Kalos/Aveo

FENDER, HOOD, TAILGATE AND TRUNK LID

FENDER

REPAIR PROCEDURE

1. Remove the related parts.
• Front bumper and mud guard.
3. Remove the fender
5. Preparation of the new fender.
• Preparation of the new fender and check damaged areas.
7. Apply the paint.
9. CAUTION
• Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed, Read the paint label before opening paint container.
• Avoid contact with skin, Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
• Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
10. Apply the mastic sealer.
• Apply the mastic sealer to the mounting bolts.





11. Preinstall the fender.
• Fasten to the wheelhouse at two places with bolts. Close the hood and check the front and rear clearances and level differences of the hood and door.





12. Tighten fully.
• After checking and adjusting the mounting position, tighten all bolts fully.
14. Install the related parts.
• Install in the reverse order in which they were removed.
16. Check clearance
• Check clearance of front bumper.

HOOD

REPAIR PROCEDURE

1. Remove the related parts.
2. Remove the hood.
• Remove the hood mounting bolts from two hinge bows.





3. Preparation of the new hood.
• Preparation of the new hood and check damagedareas.
5. Apply the paint.
7. CAUTION
• Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed.
• Read the paint label before opening paint container.
• Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
• Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
9. Preinstall the hood.
• Fasten to the hood hinges bows at two places with four bolts, carefully.





• Close the hood and check the front and rear clearances and level difference of hood. fender and head lamps.





10. Tighten fully.
• After checking and adjusting the mounting position, tighten all bolts fully.
12. Install the related parts.
• Install in the reverse order in which they were removed.
14. Check and adjust.
• Check clearances and level differences.
• Check the hood locking and unlocking condition.

TRUNK LID

REPAIR PROCEDURE

1. Remove the related parts.
• Wiring harness and solenoid valve.
• Lock set, latch set and others.
3. Remove the trunk lid.
• Remove the trunk lid mounting bolts from twohinge bows.





4. Preparation of the new trunk lid.
• Preparation of the new trunk lid and check damaged areas.
6. Apply the paint.
8. CAUTION
• Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed.Read the paint label before opening paint container.
• Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when painting.
• Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.
9. Preinstall the trunk lid.
• Fasten to the trunk lid hinges bows at two placeswith four bolts, carefully.
• Install bumper.





• Close the trunk lid and check the clearances andlevel difference of trunk lid, side panel outers andrear combination lamps.





10. Tighten fully.
• After checking and adjusting the mounting position, tighten all bolts fully.
12. Install the related parts.
• Washer hose and nozzles.
• Install in the reverse order in which they were removed.
14. Check and adjust.
• Check clearances and level differences.
• Check the hood locking and unlocking condition.
• Check spary conditions of washer liquid and adjust washer spray nozzels on the hood panel.
15. • Close the trunk lid and check the clearances and level difference of trunk lid, side panel outers and rear combination lamps.
    
    
    
    
    
16. Tighten fully.
• After checking and adjusting the mounting position tighten all bolts fully.
18. Install the related parts.
• Wiring harness and solenoid valve.
• Lock set, latches and linkages.
• Install in the reverse order in which they were removed.
20. Check and adjust.
• Clean the trunk compartment.
• Check clearances and level differences.
• Check the trunk lid locking and unlocking condition.
• Check the trunk lid locking and unlocking condition.
• Check for water leaks in the trunk compartment.

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