REAR DOOR OUTER PANEL ASSEMBLY REPLACEMENT

A002Y97

  1. REMOVAL

    Symbol Meaning
    A002Y4P Remove Weld Points
    A002YC9 Brazing or Arc Brazing for Removal

      REMOVAL POINT

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

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

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

    A002YFPC02
    *a Positioning Tape *b Installation Position
    *c Hemming Location *d Disc Sander

  2. INSTALLATION

    Symbol Meaning
    A002YAM Plug Weld
    A002YC9 Braze
    A002YCP Spot MIG Weld
    A002Y5H Body Sealer

      INSTALLATION POINT

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

      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 and side impact protection beam to make contact.

    2. Bend the flange hem about 30° with a hammer and dolly. Then, fasten tightly with a hemming tool.

      Tech Tips


      • Perform hemming in three steps, being careful not to warp the panel.

      • If a hemming tool cannot be used, hem with a hammer and dolly.

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

    A002YGDC01
    *a Positioning Tape *b Do not close the drain hole.
    *c Cloth Tape *d Hemming Tool
    *e mm (in.) - -