FRONT DOOR OUTER PANEL ASSEMBLY REPLACEMENT

Info Added 2017-08-29

B000GUM

  1. REMOVAL

    Symbol Meaning
    B003XIE Remove Weld Points

    1. Before removing the outer panel, mark the installation position with tape.

      Tech Tips

      Before removing the outer panel, establish its exact position in relation to the window frame using a reference marker, etc.

      B000GTNC01
      *a Positioning Tape *b Installation Position

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

      B000GJKC01
      *a Disc Sander *b Hemming Location

  2. INSTALLATION

    Symbol Meaning
    B003XI7 Plug Weld
    B000GPY Spot MIG Weld
    B000GPP Body Sealer

    1. Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

    2. Before temporarily installing the new parts, apply body sealer to the 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.

      B000GQ4C01
      *1 FRONT DOOR PANEL OUTER - -
      *a 10 mm (0.39 in.) *b Drain Hole

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

      Tech Tips

      Bend the panel gradually so as not to distort it.

      B000GO1C01
      *a Positioning Tape *b Cloth Tape
      *c Dolly *d Wooden Hammer

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

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