REAR DOOR OUTER PANEL INSTALLATION [PANEL REPLACEMENT]

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Symbol Mark

ac5wzb00000416

Installation Procedure (4SD)


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.
am6zzb00000657

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

am6zzb00000658

4.  Adjust the rear door inner panel so that it fits properly before installing a new rear door outer panel 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 locations indicated by (A) shown in the figure using a hammer and a hard-plastic dolly.

am6zzb00000659

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.

ac5wzb00000444

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 (3), 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.
am6zzb00000680

9.  Arc-spot weld the 4 locations indicated by (B) shown in the figure from the rear door inner side.

am6zzb00000661

10.  After crimping the flange in the upper part of the front door outer panel using pliers, crimp the location indicated by (C) shown in the figure using a hammer, hard-plastic dolly, and punch.

am6zzb00000662

11.  Plug weld the 2 locations indicated by (D) shown in the figure from the rear door outer side, and install the rear door outer panel.

am6zzb00000663

12.  Apply body sealer to the hemming part of the rear 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 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.
am6zzb00000657

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

am6zzb00000658

4.  Adjust the rear door inner panel so that it fits properly before installing a new rear door outer panel 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 locations indicated by (A) shown in the figure using a hammer and a hard-plastic dolly.

am6zzb00000659

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.

ac5wzb00000444

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 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.
am6zzb00000664

8.  Arc-spot weld the 4 locations indicated by (B) shown in the figure from the rear door inner side.

am6zzb00000661

9.  After crimping the flange in the upper part of the front door outer panel using pliers, crimp the location indicated by (C) shown in the figure using a hammer, hard-plastic dolly, and punch.

am6zzb00000662

10.  Plug weld the 2 locations indicated by (D) shown in the figure from the rear door outer side.

am6zzb00000663

11.  Apply body sealer to the hemming part of the rear 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])


Installation Procedure (WGN)


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.
am6zzb00000665

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

am6zzb00000666

4.  Adjust the rear door inner panel so that it fits properly before installing a new rear door outer panel 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 locations indicated by (A) shown in the figure using a hammer and a hard-plastic dolly.

am6zzb00000667

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.

ac5wzb00000444

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 (3), 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.
am6zzb00000679

9.  Arc-spot weld the 4 locations indicated by (B) shown in the figure from the rear door inner side.

am6zzb00000669

10.  After crimping the flange in the upper part of the front door outer panel using pliers, crimp the location indicated by (C) shown in the figure using a hammer, hard-plastic dolly, and punch.

am6zzb00000662

11.  Plug weld the 2 locations indicated by (D) shown in the figure from the rear door outer side, and install the rear door outer panel.

am6zzb00000673

12.  Apply body sealer to the hemming part of the rear 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 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.
am6zzb00000665

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

am6zzb00000666

4.  Adjust the rear door inner panel so that it fits properly before installing a new rear door outer panel 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 locations indicated by (A) shown in the figure using a hammer and a hard-plastic dolly.

am6zzb00000667

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.

ac5wzb00000444

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 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.
am6zzb00000675

8.  Arc-spot weld the 4 locations indicated by (B) shown in the figure from the rear door inner side.

am6zzb00000669

9.  After crimping the flange in the upper part of the front door outer panel using pliers, crimp the location indicated by (C) shown in the figure using a hammer, hard-plastic dolly, and punch.

am6zzb00000662

10.  Plug weld the 2 locations indicated by (D) shown in the figure from the rear door outer side.

am6zzb00000673

11.  Apply body sealer to the hemming part of the rear 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])