FRONT DOOR OUTER PANEL INSTALLATION [PANEL REPLACEMENT]

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Symbol Mark

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Installation Procedure


Using hemming tool

1.  Drill the plug weld holes at the locations for the plug welds before installing a new part.

2.  Apply body sealer to the contact surface of the damping material shown in the figure and the front door (outer) panel.

Note
•  Body sealer is applied to fill the gap between the damping material and the front door (outer) panel for the purpose of front door (outer) panel vibration prevention and vibration sound prevention.
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3.  Apply adhesive agent to the shaded area of the front door (inner) panel.

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4.  Adjust the front door (inner) panel so that it fits properly before installing a front door (outer) panel (new part) and before the adhesive dries.

Note
•  For adhesive agent, use the following recommended agent or equivalent.

Recommended agent

Handleability time (minute)

Hardening time (minute)
ThreeBond 2088E
70
•  25°C {77°F}:1,440
•  120°C {248°F}:60
3M Panel Bonding Adhesive PN 8115
45
•  25°C {77°F}:1,440
•  60°C {140°F}:90

5.  After the adhesive agent has dried, perform on-dolly work for the 2 locations in area A shown in the figure using a hammer and a hard-plastic dolly.

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6.  Using a hammer, bend the flange of the front door (outer) panel to the angle where the flange can be pinched using a hemming tool.

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7.  Set the hemming tool to the flange part of the front door (outer) panel.

8.  Move the hemming tool in the direction of the arrows in the order of (1), (2), and (3), and adhere the flange of the front door (outer) panel to the front door (inner) panel by applying pressure.

Caution
•  When performing the hemming to the press line area, use a hammer and a hard-plastic dolly. If the hemming tool is used alone, it could deform the press line area.
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9.  Arc spot welds in the 4 locations in area B shown in the figure from the front door (inner) panel.

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10.  After crimping the flange in the upper part of the front door (outer) panel using pliers, crimp the 5 locations in area C shown in the figure using a hammer, hard-plastic dolly, and ponch.

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11.  Plug welds in the 2 locations in area D shown in the figure from the front door (outer) and install the front door (outer) panel.

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12.  Apply body sealer to the hemming part of the front door (outer) panel. (See BODY SEALING [WATER-PROOF AND RUST PREVENTIVE].)

13.  Apply rust prevention oil to the specified position. (See RUST PREVENTIVE TREATMENT [WATER-PROOF AND RUST PREVENTIVE].)


Not using hemming tool

1.  Drill the plug weld holes at the locations for the plug welds before installing a new part.

2.  Apply body sealer to the contact surface of the damping material shown in the figure and the front door (outer) panel.

Note
•  Body sealer is applied to fill the gap between the damping material and the front door (outer) panel for the purpose of front door (outer) panel vibration prevention and vibration sound prevention.
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3.  Apply adhesive agent to the shaded area of the front door (inner) panel.

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4.  Adjust the front door (inner) panel so that it fits properly before installing a front door (outer) panel (new part) and before the adhesive dries.

Note
•  For adhesive agent, use the following recommended agent or equivalent.

Recommended agent

Handleability time (minute)

Hardening time (minute)
ThreeBond 2088E
70
•  25°C {77°F}:1,440
•  120°C {248°F}:60
3M Panel Bonding Adhesive PN 8115
45
•  25°C {77°F}:1,440
•  60°C {140°F}:90

5.  After the adhesive agent has dried, perform on-dolly work for the 2 locations in area A shown in the figure using a hammer and a hard-plastic dolly.

a30zzb00000201

6.  Using a hammer, bend the flange of the front door (outer) panel to the angle where the flange can be pinched using a hemming tool.

a30zzb00000202

7.  Perform on-dolly work in the direction of the arrows in the order of (1), (2), and (3) using a hammer and a hard-plastic dolly, and adhere the flange of the front door (outer) panel to the front door (inner) panel by applying pressure.

Caution
•  After performing on-dolly work for the flange of the front door (outer) panel, verify that there is no gap between the flange and the front door (inner) panel. Otherwise, cracking could occur on the body sealer and water may penetrate resulting in rust, or vibration noise could occur caused by the flange vibrating.
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8.  Arc spot welds in the 4 locations in area B shown in the figure from the front door (inner) panel.

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9.  After crimping the flange in the upper part of the front door (outer) panel using pliers, crimp the 5 locations in area C shown in the figure using a hammer, hard-plastic dolly, and ponch.

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10.  Plug welds in the 2 locations in area D shown in the figure from the front door (outer) and install the front door (outer) panel.

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11.  Apply body sealer to the hemming part of the front door (outer) panel. (See BODY SEALING [WATER-PROOF AND RUST PREVENTIVE].)

12.  Apply rust prevention oil to the specified position. (See RUST PREVENTIVE TREATMENT [WATER-PROOF AND RUST PREVENTIVE].)