Hyundai Atos: Body Repair Instruction - page 1


GENERAL INFORMATION - General guide lines and precautions


The Hyundai ATOS PRIME 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 ATOS PRIME
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 ATOS PRIME 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.






The Hyundai ATOS PRIME 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.










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
Therefore, take the following precautions during body repair to prevent damage to the CONTROL MODULS (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 MODULS to ambient temperatures above 80° C (176°F).

If it is possible the ambient temperatures may reach 80° C (176° F) or more, remove the CONTROL MODULS
from the vehicle before starting work.

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


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

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.


The side body panel for ATOS PRIME 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



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% CO



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

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

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



Weld around
edges first
working in
towards the
(Top wiew)


8mm or 5/16" dia. hole

Illustration-Welding in collision Repair


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
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.

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