Hyundai Sonata 2005 Body Repair Manual

The Hyundai SONATA 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 SONATA 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 SONATA 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.

CONTENTS

  • GENERALINFORMATION
    • GENERALGUIDELINESAND PRECAUTIONS
    • SRS AIR-BAG
    • ELECTRONIC PARTS
    • CORROSION PROTECTION AND SEALING
    • SIDE BODY PANELS
    • WELDING
  • BODY CONSTRUCTION
    • BODY COMPONENTS
    • ZINC-GALVANIZED STEEL PANELS
    • HIGH-STRENGTH STEEL PANELS
    • FRONT BODY
    • SIDE BODY
    • FLOOR
    • FENDER & HOOD
    • ROOF
    • DOOR
    • TRUNKLID
  • REPLACEMENT PARTS
    • FRONT BODY
    • SIDE BODY
    • REAR BODY
    • DOOR
  • BODY DIMENSIONS
    • MEASUREMENT METHOD
    • UPPER BODY
    • SIDE BODY
    • INTERIOR
    • UNDERBODY
    • ENGINE COMPARTMENT
    • LUGGAGE COMPARTMENT
  • BODY PANEL REPAIR PROCEDURE
    • FENDER APRON PANEL (PARTIAL
    • FENDER APRON AND FRONT SIDE MEMBER (ASSEMBLY
    • FRONTSIDE MEMBER (PARTIAL)
    • FRONT PILLAR
    • CENTER PILLAR
    • SIDE SILL (ASSEMBLY)
    • SIDE SILL (PARTIAL)
    • QUARTER PANEL
    • REAR FLOOR PANEL
    • REAR FLOOR SIDE MEMBER (ASSEMBLY
    • REAR FLOOR SIDE MEMBER (PARTIAL
    • FRONTAND REAR DOOR OUTER PANELS
  • BODY SEALING LOCATIONS
    • FLOOR
    • UPPER & SIDE BODY
  • CORROSION PROTECTION
    • ZINC-GALVANIZED STEEL PANELS
    • ZINC-PHOSPHATE COAT&CATIONIC ELECTODEPOSITION PRIMER
    • ANTIVIBRATION PADS-LOCATION& SECTION
    • ATTACHMENTOFANTIVIBRATION PADS
    • UNDER BODY COAT
    • SIDE BODY
    • CAVITY WAX INJECTION
    • UNDER BODY ANTI-CORROSION AGENT

Language: English
Format: PDF
Pages: 129

Hyundai Sonata 2005 Body Repair Manual

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