REAR DOOR OUTER PANEL ASSEMBLY REPLACEMENT

A01R1O4

  1. REMOVAL

    Symbol Meaning
    A01R1KN Remove Weld Points
    A01R1PE Cut with Disc Sander etc.
    A01R1SN Brazing or Arc Brazing for Removal

    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.

      A01R1MCC01
      *a Positioning Tape *b Installation Position

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

      A01R1N2C01
      *a Disc Sander *b Hemming Location

  2. INSTALLATION

    Symbol Meaning
    A01R1OT Plug Weld
    A01R1NX Fillet Weld
    A01R1SN Braze
    A01R1QI Spot MIG Weld
    A01R1SC 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.

      A01R1TTC02
      *A except Korea *B for Korea
      *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.

      A01R1QUC01
      *a Positioning Tape *b Cloth Tape
      *c Dolly *d Wooden Hammer
      *e 7 mm (0.28 in.) - -

    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.