REAR DOOR OUTER PANEL REMOVAL [PANEL REPLACEMENT]

id098008560200

Symbol Mark

ac5uub00000086

Removal Procedure

Using remover tool

1.  Refer to [DAMAGED VEHICLE HANDLING] and [HIGH VOLTAGE SERVICE CAUTIONS] in the general information, implement the necessary measures, and then start the procedure.(See DAMAGED VEHICLE HANDLING [(E)].) (See HIGH VOLTAGE SERVICE CAUTIONS.)

2.  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.

a30zzb00000098

3.  Drill the spot welds in the 67 locations in area A shown in the figure from the rear door (outer) panel.

Note

•  When drilling the spot welds in the 67 locations in area A shown in the figure, do not drill through-holes in consideration of the workability when installing.

a30zzb00000099

4.  Drill the spot welds in the 4 locations in area B shown in the figure from the rear door (inner) panel.

Note

•  When drilling the spot welds in the 4 locations in area B shown in the figure, do not drill through-holes in consideration of the workability when installing.

a30zzb00000100

5.  Using a disc grinder, grind the location in area C shown in the figure.

a30zzb00000258

6.  Partially spread open the wider part of the flange for each rear door (outer) panel using remover pliers.

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

8.  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.

a30zzb00000102

9.  Tap a chisel in the 2 locations in area D shown in the figure and peel off the adhesive adhering to the rear door (outer) panel and the rear door (inner) panel.

a30zzb00000259

10.  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 adhesive remaining on the rear door (inner) panel, degrease and clean the area after removing the rear door (outer) panel.

a30zzb00000124

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.

a30zzb00000098

2.  Drill the spot welds in the 3 locations in area A shown in the figure from the rear door (outer) panel.

Note

•  When drilling the spot welds in the 3 locations in area A shown in the figure, do not drill through-holes in consideration of the workability when installing.

a30zzb00000099

3.  Drill the spot welds in the 5 locations in area B shown in the figure from the rear door (inner) panel.

Note

•  When drilling the spot welds in the 5 locations in area B shown in the figure, do not drill through-holes in consideration of the workability when installing.

a30zzb00000100

4.  Using a disc grinder, grind the edge around the hemming part of the rear door (outer) panel.

a30zzb00000125

5.  Insert a chisel into the 2 locations in area C shown in the figure and peel off the adhesive adhering to the rear door (outer) panel and the rear door (inner) panel.

a30zzb00000260

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 adhesive remaining on the rear door (inner) panel, degrease and clean the area after removing the rear door (outer) panel.

a30zzb00000127