REAR DOOR OUTER PANEL CUT AND JOIN REPLACEMENT SECTIONS

A01IE78

  1. REMOVAL

    Symbol Meaning
    B006JOY Remove Weld Points
    B006JPE Cut and Join Location

    1. After grinding off the hemming location, remove the outer panel.

      A01IEDVC01
      *a Disc Sander *b Hemming Location

  2. INSTALLATION

    Symbol Meaning
    B006JU9 Plug Weld
    B006JOP Butt Weld
    A01IEF9 Spot MIG Weld
    B006JSM Body Sealer

    1. Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts.

      Note

      Do not close the drain hole.

      Tech Tips

      Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement to make contact.

      A01IE8AC01
      *1 REAR DOOR PANEL OUTER - -
      *a Drain Hole *b 10 mm (0.39 in.)

    2. Bend the flange hem with a wooden hammer and dolly.

      Tech Tips

      Bend the panel gradually so as not to distort it.

      A01IE80C01
      *a Cloth Tape *b Dolly
      *c Wooden Hammer - -

    3. After welding, apply body sealer to the corresponding parts. (See the painting/coating)

    4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.