Hyundai Trajet Body Repair Manual

The Hyundai TRAJET is a compieteiy 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 TRAJET 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 TRAJET 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

• GENERAL INFORMATION
  • GENERAL GUIDELINES AND PRECAUTIONS
  • SRS AIRBAG
  • ELECTRONIC PARTS
  • CORROSION PROTECTION AND SEALIN
  • SIDE BODY PANELS
  • WELDING
  • SAFETY FACTORS
• BODY CONSTRUCTION
  • BODY COMPONENTS
  • FRONT END STRUCTURE
  • FRONT BODY
  • SIDE BODY
  • FLOOR
  • ROOF
  • HOOD
  • TAILGATE
  • DOOR
  • FRONTCROSSMEMBER
• BODY DIMENSIONS
  • GENERAL
  • SIDE BODY
  • INTERIOR
  • UPPERBODY
  • UNDERBODY
  • FRONT BODY
  • REAR BODY
• BODY PANEL REPAIR PROCEDURE
  • FENDER APRON AND FRONTSIDE MEMBER (ASSEMBLY)
  • FRONT PILLAR
  • CENTER PILLAR
  • QUARTER PANEL
  • REAR FLOOR
  • GAS INTERM FLOOR
  • FRONT AND REAR DOOR OUTER PANELS
• BODY SEALING LOCATIONS
  • FLOOR, UPPER & SIDE BODY
• CORROSION PROTECTION
  • ZINC-GALVANIZED STEEL PANELS
  • ZINC-PHOSPHATE COAT & CATIONIC ELECTODEPOSITION PRIMER
  • ANTI-CORROSION PRIMER
  • UNDER BODY COAT (FLOOR)
  • UNDER BODYCOAT(SIDE BODY)
  • CAVITY WAX INJECTION
  • UNDER BODY ANTI-CORROSION AGENT

Language: English
Format: PDF