor center cross member assembly
G Rear floor side member assembly LH/RH
DOOR
D
B
H
F
BMCRP6005
PART NAME
A Front door panel assembly LH/RH

B Front door outer panel LH/RH
C Front door upper hinge assembly LH/RH
D Front door lower hinge assembly LH/RH
E Rear door panel assembly LH/RH
F Rear door outer panel LH/RH
G Rear door upper hinge assembly LH/RH
H Rear door lower hinge assembly LH/RH
BODY
DIMENSIONS
GI
BC
RP
BD
BP
BS
CP
BT
PP
BD-2 BODY DIMENSIONS
GENERAL MEASUREMENT METHOD

1. Basically, all measurements in this manual are taken PROJECTED DIMENSIONS
with a tracking gauge.
1. These are the dimensions measured when the
2. When a measuring tape is used, check to be sure measurement points are projected into the reference
there is no elongation, twisting or bending. plane, and are the reference dimensions used for body
alterations.
3. For measuring dimensions, both projected dimension
and actual-measurement dimension are used in this 2. If the length of the tracking gauge probes are
manual. adjustable, make the measurement by lengthening one
probe by the amount equivalent to the difference in
height of the two surfaces.
Height
Projected Dimension
BMCBD6001
BODY DIMENSIONS BD-3
ACTUAL-MEASUREMENT DIMENSIONS MEASUREMENT POINT

1. These dimensions indicate the actual linear distance 1. Measurements should be taken at the hole center.
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')
CAUTION
Check the probes and gauge itself to make sure
there is no free play.
Hole Center
BMCBD6003
Ac
tu
al
ly-
M A'
ea
su
re
d
Di
m
en
sio
n
BMCBD6002
FRONT BODY
G G'
A F'
C
B
A'
C'
B'
D E'
D'
BMCBD6010
* These dimensions indicated in this figure are actual-measurement dimensions.
Point symbol A-A' A-B A-B' B-B' C-C' D-D' E-E' F-F'
Length(mm) 1431.0 500.9 1482.2 1360.0 999.7 918.0 947.8 1337.5
Point symbol F-G F-G' G-G'
Length(mm) 762.3 1285.0 800.4

A B C
C,C'
A,A' B,B'
BMCBD6011 BMCBD6012 BMCBD6013
Tooling hole (ø8) Fender mounting hole (ø11) Front suspension mounting
hole (ø9)
D D,D'
E E'
E
E'
Front end module guide mounting Transaxle bracket mounting hole Engine bracket mounting hole
hole (ø9) (ø12) (ø13)
F G G,G'
F,F'
BMCBD6017 BMCBD6018
Location notch Windshield glass stopper

mounting hole (9x17)
SIDE BODY
D
B F
A G
E
C
BMCBD6020
Point symbol A-B A-C A-D A-E B-C B-D B-E C-D
Length(mm) 684.5 738.2 1724.8 1720.5 345.1 1041.1 1068.6 1113.8

Point symbol C-E D-E D-F D-G E-F E-G
Length(mm) 1020.4 373.5 837.8 1607.7 871.9 1610.0

A A B C C
B
Wiring mounting slot Front door upper hinge mounting Front door lower hinge mounting
(7x12) hole (ø12) hole (ø12)
D E F
F
E
D
Rear door upper hinge mounting Rear door lower hinge mounting Rear door switch mounting hole
hole (ø12) hole (ø12) (ø18)
G
G
BMCBD6027
Rear bumper mounting hole

(6x8)
INTERIOR A
A' D' G'
D G
A
B'
B
E E'
H
H'
C J
F
C
J'
C'
F'
BMCBD6030
Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-H'
Length(mm) 1130.4 1289.2 1353.4 1078.2 1331.7 1372.1 1094.0 1360.0
Point symbol J-J'
Length(mm) 1370.0
A B C
C,C'
A,A' B,B'
Front pillar trim upper mounting Front pillar trim lower mounting Hood release handle mounting
hole (ø6.6) hole (ø8.5) hole (ø6.6)
D E F
D,D'
F,F'
E,E'
Center pillar upper trim upper Center pillar upper trim lower Center pillar lower trim mounting
mounting hole (ø9) mounting hole (ø8.5) hole (ø8.5)
G H J
H,H'
J,J'
G,G'
Tooling hole (ø7) Curtain airbag fixed hole (ø6.6) Tooling hole (ø12)
INTERIOR B
A' D'
G'
D G
A
B'
B
E'
H
H'
J
C
J'
C' K
F'
BMCBD6040
Point symbol K-A K-B K-C K-D K-E K-F K-G K-H
Length(mm) 1102.7 1064.3 887.0 1257.4 1044.3 745.9 1647.2 1578.6
Point symbol K-J
Length(mm) 1299.0
A B C
C,C'
A,A' B,B'
D E F
D,D'
F,F'
E,E'
G H J
H,H'
J,J'
G,G'
K K
BMCBD6041
Tooling hole (ø8)

INTERIOR C
D'
A' G'
D
G
A
B'
B E
E'
H
H'
C J
F
K J'
C'
F'
BMCBD6050
Point symbol K-A K-B K-C K-D K-E K-F K-G K-H
Length(mm) 1294.1 1481.7 1461.4 1066.6 868.1 832.0 1130.8 977.5
Point symbol K-J
Length(mm) 766.8
A B C
C,C'
A,A' B,B'
D E F
D,D'
F,F'
E,E'
G H J
H,H'
J,J'
G,G'
K
K
BMCBD6051
Floor wiring fixing hole (7x12)

REAR BODY
A' A
B' B
C' C
E' E
D' D
BMCBD6060
Point symbol A-A' A-B A-B' B-B' B-C B-C' C-C' C-D
Length(mm) 800.4 569.6 1052.4 978.4 466.8 1278.5 1447.9 388.4
Point symbol C-D' D-D' E-E'
Length(mm) 1306.1 1074.0 700.0

A A,A' B C
C,C'
BMCBD6061 B,B' BMCBD6062 BMCBD6063
Rear window glass stopper Rear window glass stopper Rear combination lamp mounting
mounting hole (9x17) mounting hole hole (10x13)
D E E,E'
D,D'
BMCBD6064 BMCBD6065
Rear bumper mounting hole Transverse trim mounting hole

(10x13) (ø8)
UNDER BODY ( PROJECTED DIMENSIONS )
E F
A G
B C D
B' D'
C'
A' G'
E' F'
AB C D E F G
BMCBD6070
* These dimensions indicated in this figure are projected dimensions.
Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-A
Length(mm) 953.0 950.0 990.0 768.7 1100.0 1070.0 976.0 188.0
Point symbol H-B H-C H-D H-E H-F H-G A-B B-C
Length(mm) 89.8 58.6 56.3 11.0 120.8 155.0 78.0 858.0
Point symbol C-D D-E E-F F-G
Length(mm) 841.0 691.0 533.3 578.7

A B C
B
Tooling hole (ø25) Side frame front mounting pipe Tooling hole (ø7)
nut (ø16)
D E F
E
D
F
Center side member hole (ø12) Tooling hole (ø11) Rear floor side member trailing
arm mounting hole (ø40)
BMCBD6077
Rear floor side rear member hole

(ø28)
UNDER BODY
E F
A B C G
D
D'
A' B' C' G'
E' F'
BMCBD6080
Point symbol A-A' A-B' B'-C B-D' C-D' C'-E C'-F D'-E
Length(mm) 953.0 975.6 1295.8 1904.5 1216.8 1855.8 2314.9 1164.1
Point symbol D-F' D'-G E-F' E'-G F'-G G-G'
Length(mm) 1541.3 2032.0 1214.0 1542.6 1185.8 976.0

A B C
B
Tooling hole (ø25) Side frame front mounting pipe Tooling hole (ø7)
nut (ø16)
D E F
E
D
F
Center side member hole (ø12) Tooling hole (ø11) Rear floor side member trailing
arm mounting hole (ø40)
BMCBD6077
Rear floor side rear member hole

(ø28)
BODY PANEL
REPAIR
PROCEDURE GI
BC
RP
BD
BP
BS
CP
BT
PP
BP-2 BODY PANEL REPAIR PROCEDURE
FENDER APRON PANEL (PARTIAL)
WELDING POINTS
LH
140mm
105mm
MIG plug welding

MIG butt welding
MIG lap welding
BMCBP6001
RH
140mm
110mm
MIG plug welding

MIG butt welding
MIG lap welding
BMCBP6002
BODY PANEL REPAIR PROCEDURE BP-3
PENDER APRON AND FRONT SIDE MEMBER (ASSEMBLY)
WELDING POINTS
MIG plug welding

BMCBP6003
B C
B D
D
MIG plug welding

MIG butt welding
MIG lap welding
BMCBP6004
NOTE
2. Remove CO2 weld points using a grinder and laser weld
points using a cut grinder.
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.
BMCBP6007
3. Drill out all the spotwelds and cut all laser welds
attaching the cowl side upper outer panel.
NOTE
BMCBP6005
If it is possible that the fender apron upper outer panel
is reusable, be careful not to damage it while removing.
REMOVAL
1. Drill out all the spotwelds and cut all laser welds to
separate cowl side upper outer panel from front pillar
outer lower reinforcement, shock absorber housing
gusset and fender apron upper outer panel.
NOTE
When spotwelded portions are not apparent, remove
paint with a rotary wire brush.
BMCBP6008
BMCBP6006
4. Using a spotweld cutter, drill out all the spotwelds 7. Grind and smooth any weld traces which might be left
attaching the fender apron to the dash panel, shock on the body surface by using an air grinder or similar
absorber housing gusset and front side member. tool, being careful not to damage any of the panels
which is not to be replaced.
5. Remove the fender apron panel.
BMCBP6012
BMCBP6009
8. Using a hammer and dolly, correct any flanges that
NOTE
become bent or deformed when spotwelds are broken.
If collision damage requires replacement of fender
apron and front side member together, remove both of
them at the same time.
BMCBP6013
BMCBP6010
6. Using a spotweld cutter, remove the front side member

by drilling out the spotwelds.
BMCBP6011
INSTALLATION 3. Temporarily install new parts in place.
1. Drill 8 mm holes in the new fender apron and front side 4. Measure each measurement point (Refer to the BODY
member for MIG plug welding. DIMENSIONS) and correct the installation position.
2. Remove paint from both sides of all portions that are

to be welded such as peripheries of MIG plug weld
holes.
BMCBP6005
5. MIG plug weld all holes

BMCBP6014
BMCBP6017
BMCBP6015
6. Clean MIG welds with a disc grinder.
BMCBP6018
NOTE
8. Install the cowl side upper outer panel in place.
1. Be careful not to grind welded portions too much.
9. MIG plug weld all holes.
2. The internal parts will be stronger if the weld traces
are not ground.
10. Clean and prepare all welds, and remove all residue.
11. Apply the two-part epoxy primer to the interior of the

each panel.
BMCBP6023
7. Before welding the cowl side upper outer panel, apply BMCBP6025
the two-part epoxy primer and anti-corrosion agent to
the interior of the cowl side upper outer 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.
BMCBP6024
BMCBP6026
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.
BMCBP6019
19. After completing body repairs, carefully apply under

coating to the front side member and fender apron
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).
BMCBP6020
FRONT SIDE MEMBER (PARTIAL)
WELDING POINTS
LH
30mm
190mm
MIG plug welding

MIG butt welding
BMCBP6021
RH
20mm
20mm
MIG plug welding

MIG butt welding
BMCBP6022
REMOVAL 2. In order to perform cutting and separation of spotwelded

points use a spot weld cutter which is larger than the
NOTE size of the nugget to make a hole only in the panels to
This procedure is to be used only for repair of minor damage be replaced.
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 side
member.
1. Measure and mark the vertical cut lines on front side

member inner tooling hole center.
BMCBP6029
3. Cut through the front side member inner and outer at

cut lines.
NOTE
Take care not to cut through front side member inner
reinforcement.
BMCBP6027
4. Prepare all surfaces to be welded.

2. Drill out all the spotwelds to separate front side member
outer front extension from front side member.
NOTE
1. When spotwelded portions are not apparent, remove
paint with a rotary wire brush.
BMCBP6030
BMCBP6028
INSTALLATION 5. Measure each measurement point (Refer to the BODY

DIMENSIONS) and correct the installation position.
1. Transcribe the front side member inner and outer cut
line 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.
BMCBP6005

front side member.
BMCBP6031
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.
BMCBP6034
BMCBP6032
8. Apply an anti-corrosion agent as required

9. Prepare the exterior surfaces for priming using wax

and grease remover.

(Refer to the BODY SEALING LOCATIONS).
BMCBP6035
FRONT PILLAR
WELDING POINTS
A 40mm
50mm
50mm
MIG plug welding

MIG butt welding
MIG lap welding
BMCBP6036
REMOVAL 4. To remove the front pillar, grind away and drill out all
welds and cut all laser welds attaching the cowl side
1. Measure and mark the each cut line on the front outer upper outer panel as shown in the illustration.
pillar at 50mm from the roof panel end line as indicated
in the illustration.
NOTE
If it is possible that the cowl side upper outer panel is
reusable, be careful not to damage it while removing.
40mm
50mm
50mm
BMCBP6037
2. Measure and mark the cut line on front side sill outer
panel as shown in the illustration. BMCBP6008
3. Depending on the extend of damaged area, it may be

5. Drill out all welds attaching the front pillar to cowl cross
possible to determine the cutting range within indicated
member bracket.
in the illustration.
6. Remove spotwelds attaching cowl cross member
bracket to remove side inner pillar.
200mm
50mm 50mm
BMCBP6038
BMCBP6040
7. Before cutting front pillar, be sure to support roof panel. 10. Cut the side outer reinforcement as shown in the
illustration.
11. Cut the side sill inner panel vertical cutting line and
remove the front pillar.
BMCBP6041
8. Cut the front pillar through each cut line, taking care
not to damage the other panel as illustration.
BMCBP6044
Roof side outer reinforcement

12. Straighten all flanges as necessary, prepare all
surfaces to be welded.
Front pillar
outer panel
Side inner panel
Front pillar outer lower

reinforcement
BMCBP6042
9. Before cutting the front side sill outer panel, make a

rough cut the side sill outer panel only.
BMCBP6045
NOTE
When cutting the front side sill outer panel, be careful
not to cut side outer reinforcement.
BMCBP6043
INSTALLATION 4. Transcribe the cutline to the new side inner panel, adding
30mm overlap to end and cut to length.
1. Transcribe the cut line to the new side inner panel, cut
to length and chamfer butt end to improve weld surface. 5. Drill 8mm holes in the side inner panel for MIG plug
welding.
6. Fit and clamp the new side inner panel in place for
welding.
7. MIG plug weld all holes and MIG butt weld the seams.
BMCBP6046
2. Transcribe the cut line to the new side outer

reinforcement and new front pillar, adding 30mm
overlap to end and cut to length.
3. Drill 8mm holes along outer panel flanges in production BMCBP6048

location for attachment to other panels.
8. Temporarily install front pillar 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.
BMCBP6047
BMCBP6049
11. MIG butt weld front pillar outer panel and side sill outer 17. Clean all welds with a disc grinder.
reinforcement seams.
NOTE
12. Reattach the cut away front pillar outer panel section,
1. Be careful not to grind welded portions too much.
then MIG butt weld.
2. The internal parts will be stronger if the weld traces
are not ground.
m
0m
10
Front pillar outer panel section

BMCBP6050
BMCBP6052
13. MIG plug weld all holes and MIG butt weld all seams
in the side outer panel.
18. Before welding the cowl side upper outer panel, apply
14. Clean and prepare all welds, remove all residue.
the two-part epoxy primer and anti-corrosion agent to
the interior of the cowl side upper outer panel.
15. Apply body filler to joints and sand as needed.

front pillar.
BMCBP6024
BMCBP6051
19. Install the cowl side upper outer panel in place. 27. Apply the correct seam sealer to all joints carefully
(Refer to the BODY SEALING LOCATIONS).
20. MIG plug weld all holes.
BMCBP6056
BMCBP6054
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.
BMCBP6055
CENTER PILLAR
WELDING POINTS
120mm
50mm
A 50mm
B C
B C
50mm 50mm
50mm 50mm
300mm 200mm
MIG plug welding

MIG butt welding
BMCBP6057
REMOVAL 4. Drill out all spotwelds and cut all laser welds attaching
the center outer pillar to the body to remove center
1. Measure and mark the horizontal cutting line on center outer pillar.
pillar outer panel as indicated in the illustration.
120mm
50mm
50mm
BMCBP6061
BMCBP6058
5. Cut through center outer pillar and side sill outer panel
2. Measure and mark the vertical cutline on side sill outer at cutlines.
panel 50mm from the front door step trim mounting
hole.
NOTE
When cutting side sill outer panel take care not to cut
through mating flanges or side outer reinforcement.
6. After cutting side outer panel (center pillar outer & side
sill), cut the center pillar outer reinforcement and center
pillar inner panel.
50mm 50mm 50mm 50mm
BMCBP6059
3. Before cutting center pillar, be sure to support roof

panel.
BMCBP6062
BMCBP6060
7. Remove the center pillar. 9. Straighten all flanges as necessary.
NOTE
When cutting center inner pillar, be careful not to cut
front seat belt mounting upper bracket.
BMCBP6068
BMCBP6064
8. Determine if the side outer reinforcement is damaged

and needs to be replaced. If replacing is necessary,
mark out the damaged portion of the reinforcement.
Cut at cutlines and remove damaged portion.
Center piller
outer panel
Side inner
panel Side inner panel
Side outer
reinforcement
BMCBP6066
INSTALLATION 5. MIG butt weld all seams in center inner pillar and sill
side outer reinforcement as shown in the illustration.
1. In order to install center inner pillar drill out all spotwelds
attaching the roof side outer rail to center inner pillar to
separate them.
BMCBP6071
6. Transcribe the cutting line dimensions to the new side

BMCBP6069 sill outer reinforcement, adding 30mm overlap to each
end and cut to length.
2. Transcribe the center outer pillar cutlines to the new
center outer pillar, adding 30mm overlap at center lower 7. Drill 8mm holes in overlap areas on each end of new
pillar ends. side sill outer reinforcement and clamp the new side
sill outer reinforcement in place.
3. Cut and chamfer butt end to improve weld surface.
8. MIG plug weld all holes and MIG butt weld seams.
4. Drill 8mm holes in overlap area and along outer panel
flanges.
NOTE
The reinforcement will be stronger if the weld traces
are not ground.
30mm
30mm
30mm
30mm
BMCBP6070
BMCBP6072
9. Temporarily install new center outer panel in place. 19. Prepare exterior surfaces for priming, using wax and
grease remover.
10. Screw center pillar in place.
11. Measure and each measurement point (Refer to the

BODY DIMENSIONS) and correct the installation
position.
BMCBP6075

BMCBP6073
12. Check the fit of the front and rear doors.
13. Reinstall center outer pillar and screw in place. (Refer to the BODY SEALING LOCATIONS).
14. MIG plug weld all holes and MIG butt weld all seams. 24. Reprime over the seam sealer to complete the repair.
16. Apply body filler to the outer center pillar seam. Sand
and finish.
BMCBP6076
BMCBP6074

center pillar.

interior of the center pillar (Refer to the CORROSION
PROTECTION).
BMCBP6077
SIDE SILL (ASSEMBLY)
WELDING POINTS
MIG plug welding

MIG butt welding
BMCBP6078
REMOVAL 2. At the front and center pillar, measure and mark

horizontal cutting lines from the door hinge mounting
1. Measure and mark vertical cutting line from the rear hole on the side sill outer panel as shown in the
door step trim mounting hole on the rear side sill outer illustration.
panel.
15mm 10mm
150mm
BMCBP6079 BMCBP6080
3. Cut the side sill outer panel along cutlines. Be careful INSTALLATION
not to cut mating flanges.
1. Transcribe cutline dimension to side sill outer panel,
4. Drill out all spotwelds, attaching the side sill outer panel adding 30mm overlap to rear end and cut to length.
to side sill outer reinforcement.
2. Drill 8mm holes in overlap area on rear end and along
5. Remove the side sill outer panel. front flange.
3. Fit and clamp the side sill outer reinforcement in place.
BMCBP6081
6. Determine if the side sill outer reinforcement is

damaged and needs to be replaced, and measure
cutting line on reinforcement as shown in the BMCBP6083
illustration.
5. Before welding the side sill outer panel, apply the two-
7. Cut side sill outer reinforcement along the cutting line. part epoxy primer and anti-corrosion agent to the
welded parts.
8. Drill out spotwelds attaching the side sill outer
reinforcement to the body and remove side sill outer NOTE
reinforcement.
are not ground.
BMCBP6084
BMCBP6082
6. Using service panel for replacement of side sill outer 13. Apply an anti-corrosion agent to welded parts and
panel, drill 8mm holes in overlap areas and along upper interior of the side sill (Refer to the CORROSION
and lower flanges. PROTECTION).
14. Prepare the exterior surfaces for priming, using wax

and grease remover.
BMCBP6085
7. Crimp flanges on the remaining portion of the side sill

outer panel at all joint for overlap.
8. Fit and clamp the side sill outer panel in place.
10. Clean and prepare all welds, and remove all residue. BMCBP6087
11. Apply body filler to the side sill outer seams. 18. Apply the correct seam sealer to all joints (Refer to
the BODY SEALING LOCATIONS).
side sill. 19. Reprime over the seam sealer.
BMCBP6086 BMCBP6088
SIDE SILL (PARTIAL)
WELDING POINTS
MIG plug welding

MIG butt welding
BMCBP6089
REMOVAL 2. Drill out the spotwelds in upper and lower flanges of

side sill between cutlines to remove side sill outer panel
1. Depending on the extent of damage, mark out the and cut the damaged portion of the side sill at the
damaged portion of the side sill. cutlines.
200mm
100mm
BMCBP6090 BMCBP6091
3. Determine if the side sill outer reinforcement is INSTALLATION

damaged and needs to be replaced. If replacing is
necessary, mark out the damaged portion of the side 1. Transcribe the cutting line to the new side sill outer
sill outer reinforcement. reinforcement, adding 30 mm overlap to each end and
Cut at cutting lines and remove the damaged portion. cut to length
4. Prepare all surfaces to be welded. 2. Drill 8 mm holes in overlap areas on each end and
upper flange of new side sill outer reinforcement and
clamp the new side sill outer reinforcement in place.
BMCBP6092
BMCBP6093
3. MIG plug weld all holes and MIG butt weld all seams.
NOTE
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.
BMCBP6094
5. Transcribe the side sill outer panel cutline to the new 12. Apply an anti-corrosion agent to the welded parts and
side sill, adding 30 mm overlap to each end, cut and interior of the side sill (Refer to the CORROSION
chamfer butt end to improve weld surface. PROTECTION).
6. Drill 8 mm holes in overlap areas on each end and 13. Prepare the exterior surfaces for priming, using wax
along upper and lower flanges of the new side sill outer and grease remover.
panel for MIG plug welding.
BMCBP6095
7. Fit and clamp the side sill in place.
BMCBP6097
10. Apply body filler to the side sill outer seams.

side sill.
BMCBP6096
QUARTER PANEL
WELDING POINTS
40mm
B
C D
C
200mm
MIG plug welding

MIG butt welding
BMCBP6098
REMOVAL INSTALLATION
1. Depending on the extent of damage, measure and mark 1. Transcribe the cutline to the new quarter outer panel,
cutlines on the quarter outer panel as indicated in the adding 30mm for overlap at the old joint.
illustration.
2. Drill 8 mm holes in overlap areas and along upper and
lower flanges of the new quarter outer panel for MIG
plug welding.
40mm
200mm
BMCBP6099
2. Drill out all attaching spotwelds and cut all laser welds
on the quarter outer panel, including the seam around BMCBP6101
the door lip opening.
3. Fit and clamp the quarter outer panel in place.
3. Cut the quarter outer panel at cutlines and remove the
quarter outer panel as illustration. 4. MIG plug weld all holes and MIG butt weld seams. At
the wheel well the edge must be crimped over the wheel
NOTE
housing.
This joint may be welded after crimping or applying a
When cutting the quarter outer panel, be careful not to
bead of adhesive which may be applied to the joint
cut side inner panel.
before or after crimping.
BMCBP6100
BMCBP6102
6. Apply body filler to the welded seam. Sand and finish. 12. Apply the correct seam sealers to all joints.
Apply the two-part epoxy primer to the interior of the
quarter outer panel. 13. Reprime over the seam sealer to complete the repair.
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).
BMCBP6103

interior of the quarter outer panel (Refer to the
CORROSION PROTECTION). BMCBP6105

grease remover.
BMCBP6104
REAR FLOOR SIDE MEMBER (PARTIAL)
WELDING POINTS
MIG plug welding

MIG butt welding
BMCBP6106
REMOVAL
NOTE
Because the rear floor 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 applies when only one rear floor side member needs to be replaced. If both side members are
damaged and need to be replaced, then the procedure of rear floor 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.
1. Depending on the extent of damage, if the right side INSTALLATION

member is to be replaced it should be measured and
marked 20mm from the rear floor side member tooling 1. Transcribe the cutline to the new rear floor side member.
hole center. Cut at line and drill out the spotwelds attaching the
reinforcement and separate it.
NOTE
The flowing procedure illustrates a repair for the right
rear floor side member. The procedure may also be
applied the left rear floor side member.
20mm
BMCBP6109
2. Fit and clamp the new rear floor side member in place
for welding.
BMCBP6107
Measure the dimensions to ensure they are accurate
as given in the body dimension charts.
2. Cut through rear floor side member at cutline being
3. MIG plug weld at the holes and MIG butt weld the
careful not to cut rear floor side member reinforcement.
seam in the side member.
3. Remove the rear floor side member by drilling out all
4. Clean and prepare all surfaces to be welded, and
attaching spotwelds.
remove all residue.
rear floor side member.
BMCBP6108
BMCBP6110
6. Apply an anti-corrosion to the interior of the rear floor 13. After completing body repairs, carefully apply under
side member coating to the under body (Refer to the CORROSION
(Refer to the CORROSION PROTECTION). PROTECTION).
7. Prepare exterior surfaces for priming, using wax and 14. In order to improve corrosion resistance, if necessary,
grease remover. apply an under body anti-corrosion agent to the panel
which is repaired or replaced (Refer to the CORROSION
8. Apply metal conditioner and water rinse. PROTECTION).
BMCBP6113
BMCBP6111
11. Apply the correct seam sealer to all joints (Refer to

the BODY SEALING LOCATIONS).
BMCBP6112
FRONT AND REAR DOOR OUTER PANELS
WELDING POINTS
FRONT DOOR
REAR DOOR
MIG plug welding

MIG lap welding
BMCBP6114
REMOVAL INSTALLATION
1. Cut door outer panel hem with a sander. 1. Apply adhesive or equivalent to outer panel hem.
2. After grinding off the hemming location, remove the 2. Apply mastic sealer or equivalent to the door upper
outer panel. member and door reinforcement beam as shown in
the figure.
BMCBP6115
BMCBP6117
3. Dress rusty part with a sander and prepare surface to
be hemmed.
BMCBP6118
BMCBP6116
3. Bend the flange hem with a hammer and dolly, then 4. After completing the hemming work, make MIG spot
fasten tightly with a hemming tool. welds at 50mm intervals on the inside.
NOTE 5. Clean and prepare all welds, and remove all residue.
1. Hemming work should be done in three steps as
illustration.
door panel.
2. If a hemming tool cannot be used, hem with a
hammer and dolly.
BMCBP6122
BMCBP6119
lower inside of the door panel (Refer to the
CORROSION PROTECTION).

grease remover.
BMCBP6120
BMCBP6123
BMCBP6121
12. Apply the correct seam sealer to whole panel edge.
BMCBP6124
BODY SEALING
LOCATIONS
GI
BC
RP
BD
BP
BS
CP
BT
PP
BS-2 BODY SEALING LOCATIONS
FLOOR
A D
F K
C H N
G M
B E
BMCBS6010
A B
BMCBS6011 BMCBS6012
C D
BMCBS6013 BMCBS6014
BODY SEALING LOCATIONS BS-3
E F
BMCBS6015 BMCBS6016
G H
BMCBS6017 BMCBS6018
K M
BMCBS6019 BMCBS6021
N P
BMCBS6022 BMCBS6023
UPPER AND SIDE BODY
E G
D
M
A
B
P
BMCBS6030A
BMCBS6030B
A B
BMCBS6031 BMCBS6032
C D
BMCBS6033 BMCBS6034
E F
BMCBS6035 BMCBS6036
G H
BMCBS6037 BMCBS6038
K M
BMCBS6039 BMCBS6041
N P
BMCBS6042 BMCBS6043
UNDER BODY
A B C D
BMCBS6050
A B
BMCBS6051 BMCBS6052
C D
BMCBS6053 BMCBS6054
CORROSION
PROTECTION
GI
BC
RP
BD
BP
BS
CP
BT
PP
CP-2 CORROSION PROTECTION
ZINC-GALVANIZED STEEL PANELS

Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency
below.
97
114
96
98
111
79
95
94
45
93
77
44
92
76
106
43
91
109
74
75
73
71
72
70
36
68
33
32
30
64
66
82
84
85
26
16
83
27
62
15
63
25
61
14
81
12
60
59
56
23
53 54
55
58
51
52
50
57
9
1
10
49
21
48
47
19
8
18
17
BMCBC6002
CORROSION PROTECTION CP-3

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
BMCCP6020
ANTIVIBRATION PADS-LOCATION & SECTION
84113-1G000 84115-1G000
A' B' E' H'
G'
D'
J J'
C C' F F'
C B
A G E H
D
84125-1G000 84151/61-1G000 84187-1G000
BMCCP6030
Side sill inner panel Side sill inner panel
Center floor Front side

Center floor
panel Front side rear upper member
panel
rear upper member
84137-1C000
84134-22000
Front side rear

lower member Center floor
side member
A - A' BMCCP6031 B - B' BMCCP6032
Dash panel
84115/25-1G000
84138-1G000
Center floor
84138-1G000 side member
Front seat rear
inner bracket
assembly Center floor
panel
Center member mounting

rear brackef
C - C' BMCCP6033 D - D' BMCCP6034

Side sill inner extention 84151/61-1G000

Rear floor Rear floor front
front extention panel assembly
Rear floor
front panel
assembly
rear side member
assembly
84151/61-1G000
Rear floor front
cross member
E - E' BMCCP6035 F - F' BMCCP6036
Rear floor side

Center floor member assembly
panel assembly
84136-2E000
84187-1G000
Rear floor rear

Center floor panel assembly
side member
G - G' BMCCP6037 H - H' BMCCP6038
Back panel
60400-1G294 assembly
84187-1G200
Rear floor rear

panel assembly
J - J' BMCCP6039
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).
84113-1G000 84115-1G000
A' B' E' H'
G'
D'
J J'
C C' F F'
C B
A G E H
D
84125-1G000 84151/61-1G000 84187-1G000
BMCCP6030A
1. Heat the "antivibration pad" with a blow drier to soften 2. Align the antivibration pad layer in the position where
it. 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).
BMCCP6041
BMCCP6042
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
B'
A A'
C C'
Because parts are to be mounted in these locations, mask the location, before applying
the under body coat.
Under body coating (Thickness : 0.8 mm , :1.0 mm , :2.0 mm )

BMCCP6050
Side outer panel

Dash panel
Center floor panel Front side rear

Side sill
inner panel lower member
Center member mountion Center floor

rear bracket panel
Rear transverse
Rear floor panel
Rear Towing hook bracket

C - C' BMCCP6053
SIDE BODY
A' E'
D'
B'
A Y D
Z W
B E

BMCCP6060
Front shock
absorber cover panel Fender apron
fender apron upper member Side sill panel Center floor panel
inner panel
Front side outer

member Cowl side outer
member
front side
inner member
Rear shock Side outer panel

absorber cover
Wheel house
Wheel house
inner panel
inner panel Side outer panel
Rear floor panel
Quarter inner panel

Rear floor Quarter inner panel
side member
C - C' BMCCP6063 D - D' BMCCP6064
Z BMCCP6065 W BMCCP6066
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.
B'
Y
X A'
Cavity wax injection (Thickness 40 - 50 )
BMCCP6070
Side sill Side sill outer

Side outer panel
inner panel reinforcement
Side inner Side outer panel

panel
50 mm
Quarter inner
lower panel
Center floor panel
Wax injection holes ( 13mm) Wax injection holes ( 13mm)
X BMCCP6073 Y BMCCP6074
Wax injection hole
Wax injection holes
300 mm
A A'
300 mm
Wax injection holes
Wax injection hole
B'
150 mm
150 mm
Wax injection must be done through access holess marked.

BMCCP6080
Hood outer panel
mm
50
30 mm
Hood inner panel

A' A1'
130 mm
130 mm
A A1
Wax injection holes
Wax injection must be done through access holess marked.

BMCCP6090
Door outer panel
Door inner panel

60 mm
A - A' / A1 - A1' BMCCP6091

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.
B'
A A'
C C'
BMCCP6050A
BODY
MODIFICATION
TOOLS GI
BC
RP
BD
BP
BS
CP
BT
PP
BT-2 BODY MODIFICATION TOOLS
BODY MODIFICATION TOOLS

MODIFICATION TOOLS
Name Used for Figure
A3EB3501
Frame straightener Modify twisted or bent body
A3EB3502
A3EB3503
Port power Push out, stretch, pull in damaged area
A3EB3504
Body puller Stretch damaged area
A3EB3505
BODY MODIFICATION TOOLS BT-3
CUT AND DISASSEMBLY TOOLS

Air saw Cut a panel
A3EB3506
Cut or bend a panel, cut and

Air chisel
disassemble spot welded area
A3EB3507
Rotary cutter Cut a panel
A3EB3508
Hand saw and

Cut a panel
metal scissors
A3EB3509
Fix a spot cutter or drill to cut or

Air drill disassembly spot welding area, to
finish a hole
A3EB3510
Spot cutter Cut and disassemble spot welded area
A3EB3511
ASSEMBLY TOOLS
Vice pliers Fix a panel or area to weld
A3EB3512
Finish contact area of flange and finish

Air bench
a hole for plug welding
A3EB3513
Quick bench Finish a hole for plug welding
A3EB3514
Flanging tool Finish contact area of flange
A3EB3515
MEASUREMENT TOOLS
Centering gauge Measure distortion of body and frame
A3EB3516
Tracking gauge Measure body and frame
A3EB3517
WELDING MACHINE
Gas welding machine Cut a panel
A3EB3518
Spot welding machine Weld a panel
A3EB3519
Carbon arc welding

Weld a panel
machine
A3EB3520
Stretch a panel, weld a stud bolt to fix

Stud welding machine
front window mold clip
A3EB3521
BUFFING AND GRINDING TOOLS

Disk grinder Buff
A3EB3522
Disk sander Buff
A3EB3523
Belt sander Buff paints
A3EB3524
Small sized grinder Buff paints or smooth finishing
A3EB3525
Grind rough area of puttee assembled

Double action sander
area
A3EB3526
Grind rough area of puttee assembled

Orbital sander(short)
area
A3EB3527
Orbital sander(long) Used for puttee grinding of wide area
A3EB3528
Grind touch up area, uneven area of a

Flexible file
panel
A3EB3529
Surform tool Buff rough area of puttee area
A3EB3506
A3EB3530
Hand file Grind body puttee, pulley, finish puttee
A3EB3531
HANDHELD TOOLS
Body hammer and dolly -
A3EB3532
Punch a hole in the middle of a spot

Center punch
welding area
A3EB3533
Plane chisel Cut and disassemble a panel
A3EB3534
Weight hammer Used when greater force is required
A3EB3535
Bowl pin hammer Used when smaller force is required
A3EB3536
Used for an area where not reached by

Spoon
hand
A3EB3537
Bend rough body line damaged or sheet

Body chisel
metal etc.
A3EB3538
Remove paints, rust, slag on welded

Wire brush
area which are hard to recognize
A3EB3539
REPAIR TOOLS SET

Window tool set Repair window collar
A3EB3540
Repair tool set for

Repair plastic parts
plastics
A3EB3541
PLASTIC PARTS
GI
BC
RP
BD
BP
BS
CP
BT
PP
PP-2 PLASTIC PARTS
POLYPROPYLENE(PP) BUMPER
REPAIRABILITY
The three types of damaged bumpers shown below can be
repaired. Because of cost and quality considerations,
bumpers with more damage may be repaired, but replacing
the bumper is encouraged.
1. If a hole on a bumper is less than 2 in.(50 mm).
A3EB3601
2. If a crack on a bumper is less than 4 in.(100 mm).
A3EB3602
3. If a crack on bumper sectionis [A] is less than 4 in.

(100 mm) (less than half of the bumper height).
Bumper height Crack on section [A]
A3EB3603
PLASTIC PARTS PP-3
BUMPER REPAIR PROCEDURE
Surface of Surface of Remove paint.

bumper is not bumper is
visible. visible.
Sand damaged area smooth.
Apply aluminum tape on the rear

side of bumper. Replace damaged bumper with a new
bumper.
Apply primer for polypropylene over
bumper surface.
Weld damaged area.
Sand damaged area with a rough sandpaper.
Clean and degrease damaged area(use TCE de-oil material).
Apply primer for polypropylene over damaged area.
Apply solvent over damaged area.
Spray primer surface over bumper and let dry.
Sand surface of bumper with sandpaper.
Clean and degrease with TCE de-oil material.
Wipe the surface of bumper with a tack cloth.
Paint bumper with a paint of the same color and let dry.
VQPP001
PP-4 PLASTIC PARTS
REPAIR METHOD FOR PP BUMPER

Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Use the repair methods
shown below to repair damage that reaches the surface of the polypropylene.
Hole Crack Scar
B C D
A
A' B' C' D'
Section B-B'
Section A-A' 1 Section D-D'
Section C-C'
2
3
1 Upper layer (coating) 2 Primer surface layer

3 Primer layer 4 Polypropylene layer
VQPP002
1. Rough cut the damaged area 45 using a knife and then sand the angle smooth.
A-A' Section D-D'

Cut with a knife. Section B-B' Cut with knife.
C-C'
Surface of polypropylene
Make an angle with a sander .

Make an angle with a sander
45
Angle of 45 is required for accumulation of polypropylene welding rod.
VQPP003
PLASTIC PARTS PP-5
2. Welding damaged area

a) To repair cracked area, melt the area using a heat gun and attachment.
Heat gun
Melt the surface using a heat gun.
Apply on surface
Surface of polypropylene Section view after melt
VQPP004
b) To repair a hole, remove oil from the damaged area and apply aluminum tape to the rear side of the damaged area.
Section A-A’
Remove oil.
Apply aluminum tape on the rear side of the damaged area.

VQPP005
3. Melt polypropylene welding rod using a heat gun and fill in the cracked area.
A-A’
Section B-B’ Polypropylene
C-C’ welding rod
Polypropylene
Melt here. welding rod
Melt here
VQPP006
NOTE
• Heat and melt the area indicated.
• Melt the welding rod carefully so that it does not over-melt. If the welding rod over-melts like jelly, the welding
strength will deteriorate.
• Use the heat gun 0.4~0.8 in.(10~20 mm) away from the repair area to be welded.
Welding rod should not move until the welded area is cooled.
Section A-A’
Polypropylene welding rod Polypropylene welding rod
Surface of
polypropylene
Tape Plane view

VQPP007
PP-6 PLASTIC PARTS
4. Grind polypropylene surface carefully. It melts easily due to the heat generated by friction. If melted, remove that area.
Also, grind the area where solvent is to be applied.
Area to apply solvent

Do not grind continuously. Paint
Grind painted area and rough surface.

VQPP008
5. Apply polypropylene primer evenly with a brush over an area wider than the area to be repaired.
Dry it at 20 C (68 F) for more than 10 minutes.
Apply primer wider than the area to repair.
Polypropylene primer
VQPP009
6. Mix main filler material and hardener at a ratio depending on paint specifications. Mix filler material and apply over the
damaged area.
NOTE
• Mix main filler material and hardener so that no bubbles are made.
• Work immediately after mixing filler material because the filler material hardens quickly(in about 5 minutes).
• Dry it at 20 C (68 F) for about 30 minutes before sanding.
Filler material Do not allow bubbles to be created.
Weld Surface of polypropylene
VQPP010
• Filler material consists of two types of epoxy.

When the filler material hardens, you will have a desirable finish with flexibility like polypropylene.
• Use only filler material designed for use on polypropylene bumpers.
PLASTIC PARTS PP-7
7. Sand the damaged area with sandpaper using #180~#240 grit paper.
NOTE
• The surface will not be even if excessive force is applied during sanding.
• If there is fuzz in the damaged area, heat it a little bit with a heater gun and melt it.
8. Degrease the painted surface.
VQPP011
9. Mix polypropylene primer and hardener at a ratio depending on paint specifications.

Spray polypropylene primer on the surface of the damaged area and the bumper.
Polypropylene primer Primer hardener
Use the primer within 16 hours after it is mixed.

VQPP012
10. Apply polypropylene primer.
NOTE
Use only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.
11. Lightly sand the sprayed area using a primer a sandpaper(#400~#600).

The polypropylene surface should not be exposed.(Either wet sanding or dry sanding is all right.)
12. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil, and wipe the finished surface of the
bumper quickly with a clean cloth.
NOTE
• The painting method for the polypropylene bumper is the same used to paint the urethane bumper.
• Therefore, use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers.
13. Air dry at 20 C(68 F) for about 8 hours, or dry in 60 C(140 F) for about 2 hours.
(Since drying time varies according to the type of paint used, follow paint manufacturers directions for drying times.)
NOTE
Air dry if possible. Forced drying may create air bubbles on the top layer.

Manual de Chapisteria Del Hyundai Accent 2006

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Manual de Chapisteria Del Hyundai Accent 2006

Hochgeladen von

Copyright:

Verfügbare Formate

INTRODUCTION

July 2005, Printed in Korea

BODY PANEL REPAIR PROCEDURE BT

BODY SEALING LOCATION

BODY MODIFICATION TOOLS

GENERAL GUIDE LINES AND PRECAUTIONS

Certain guidelines and precaution are noted as follow.

Side impact sensor

BPT When it is deployed

Also take the following precautions when repairing the body:

CORROSION PROTECTION AND SEALING

SIDE BODY PANELS

: Service part line

8mm or 5/16" dia. hole

Illustration-Welding in collision repair

1. Roof panel 60. Center member rear bracket

ZINC-GALVANIZED STEEL PANELS

1. Roof panel 60. Center member rear bracket

HIGH STRENGTH STEEL PANELS

1. Roof panel 60. Center member rear bracket

No. PART NAME

1 Front side member assembly LH/RH

1. FRONT SIDE MEMBER

No. PART NAME No. PART NAME

1 Front side inner member 14 Side sill inner front extension

< Cross-Sectional Views >

A - A' BMCBC6007 B - B' BMCBC6008

2. FENDER APRON PANEL

No. PART NAME

1 Fender apron upper reinforcement LH/RH

< Cross-Sectional Views >

Front shock absorber

Fender apron inner

A - A' BMCBC6011 B - B' BMCBC6012

No. PART NAME No. PART NAME

1 Dash panel assembly 7 Dash lower member assembly

< Cross-Sectional Views >

A - A' BMCBC6015 B - B' BMCBC6016

No. PART NAME

1 Cowl inner lower panel assembly

< Cross-Sectional Views >

D' C' B' A'

Hood Cowl top cover Cowl top

A - A' BMCBC6019 B - B' BMCBC6020

Cowl top Cowl inner lower

C - C' BMCBC6021 D - D' BMCBC6022

A Side inner panel assembly LH/RH

< Cross-Sectional Views >

Side inner panel Side inner panel

A - A' BMCBC6024 B - B' BMCBC6025

C - C' BMCBC6026 D - D' BMCBC6027

Side inner panel

E - E' BMCBC6028 F - F' BMCBC6029

Quarter inner panel Quarter

G - G' BMCBC6030 H - H' BMCBC6031

Quarter Side outer panel

L - L' BMCBC6032 N - N' BMCBC6033

P - P' BMCBC6034 R - R' BMCBC6035

CENTER FLOOR PANEL

A Center floor panel

REAR FLOOR & SIDE MEMBER

A Rear floor panel

< Cross-Sectional Views >

Rear floor complete