REAR DOOR OUTER PANEL ASSEMBLY REPLACEMENT

A01GHGU

  1. REMOVAL

    Symbol Meaning
    B002F5A Remove Weld Points

    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.

      A01GH5JC02
      *a Installation Postion *b Positioning Tape
      *c Hemming Location *d Disc Sander

  2. INSTALLATION

    Symbol Meaning
    B002F3I Plug Weld
    A01GHB6 Spot MIG Weld
    A01GHI7 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 and side impact protection beam to make contact.

      A01GHEAC01
      *1 REAR DOOR PANEL OUTER - -
      *a Positioning Tape *b 10 mm (0.39 in.)
      *c Drain Hole - -

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

      Tech Tips

      Bend the panel gradually so as not to distort it.

      A01GHG5C01
      *a Dolly *b Cloth Tape
      *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.