TOYOTA 2003-2008 4Runner Repair Manual, Front Door Outer Panel (Assy)

BODY PANEL REPLACEMENT

FRONT DOOR OUTER PANEL (ASSY)

REMOVAL

BP-23

F14039-A

POINT

1 Before removing the outer panel, make the installation position with a tape. 2 After grinding off the hemming location, remove the outer panel.

F14039

BP-24

INSTALLATION

 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension

diagram. (See the body dimension diagram)

 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the

finish.

 After welding, apply the polyurethane foam to the corresponding parts.  After welding, apply body sealer and under-coating to the corresponding parts.  After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

BODY PANEL REPLACEMENT

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection

beam and back side of the new parts.

HINT:

1) Apply sealer evenly about 10mm (0.39in.) from the flange and 3mm (0.12in.) in diameter to the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.

2 Bend the flange hem about 30 with a hammer and dolly, then fasten tightly with a hemming tool.

HINT:

1) Perform hemming in three steps, being careful not to warp the panel.

2) If a hemming tool cannot be used, hem with a hammer and dolly.