FRONT DOOR OUTER PANEL REMOVAL [PANEL REPLACEMENT]

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Symbol Mark

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Removal Procedure

Using remover tool

1.  Insert a scraper from the service hole of the front door inner panel, and peel off the damping material shown in the figure from the front door outer panel.

Note

•  Use the scraper along the front door outer panel, and peel off the damping material so that it remains on the side-impact bar side.

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2.  Drill the spot welds in the 3 locations in area A shown in the figure from the front door outer side.

Caution

•  When a drill the spot welds in the 3 locations in area A shown in the figure, the through hole is not made in consideration of the workability at the installing.

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3.  Drill the spot welds in the 5 locations in area B shown in the figure from the front door inner side.

Caution

•  When a drill the spot welds in the 5 locations in area B shown in the figure, the through hole is not made in consideration of the workability at the installing.

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4.  Grind the 2 locations in area C shown in the figure using a disc grinder.

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5.  Partially spread open the wider part of the flange for each front door outer panel using remover pliers.

6.  Install the remover tool to the wider part of the flange partially spread open in Step 5.

7.  Move the remover tool in the direction of the arrows in the order of (1), (2), and (3), and raise the flange in each area.

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8.  Tap a chisel in the 2 locations in area D shown in the figure, and peel off the weld bond adhering to the front door outer panel and the front door inner panel.

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9.  Remove the 3 crimps in area E shown in the figure using remover pliers.

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10.  Move and remove the front door outer panel in the order of arrows (4) and (5) shown in the figure.

Note

•  To facilitate installation, peel off the weld bond remaining on the front door inner panel, degrease and clean the area after removing the front door outer panel.

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Not using remover tool

1.  Insert a scraper from the service hole of the front door inner panel, and peel off the damping material shown in the figure from the front door outer panel.

Note

•  Use the scraper along the front door outer panel, and peel off the damping material so that it remains on the side-impact bar side.

ac5wzb00000450

2.  Drill the spot welds in the 3 locations in area A shown in the figure from the front door outer side.

Caution

•  When a drill the spot welds in the 3 locations in area A shown in the figure, the through hole is not made in consideration of the workability at the installing.

ac5wzb00000451

3.  Drill the spot welds in the 5 locations in area B shown in the figure from the front door inner side.

Caution

•  When a drill the spot welds in the 5 locations in area B shown in the figure, the through hole is not made in consideration of the workability at the installing.

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4.  Grind the edge around the hemming part of the front door outer panel using a disc grinder.

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5.  Insert a chisel into the 2 locations in area C shown in the figure, and peel off the weld bond adhering to the front door outer panel and the front door inner panel.

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6.  Remove the 3 crimps in area D shown in the figure using pliers.

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7.  Move and remove the front door outer panel in the order of arrows (1) and (2) shown in the figure.

Note

•  To facilitate installation, peel off the weld bond remaining on the front door inner panel, degrease and clean the area after removing the front door outer panel.

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