REAR 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 rear door inner panel, and peel off the damping material shown in the figure from the rear door outer panel.

Note

•  Use the scraper along the rear 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 3 locations indicated by (A) shown in the figure from the rear door outer side.

Caution

•  When a drill the 3 locations indicated by (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 4 locations indicated by (B) shown in the figure from the rear door inner side.

Caution

•  When a drill the 4 locations indicated by (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 locations indicated by (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 rear 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 locations indicated by (D) shown in the figure, and peel off the weld bond adhering to the rear door outer panel and the rear door inner panel.

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9.  Move and remove the rear 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 rear door inner panel, degrease and clean the area after removing the rear door outer panel.

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Not using remover tool

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

Note

•  Use the scraper along the rear 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 3 locations indicated by (A) shown in the figure from the rear door outer side.

Caution

•  When a drill the 3 locations indicated by (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 4 locations indicated by (B) shown in the figure from the rear door inner side.

Caution

•  When a drill the 4 locations indicated by (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 rear door outer panel using a disc grinder.

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5.  Insert a chisel into the locations indicated by (C) shown in the figure, and peel off the weld bond adhering to the rear door outer panel and the rear door inner panel.

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6.  Move and remove the rear 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 rear door inner panel, degrease and clean the area after removing the rear door outer panel.

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