REAR 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 rear door (outer) panel.

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

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4.  Adjust the rear door (inner) panel so that it fits properly before installing a rear 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 location 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 rear 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 rear door (outer) panel.

8.  Move the hemming tool in the direction of the arrows in the order of (1), (2) and adhere the flange of the rear door (outer) panel to the rear 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.  Plug welds in the 67 locations in area B shown in the figure from the rear door (outer) panel and install the rear door (outer) panel.

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

11.  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 rear door (outer) panel.

Note
•  Body sealer is applied to fill the gap between the damping material and the rear door (outer) panel for the purpose of rear door (outer) panel vibration prevention and vibration sound prevention.
a30zzb00000208

3.  Apply adhesive agent to the shaded area of the rear door (inner) panel.

a30zzb00000209

4.  Adjust the rear door (inner) panel so that it fits properly before installing a rear 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 location 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 rear door (outer) panel to the angle where the flange can be pinched using a hemming tool.

a30zzb00000211

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

Caution
•  After performing on-dolly work for the flange of the rear door (outer) panel, verify that there is no gap between the flange and the rear 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.  Plug welds in the 67 locations in area B shown in the figure from the rear door (outer) panel and install the rear door (outer) panel.

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

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