Replacement3-1 Rear Side Outer Panel3-23

Rear Side Outer Panel3-23

Mass Production body Welding Diagram

Left side:

Rear Side Outer Panel (cont'd)3-24

Mass Production Body Welding Diagram (cont'd)

Right side:

NOTE: The left side is symmetrical.

3-25

Removal

Cut and pry off the rear side outer panel, and if necessary replace the rear fender stiffener.

Rear Side Outer Panel (cont'd)3-26

Removal (cont'd)

Check the rear pillar gutter and rear pillar lower stiffener position, and check for damage.

If necessary, cut the rear pillar gutter, and replace the rear pillar gutter and rear pillar lower stiffener as an assembly.

Left side:

Right side:

3-27

Installation

1. Check the position of the inner panel and rear inner pillar, and weld the new rear fender stiffener or new jack holder.
   

Left side:

Right side:

2. Cut the new rear pillar gutter, and set it into position and install the mounting bolts.
   

   

   
   
3. Check the body dimensions (see section 4) , and tack weld the rear pillar gutter.
   
4. Cut the repair part (outer panel), and set it into position.
   
5. Temporarily install the door, tailgate, taillight, and rear bumper, and check for differences in level and clearance. Make sure the body lines flow smoothly.
   

   Check the operation of the door and tailgate.

6. Remove the outer panel, and weld the new rear pillar gutter.
   

   

   
   

Rear Side Outer Panel (cont'd)3-28

Installation (cont'd)

7. Clamp the new outer panel, and recheck the clearance and alignment of the tailgate and door.
   
8. Do the main welding.
   

   Weld the rear pillar lower stiffener and rear pillar gutter.

   

   
   

   Weld the outer panel and rear pillar gutter.

   

   
   

   Attach a patch at the cut section of the quarter pillar, rear pillar, side sill and plug weld them.

   

   
   

Replacement3-1 Rear Side Outer Panel3-23