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

Rear Panel



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.
Turn up the outer panel flange, and cut the lower portion of the rear pillar stiffener on both sides. From the passenger's compartment, cut the upper portion of the rear panel side front stiffener on both sides.
Pull out the rear panel complete backward, and remove it from the body.
If necessary, replace the rear frame flange at the same time.



NOTE:
Position the replacement parts.
Before doing the main welding, check the body dimensions:
?
Rear pillar gutter and rear panel positions
?
Tailgate opening
?
Front floor and rear floor, under view
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)
( ) and ( )*: The number of welds

1. Rear Frame Flange - Weld
1.
Weld the rear frame flange (C) to rear frame upper stiffener B and rear frame A.
(?)*: Welding positions with rear frame A and rear frame upper stiffener B, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 13 in the table shown below.
Spot welding conditions
No. 13
8000 A
600 ms
3432 N (350 kgf)

Welding positions (D): Must be welded according to the following conditions.
Plug hole diameter: ?10 mm (0.39 in)
Welding wire: Must use wire with a tensile strength of 980 MPa or higher (142 ksi or higher).

2. Rear Panel - Weld
1.
Remove the rear panel side front stiffener (A) from the new rear panel complete (B) on both sides.
2.
Set the new rear panel complete (A) to the body, and check it into position.
3.
Weld the rear panel side front stiffener (A) to the rear panel side rear stiffener (B), the rear inner lower pillar (C), and the rear panel upper stiffener (D) on both sides.
4.
Weld the rear panel side front/rear stiffeners (A) to the rear floor side panel (C) and rear frame upper stiffener B on both sides.
(?)*: Welding positions with rear frame upper stiffener B, include ultra high-strength steel (1500 MPa) parts.

Welding positions (D): Must be welded according to the following conditions.
Plug hole diameter: ?10 mm (0.39 in)
Welding wire: Must use wire with a tensile strength of 980 MPa or higher (142 ksi or higher).
5.
Weld the rear panel (A) to the rear floor (B) and the rear frame flange (C).
6.
Weld the rear pillar stiffener access windows (A) on both sides.
7.
Weld the outer panels (A) on both sides.

3. 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.