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GENERAL
INFORMATION
INTRODUCTION
This Body Repair Manual provides detailed repair procedures for repair of commonly
damaged structural panels on the Hyundai Getz. To aid in the information of the damaged
vehicle, body construction, replacement parts, body dimensions, body sealing locations,
corrosion protection and body repair procedures 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 Getz 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 Getz, refer
to the Getz 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.
June 2002, 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 ..............................................................................................6
SRS AIR-BAG ................................................................................................................................................ 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
FLOOR ......................................................................................................................................................... 37
REAR BODY ................................................................................................................................................ 41
FENDER & HOOD ........................................................................................................................................ 43
ROOF ........................................................................................................................................................... 44
DOOR ........................................................................................................................................................... 45
TAIL GATE ................................................................................................................................................... 47
REPLACEMENT PARTS
FRONT BODY .............................................................................................................................................. 50
SIDE BODY .................................................................................................................................................. 51
REAR BODY ................................................................................................................................................ 52
DOOR ........................................................................................................................................................... 53
BODY DIMENSIONS
MEASUREMENT METHOD .......................................................................................................................... 56
UPPER BODY .............................................................................................................................................. 57
SIDE BODY .................................................................................................................................................. 59
INTERIOR .................................................................................................................................................... 63
UNDER BODY .............................................................................................................................................. 67
ENGINE COMPARTMENT ........................................................................................................................... 71
LUGGAGE COMPARTMENT ........................................................................................................................ 73
BODY PANEL REPAIR PROCEDURE
FENDER APRON PANEL (PARTIAL) ........................................................................................................... 76
FENDER APRON AND FRONT SIDE MEMBER (ASSEMBLY) .................................................................... 77
FRONT SIDE MEMBER (PARTIAL) ............................................................................................................. 83
FRONT PILLAR ............................................................................................................................................ 87
CENTER PILLAR .......................................................................................................................................... 94
SIDE SILL (ASSEMBLY) ............................................................................................................................ 100
SIDE SILL (PARTIAL) ................................................................................................................................. 104
QUARTER PANEL ...................................................................................................................................... 107
REAR FLOOR ............................................................................................................................................. 110
REAR SIDE MEMBER (ASSEMBLY) ......................................................................................................... 111
REAR SIDE MEMBER (PARTIAL) ............................................................................................................. 116
FRONT AND REAR DOOR OUTER PANELS ............................................................................................. 119
BODY SEALING LOCATIONS
FLOOR ....................................................................................................................................................... 124
UPPER & SIDE BODY ............................................................................................................................... 127
CORROSION PROTECTION
ZINC-GALVANIZED STEEL PANELS ........................................................................................................ 132
ZINC-PHOSPHATE COAT & CATIONIC ELECTODEPOSITION PRIMER ................................................. 134
ANTI-CORROSION PRIMER ...................................................................................................................... 135
ANTIVIBRATION PADS-LOCATION & SECTION ...................................................................................... 136
ATTACHMENT OF ANTIVIBRATION PADS .............................................................................................. 137
UNDER BODY COAT ................................................................................................................................. 138
SIDE BODY ................................................................................................................................................ 139
CAVITY WAX INJECTION .......................................................................................................................... 140
UNDER BODY ANTI-CORROSION AGENT ................................................................................................ 143
GENERAL INFORMATION - General guide lines and precautions
GENERAL GUIDE LINES AND PRECAUTIONS
The Hyundai Getz 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 Getz 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 Getz 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.
TB-0010
6
GENERAL INFORMATION - SRS Air-bag
SRS AIR-BAG
SYSTEM COMPONENT
PAB
Clock spring
BPT
When it is deployed
ERKB012A
The Hyundai Getz 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 Getz SHOP MANUAL
7
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