Rear Side Outer Panel Replacement
1. Mass Production Body Welding Positions and Numbers - Remove

Rear Side Outer Panel, Rear Pillar Gutter, and Rear Pillar Stiffener





2. Construction - Remove

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new genuine supplied parts, as needed, according to the area and the degree of damage on the body.
Cut and pry off the rear side outer panel, and replace it.
NOTE: Select the sectioning location in consideration of the rear side outer panel repair part.
Check the rear pillar gutter position for damage. If necessary, replace the rear pillar gutter complete.
Check the rear pillar stiffener position for damage. If necessary, replace it separately from the rear inner pillar complete.
Replace the rear wheel arch separator and the rear pillar upper inner separator.



NOTE:
Position the replacement parts.
Before doing the main welding, check the body dimensions:
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Door hinge positions
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Rear pillar gutter and rear panel positions
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Windshield and door openings
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Tailgate opening
Temporarily install the related parts, then check for differences in level and clearance.
Check the external parts fitting positions. Make sure the body lines flow smoothly.
Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Roof and Side Panel Construction and Floor and Rear Body Construction.
Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)
( ): The number of welds

1. Rear Pillar Stiffener - Weld
1.
Remove the rear pillar stiffener (A) together with the rear upper inner separator (B) from the new rear inner pillar complete.
2.
Apply the sealer (C) without gaps all the way around the new upper inner separator and the rear inner pillar (D).
3.
Weld the rear pillar stiffener (A) to the rear pillar upper stiffener (B), the rear inner pillar (C), and the rear panel side rear stiffener (D).

2. Rear Pillar Gutter Complete - Weld
1.
Because the original adhesive (A) may burn when welding the rear pillar upper gutter, scrape out the adhesive from the underside of the roof panel (B) with a pick tool (C).
2.
Weld the rear pillar gutter complete (A) to the roof panel (B), the outer panel (C), and the rear inner pillar complete (D).

3. Wheel Arch Separator - Install
1.
Install the new wheel arch separator (A) on the rear inner panel (B). Apply the sealer (C) without gaps all the way around the separator and inside the outer panel repair part (D).

4. BSI Radar Unit Mounting Area - Check (With BSI radar unit)
1.
With Blind Spot Information (BSI) radar unit: Install the new rivnuts (A) to the outer panel repair part (B) with a rivnut tool.


5. Outer Panel Repair Part - Weld
1.
Weld the outer panel repair part (A).