REAR DOOR OUTER PANEL ASSEMBLY REPLACEMENT

K138033

  1. REMOVAL

    Symbol Meaning
    K108818

    Remove Weld Points

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

      Tip:

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

      K137865C01

      *a

      Positioning Tape

      *b

      Installation Position

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

      K137866C01

      *a

      Disc Sander

      *b

      Hemming Location

  2. INSTALLATION

    Symbol Meaning
    K108823

    Plug Weld
    K108833

    Spot MIG Weld
    K108834

    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.

      Tip:

      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.

      K137867C01

      *1

      REAR DOOR PANEL OUTER

      -

      -

      *a

      Drain Hole

      *b

      10 mm (0.39 in.)

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

      Tip:

      Bend the panel gradually so as not to distort it.

      K137868C01

      *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.