Hyundai Tiburon User manual

CONTENTS
GENERALINFORMATION
GENERALGUIDELINESANDPRECAUTIONS..6
SRSAIRBAG7
ELECTRONICPARTS8
CORROSIONPROTECTIONANDSEALING8
SIDE BODY PANELS.... 8
WELDING....9
BODYCONSTRUCTION
BODYCOMPONENTS12
ZINC-GALVANIZEDSTEELPANELS14
HIGH-STRENGTHSTEELPANELS16
FRONTBODY18
SIDE BODY .....29
UNDER BODY..... 34
REAR BODY39
FENDER& HOOD43
ROOF44
DOOR45
REPLACEMENTPARTS
FRONTBODY.48
SIDEBODY.49
REAR BODY."'50
DOOR51
BODYDIMENSIONS
GENERAL...52
UPPERBODY53
SIDE BODY55
INTERIOR58
UNDERBODY60
ENGINECOMPARTMENT64
LUGGAGECOMPARTMENT66
BODYPANELREPAIRPROCEDURE
RADIATORSUPPORTPANEL72
FENDERAPRONANDFRONTSIDEMEMBER(ASSEMBLY)73
FRONTSIDEMEMBER(PARTIAL).79
FRONTPILLAR83
SIDESILL (ASSEMBLY)90
SIDE SILL(PARTIAL)94
QUARTERPANEL97
REARFLOOR100
REARSIDEMEMBER(ASSEMBLY)101
REARSIDEMEMBER(PARTIAL)106
DOOR109
BODYSEALINGLOCATIONS
FLOOR 114
UPPER&SIDE BODY118
CORROSIONPROTECTION
ZINC-GALVANIZEDSTEELPANELS122
ZINC-PHOSPHATECOAT&CATIONICELECTODEPOSITION PRIMER124
ANTI-CORROSIONPRIMER125
ANTIVIBRATIONPADS-LOCATION& SECTION126
ATTACHMENTOFANTIVIBRATIONPADS127
UNDER BODY COAT128
SIDE BODY129
CAVITYWAXINJECTION130
UNDERBODYANTI-CORROSIONAGENT134

GENERALm

GENERALINFORMATION » Generalguidelinesandprecautions
GENERALGUIDE LINESAMD PRECAUTIONS
TheHyundaiTIBURON/COUPEisa completelynewvehicledesign.Duringitsdevelopment,closeattentionhas
beengiventosafety,stability,weightandcorrosionprotection.Typicalofunitbodydesign,theHyundaiTIBURON/
COUPEisdesignedsothatthefrontandrearcompartmentswillabsorbmuchofthecollisionenergysothat
thepassengersarebetterprotected.Duringcollisions,thesefrontandrearenergyabsorbingsystemsmaybe
severelydamaged.Duringrepair,thesedamagedareasmustbereturnedtotheiroriginalstrengthandgeometry.
If thisisnotproperlydone,thevehiclewillnotprovidetheintendedlevelofprotectiontoitsoccupantsinthe
eventofanothercollision.
TherepairsdescribedinthismanualwereperformedonTIBURON/COUPEbodyshells. In someinstancesspecial
fixtureswereweldedinplacetosupportthestructure.Duringtherepairofanactualvehicle,theinteriorwould
befullydisassembledandstandardjackscrewsorportablebracesmaybeusedfortemporarysupport.
Duringtherepairofan accident involvedvehicle,thevehiclemustfirstbereturned topre-impact dimensionsprior
tobeginningthesectioningrepairprocedures.Theextentofdamagethatmustberepairedshouldthenbeevaluated
todeterminetheappropriaterepairprocedures.Thismanualprovideslocationsandprocedureswherestructural
sectioningmaybe employed, itistheresponsibilityoftherepairtechnician,basedupontheextentofdamage,
todeterminewhichlocationandprocedureissuitablefortheparticulardamagedvehicle.
Duringtherepairofa collisiondamagedautomobile,itisimpossibletofullyduplicatethemethodsusedinthe
factoryduringthevehiclemanufacture.Therefore,autobodyrepairtechniqueshavebeendevelopedtoprovide
arepairthathasstrengthpropertiesequivalenttothoseoftheoriginaldesignandmanufacture.
Certainguidelinesandprecautionarenotedasfollows.

GENERALINFORMATION - SRS Airbag
SRSAIRBAG
SYSTEMCOMPONENT
ERKB012A
TheHyundai TIBURON/COUPE is equippedwith a SupplementalRestraintSystem(AIRBAG) to provide the vehicle's
driverand/or the frontpassengerwithadditionalprotectionthanthatoffered bythe seat-beltsystemalone, in case
of a frontal or lateralimpact of sufficientseverity.
Whenhandlingairbagcomponents(removal,installation or inspection, etc.), alwaysfollow the directionsgiven in
therepairmanual forthe relevantmodel to prevent the occurrence of accidents and airbagmalfunction.
Alsotake the followingprecautionswhenrepairing the body:
1. Workmust be startedafter approximately 30 seconds or longerfrom the time the ignition switch is turned
to the LOCKposition andthe negative (-) terminal cable is disconnectedfrom the battery. (The airbagsystem
isequippedwith a back-uppowersource so that if work is startedwithin 30 seconds of disconnecting the
negative (-) terminalcable ofthe battery, the airbag maybe deployed.)
When the negative(-)terminalcable is disconnectedfrom the battery,memory ofthe clock and audiosystems
will be cancelled. So beforestartingwork,make a record ofthe contentsmemorized bythe audiomemory
system. Thenwhenwork is finished,reset the audiosystem as before and adjust the clock.
2. Whenusingelectricwelding,firstdisconnect the SRSCM connectorsunder the lowercrash pad center.
3.Store the airbagmodulewhere the ambient temperature remainsbelow 80°C (176°F), withouthighhumidity
andawayfromelectricalnoise.
4. WARNING/CAUTIONlabels are attached tothe periphery ofthe airbagcomponents.
Refer tothe TIBURON/COUPESHOP MANUAL.

GENERALINFORMATION- Electronicparts
ELECTRONICPARTS
Vehiclestodayincludea greatmanyelectronicpartsandcomponents,andtheseareingeneralverysusceptibleto
adverseeffectscausedbyovercurrent,reversecurrent,electromagneticwaves,hightemperature,highhumidity
impacts,etc..
Inparticularsuchelectroniccomponentscanbedamagedifthereisa largecurrentflowduringweldingfromthebody
side.
Therefore,takethefollowingprecautionsduringbodyrepairtopreventdamagetotheCONTROLMODULES(ECM,
TCM, ABSCM,SRSCM,etc.)
1. Beforeremovingandinspectingtheelectricalpartsorbeforestartingelectricweldingoperations,disconnectthe
negative(-)terminalcablefromthebattery.
2. DonotexposetheCONTROLMODULEStoambienttemperaturesabove 80°C (176°F).
MOTE:
If itispossibletheambienttemperaturesmayreach80°C (176°F) ormore,removetheCONTROL
MODULES from thevehiclebeforestartingwork.
3.BecarefulnottodroptheCONTROLMODULESandnottoapplyphysicalshockstothem.
CORROSIONPROTECTIONAND SEALING
Propercorrosionprotectionandsealingisanimportantpartofanyrepair.Whenreviewingtheserepairprocedures,
itisimportanttorecognizetheneedforcorrosionrestorationtoprovideforlongtermstrengthoftherepairedmember.
Atwopart epoxy primerwasappliedtothemetalsurfacesduringthelatterpartoftherepair.Forclosedsections,
suchasfrontandrearrails,rockerpanelsandpillars,theprimerisappliedwithoutapplyingthemetalconditionerand
theconversioncoating.Thesestepsareomittedtoinsurethatnorinsewateristrappedintheclosedsections.The
primerapplicationisfollowedbyanapplicationofanoilorwaxbasedonrustproofingmaterial.
Afterthecorrosionrestorationprocessfortheclosedsectionsarecompleted,thentheprocesscanbeappliedtoall
exteriorsections.Forexteriorsurfaces,bothmetalconditionerandconversioncoatingtreatmentsareappliedtothe
exteriorsurfacepriortoapplicationoftheepoxyprimer.Theprocedureinapplyingthecorrosionrestorationprocess
isimportantinordertoinsurethatmoisture,duetothewaterrinsingofthemetalconditionerandconversioncoating
isnotinadvertentlytrappedinsideanyclosedsectionbeforetheepoxyprimerandrustproofingmaterialshavebeen
applied.
Appropriateseamsealersarethenappliedtoalljoints.Followmanufacturer'srecommendationsfortheappropriate
typeofseamsealertobeusedateachseamorjoint.
SIDEBODYPANELS
Thesidebodypanelfor TIBURON/COUPE isdesignedandstampedassinglepieceofsheetmetalinfactoryas
showninthefigure.Whiletheentiresidepanelisavailableforservice,thepartialpanelssectionedbyseveral
damagedareasarealsoavailable.Thereforewhenrepairingsidebody,referto"Replacementpartssection"ofthis
manualtoselectandusethe appropriate part.
Servicepartline
GK-0030
8

GENERALINFORMATION- Welding
WELDING
Allrepairsinthismanualrequiretheuseofa Metal-InertGas(MIG)welder,Gas(oxyacetylene)weldingmust
notbeused.
BothhighstrengthsteelandmildsteelcanbeweldedusingtheMIGwelder.The l-CAR recommendationsfor
weldingshouldbefollowed.Theshieldinggasshouldbe75%Argonand25% C02.
Therecommendedweldingwiresizeis0.23"andthewireshouldsatisfytheAmericanWeldingSocietyStandard
codeAWSER70S-6.
Duringtherepairprocess,plugweldsareusedtoduplicateoriginalfactoryspotwelds.Allplugweldsshouldbe
donewiththeMIGwelder.An8 mm(5/16")holeisplacedinthetop(weldingside)sheetmetal.
Youthenbeginweldingalongtheedgesandthespiraltowardsthecenter(seeillustration).Thisisimportantso
thatweldpenetrationbetweenthetwometalpiecesmaytakeplacealongthecircumferenceofthecircle.
Weld
around
edgesfirst
workingin
towardsthe
center
////////////////^^^^ 8mm
or 5/16" dia.hole
illustration-WeldingincollisionRepair
SAFETYFACTORS
Disconnectthenegative(-)batterycablebeforeperforminganyworkonthevehicle.
Protectyourselfbywearinggoggles,earplugs,respirators,gloves,safetyshoes,caps,etc.whenworkingona
vehicle.
Safelysupportthevehiclebeforeanyworkisdone.Blockthefrontorrearwheelsifthevehicleisnotliftedoff
oftheground.
Caporremovethefueltankwhenworkingontherearsectionofthecar.
Insureproperventilationofyourworkingarea.Somepaintandsealantcangeneratetoxicgaseswhenheated.
Useanairchiselorsawtoremovedamagedpanelsinsteadofa gastorch.
Observealllocalandnationalsafetyregulationswhenperforminganywork.
Coverinteriorwithheat-resistantcovertoinsuresafetywhenwelding.
Takecarewhenusinggasorcuttingtorchessoasnottoburnbodysealerorinterior.Extinguishimmediately
iftheyshouldcatchfire.

30DY
:!•

BODYCONSTRUCTION- Bodycomponents
BODYCOMPONENTS
Bodyconstructionwillsometimesdifferdependingonspecificationsandcountryof destination. Therefore,pleasekeepin
mindthattheinformationcontainedhereinisbasedonvehiclesforgeneraldestination.
12

BODYCONSTRUCTION - Bodycomponents
1. Radiatorsupportuppercentermember
2. Radiatorsupportcentermember
3.Radiatoruppermountingbracket
4. Radiatorsupportuppersidemember
5.Headlampsupportpanel
6.Headlampsupportgusset
7.Frontshippinghookbracket
8.Radiatorsupportlowerinnermember
9.Radiatorsupportloweroutermember
10. Dashpanel
11. Dashpanelreinforcement
12. Dashlowermember
13. Fenderapronupperouterpanel
14. Fenderaproninnerrearupperextension
15. Fenderaproninnerrearlowerextension
16. Fenderapronupperinnerpanel
17. Frontshockabsorberhousingpanel
18. Frontshockabsorberhousingupperpanel
19. Fenderaproninnerfrontpanel
20. Frontsideinnermember
21. Frontsidememberinnergusset
22. Enginemountingreinforcement
23. Transmissionmountingreinforcement
24. Frontsideoutermember
25. Frontsiderearlowermember
26. Frontsiderearuppermember
27. Frontsidememberrearlowerextension
28. Frontsidememberlowerreinforcement
29. Centerfloorpanel
30. Mufflerhangermountingbracket
31. Centerfloorreinforcement
32. Frontseatcrossmember
33. FrontseatcrossNo.2member
34. Centerfloorsidemember
35. Centerfloorsidememberreinforcement
36. Side sili innerpanel
37. Parkingbrakeleverrearmountingreinforcement
38. Rearfloorpanel
39. Rearfloorsidepanel
40. Rearfloorcentercrossupper
41. Rearfloorsidemember
42. Rearbumpermountingreinforcement
43. Rearfloorsidemembercenterreinforcement
44. Sidesillinnerrearpanel
45. Rearfloorcentercrossmember
46. Rearfloorsidememberfrontreinforcement
47. Rearfloor front extension
48. Rearfloorfrontcrossmember
49. Jackupcrosscentermember
50. Jackupcrossrearmember
51. Fenderpanel
52. Cowlsideupperpanel
53. Cowlinnerlowerpanel
54. Cowlinnerlowerreinforcement
55. Cowlsideupperinnerpanel
56. Hoodhingemountingreinforcement
57. Cowltopouterpanel
58. Roofpanel
59. Roofpanel(sunroof)
60. Rooffrontlower
61. Roofrearupperrail
62. Tailgatehingemountingreinforcement
63. Roofrearlowerrail
64. Roofcenterrail
65. RoofcenterrailNo.2
66. Sunroofringreinforcement
67. Sunroofrearlowerreinforcement
68. Backpanel
69. Reartransversemember
70. Reartransversesideextension
71. Frontinnerlowerpillar
72. Frontinnerupperpillar
73. Centerpillarinnerpanel
74. Frontseatbeltuppermountingbracket
75. Wheelhousinginnerpanel
76. Wheelhousing inner frontextension
77. Rearspringhousingcover
78. Wheelhousinginnerrearcover
79. Quarterinnerpanel
80. Quarterinnerreinforcement
81. Quarterinnerupperpanel
82. Sideouterpanel
83. Sideouterreinforcement
84. Frontdoorstrikerreinforcement
85. Frontdoorstrikerupperreinforcement
86. Sideouterrearupperextension
87. Quarterouterupperreinforcement
88. Rearcombinationlamphousingpanel
89. Hoodouterpanel
90. Hoodinnerrail
91. Doorouterpanel
92. Doorbeltouterrait
93. Doorreinforcementbeam
94. Dooruppermember
95. Doorinnerpanel
96. Doorbeltinnerrail
97. Tailgateouterpanel
98. Tailgateinnerpanel
99. Tailgatesidereinforcement
13

BODYCONSTRUCTION - Zinc- galvanizedsteelpanels
ZINC - GALVANIZEDSTEELPANELS
Becausegalvanizedsteelpanelhasexcellentresistance,itisusedinareaswhichhavea highpossibilityofpainting
deficiencybelow
14

BODYCONSTRUCTION- Zinc-galvanizedsteelpanels
1. Radiatorsupportuppercentermember
2. Radiatorsupportcentermember
3.Radiatorsupportuppersidemember
4. Headlampsupportpanel
5.Headlampsupportgusset
6.Frontshippinghookbracket
7.Radiatorsupportlowerinnermember
8.Radiatorsupportloweroutermember
9.Dashpanel
10. Dashlowermember
11. Fenderapronupperouterpanel
12. Fenderaproninnerrearupperextension
13. Fenderaproninnerrearlowerextension
14. Fenderapronupperinnerpanel
15. Frontshockabsorberhousingpanel
16. Frontshockabsorberhousingupperpanel
17. Fenderaproninnerfrontpanel
18. Frontsideinnermember
19. Frontsidememberinnergusset
20. Frontsidememberrearlowerextension
21. Centerfloorpanel
22. Mufflerhangermountingbracket
23. Centerfloorsidemember
24. Centerfloorsidememberreinforcement
25. Sidesillinnerpanel
26. Rearfloorpanel
27. Rearfloorsidepanel
28. Rearfloorsidemember
29. Rearbumpermountingreinforcement
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Rearfloorsidemembercenterreinforcement
Sidesillinnerrearpanel
Rearfloorcentercrossmember
Rearfloorsidememberfrontreinforcement
Rearfloorfrontcrossmember
Jackupcrosscentermember
Jackupcrossrearmember
Fenderpanel
Cowlsideupperpanel
Cowl innerlowerpanel
Cowlsideupperinnerpanel
Hoodhingemountingreinforcement
Cowltopouterpanel
Backpanel
Frontinnerlowerpillar
Wheelhousinginnerpanel
Wheelhousinginnerfrontextension
Rearspringhousingcover
Quarterinnerpanel
Sideouterpanel
Sideouterreinforcement
Sideouterrearupperextension
Rearcombinationlamphousingpanel
Hoodouterpanel
Hoodinnerrail
Doorouterpanel
Doorinnerpanel
Tailgateouterpanel
Tailgateinnerpanel
15

BODYCONSTRUCTION- High- strengthsteelpanels
HIGH STRENGTHSTEELPANELS
BecauseHighstrengthsteelpanelhasexcellentresistance,itisusedinareaswhichhavea highpossibilityofpainting
deficiencybelow
16

BODYCONSTRUCTION- High-strengthsteelpanels
1. Radiatorsupportlowerinnermember
2. Radiatorsupportloweroutermember
3.Dashlowermember
4. Frontshockabsorberhousingupperpanel
5.Frontsideinnermember
6.Frontsidememberinnergusset
7.Enginemountingreinforcement
8.Transmissionmountingreinforcement
9.Frontsiderearlowermember
10. Frontsiderearuppermember
11. Frontsidememberrearlowerextension
12. Frontsidememberlowerreinforcement
13. Frontseatcrossmember
14. FrontseatcrossNo.2 member
15. Centerfloorsidemember
16. Centerfloorsidememberreinforcement
17. Sidesill inner panel
18. Rearbumpermountingreinforcement
19. Rearfloorsidemembercenterreinforcment
20. Rearfloorsidememberfrontreinforcement
21. Rearfloorfrontcrossmember
22. Fenderpanel
23. Cowlinnerlowerpanel
24. Cowltopouterpanel
25. Rooffrontlower
26. Tailgatehingemountingreinforcement
27. Roofrearlowerrail
28. Roofcenterrail
29. Backpanel
30. Frontinnerlowerpillar
31. Frontinnerupperpillar
32. Centerpillarinnerpanel
33. Rearspringhousingcover
34. Frontdoorstrikerreinforcement
35. Frontdoorstrikerupperreinforcement
36. Doorouterpanel
37. Doorbeltouterrail
38. Dooruppermember
39. Doorbeltinnerrail
40. Tailgateouterpanel
41. Tailgatesidereinforcement
17

BODYCONSTRUCTION- Frontbody
FRONTBODY
CON-0090
No.
PARTNAME
Radiatorsupportpanelcomplete
Radiatorsupportcentercompletememberassembly
Fenderapronpanelassembly,
Frontsidememberassembly,
Cowlsideouterpanelassembly
Cowlpanelinnerlowerpanelassembly
Dashpanelcowersideouterupperpanel,
Cowlcrossbarassembly
LH/RH
LH/RH
LH/RH
18

BODYCONSTRUCTION- Frontbody<Radiatorsupport paneS>
1. RADIATORSUPPORTPANEL
CON-0110
No. PARTNAME
1
2
3
4
5
6
7
8
9
10
11
Radiatorsupportuppercentermember
Radiatorsupportcentermember
Radiatoruppermountingbracket
Radiatorsupportuppersidemember
Headlampsupportpanel
Headlampsupportgusset
Radiatorlowermountingbracket
Frontshippinghookbracket
Radiatorsupportlowerinnermember
Radiatorlowermountingreinforcement
Radiatorsupportloweroutermember
19

BODYCONSTRUCTION-Frontbody<Radiatorsupportpanel>
<Cross-Sectior»a!Views>
CON-0120
Frontbumpermounting
reinforcement
Frontbumperstay Frontsidememberinner
frontextension
Frontsidememberinner
gusset
SECTION A-A" CON-0130
Radiatorsupport lower^
outermember
/T
Radiatorsupport
lowerinnermember
SECTION B-B1
CON-0140
Radiatorsupportcentermember
Radiatorsupport
loweroutermember
m
Antinoisepad
Radiatorsupportlower
innermember
I
Radiatorsupportlower
innermember
/*
Radiatorsupportlower
outermember \
SECTION C-C
CON-0150
SECTION D-D'
CON-0160
20

BODYCONSTRUCTION- Frontbody<Fenderapronpanel>
2. FENDERAPRONPANEL
CON-0170
No. PARTNAME
1
2
3
4
5
6
7
8
9
10
Fenderapronupperouterpanel
Fenderaproninnerrearupperextension
Fenderaproninnerrearlowerextension
Fenderapronupperinnerpanel
Frontshockabsorberhousingpanel
Frontshockabsorberhousingupperpanel
Fenderaproninnerfrontpanel
Enginestaymountingbracket
Fendermountingbracket
ABSmodulemountingbracket
21

BODYCONSTRUCTION- Frontbody<Fenderapronpanei>
<Cross-Sectional Views>
A'
B"
Fenderapron
innercompletepanel
Fenderapronupper
outerpanel
SECTION A-A' CON-0190
Frontshock absorber
housingpanel
Frontsidemember-
Shockabsorberhousing
completepanel
Fenderaproninner
completepanel
SECTION B-B'
CON-0200
22

BODYCONSTRUCTION- Frontbody<Frontsidemember>
3.FRONTSIDEMEMBER
CON-0210
No.
PARTNAME
No. PARTNAME
1
2
3
4
5
6
7
8
9
10
11
12
13
Frontsideinnermember
Frontsidememberinnergusset
Subframe mountingfrontplate
Subframe mountingfrontsupport
Enginemountingreinforcement
Enginemountingfrontbracket
Enginemountingrearbracket
Transmissionmountingreinforcement
Transmissionmountingfrontbracket
Transmissionmountingrearbracket
Frontsideoutermember
Subframemountingstudbolt
Brakehosemountingbracket
14
15
16
17
18
19
20
21
22
23
24
25
26
Frontsiderearlowermember
Frontsiderearuppermember
Frontsidememberrearlowerextension
Frontsidememberlowerreinforcement
Frontbackbeammountingbracket
Subframerearmountingbracket
Subframerearmountingreinforcement
Subframerearmountingsupport
Subframefrontmountingbracket
Frontsidememberinner front extension
Frontsidememberouterfrontextension
Fronttiedownhook
Undercovermountingbracket
23