- Remove the related parts.
- Parts to be removed when removing the back
panel.
- Rear seat belt and rear seat.
- Muffler, fuel tank and related parts.
- Chassis parts.
- Other related parts.
Caution : Do not smoke while working near the fuel
system. Keep open flame away from the fuel system. If necessary, remove the fuel tank and off lines.
- Roughly pull out and straighten the damaged area.
- Check the damage and roughly pull out and re
pair the related back panel, side panel, wheel
house inner, rear longitudinal and other damaged
parts with the frame straightener before remov
ing the extension rear floor panel, rear floor pane
and back panel.
- Attach the car to the frame straightener by tightening the underbody clamps located at the jack
up designated points on the bottom of the frame
door opening.
Note : Measure in reference to the dimensions on
the body repair chart.
- Cut and pry off the back panel.
- The back panel to be cut and pried off when removing the back panel.
- Cut and pry off the rear floor and extension rear floor
panel.
- Cut off the rear floor and extension rear floor with
a gas torch or air chisel leaving the spot welded
flanges of the rear longitudinal along the bold line
in the figure below.
Note : Cut the rear floor 15mm(0.59in.) from welded
flange of the cross member rear seat.
- Center punch around the spot weld imprints with
the rear longitudinal, extension rear longitudinal
and web plate.
- Use the special spot cutter to drill holes at the
spot weld nuggets on the center punched areas.
Note : When drilling holes be careful not to drill down
to the rear longitudinal, extension rear longitudinal
and web plate themselves.
- Cut and pry off the remaining rear floor and extension rear floor panel with an air chisel, leaving
the welding flanges intact.
- Level and finish the burrs from the pried off spot
welds with disc sander and repair all cracks, holes
or other defects by welding also repair the rear
longitudinal and extension rear longitudinal if necessary.
Caution : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grinding.
- Peel off the undercoat and sealer.
- Heat the undercoat and sealer at the welding
areas with a gas torch and peel off the undercoat
and sealer with a steel spatula.
- Mold damaged related parts.
- Use a hammer and dolly to mold damaged areas
of the rear longitudinal and extension rear longitudinal.
- Even out the welding flanges with a hammer and
dolly.
- Fill any holes drilled by welding.
Caution : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
- Level and finish the burrs from the pried off spot
welds with disc sander.
- Sand off the paint and undercoat from both sides
of the flange to be welded.
- Cut the new rear floor to align it with the body, then
set the new rear floor and extension rear floor.
- Cut the new part so it overlaps the cross member rear seat by approximately 40mm(1.57in.).
- Grind both sides of the welding section of the rear
floor and extension rear floor with a disk sander
to remove the paint and expose the steel plate.
Caution : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grinding.
- Set and clamp the new panel in place with the vise grips.
Note : Use of jigs is recommended for correct positions and check that the both rear logitudinal is parallel.
- Tack weld the clamped section for temporary installation.
Caution : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
- Remove the vise grips and temporarily install the
rear panel, then check the alignment, level differences and outer appearance.
- Remove the main welding.
- Weld the rear floor and cross member rear seat
with a MIG welder fillet weldings as shown.
- Spot weld the rear floor and extension rear floor
with rear longitudinal flange areas and web plate
flanges as shown.
Caution : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
- Perform a trial welding first, and check the weld
ing condition.
- Increase the number of spot by 20% for areas to
be spot welded.
- Weld the back panel
- The back panel to be welded when replacement
the back panel.
- Finish the welding area.
- Level the MIG welded areas with a disc sander,
then even out high areas with a hammer being
careful not to deform them.
Caution : To prevent eye injury, wear goggles or
safety glasses whenever standing, cutting, or grinding.
- Use a hammer and dolly to even out the spot
welded areas for a close fill the flange surface
together.
- Apply the sealer.
- Apply the sealer at the overlapped areas of the
rear floor and extension rear floor, and welded
surfaces of the matching panel and all sealing
gaps completely.
- Apply the undercoat.
- Undercoat to the rear wheelhouse and designated
rear floor.
- Apply the paint
- CAUTION
- Ventilate when spraying paint. Most paint contains
substances that are harmful if inhaled or swallowed.
Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate
clothing when painting.
- Paint is flammable. Store in a safe place, and
keep it away from sparks, flames or cigarettes.
- Apply the deadner.
- Clean the passenger and trunk compartment.
- Apply the deadner to the surface of rear floor and
extension rear floor.
- Install the related parts.
- Install in the reverse order in which they were removed.
- Check and adjust
- Check clearances and level differences.
- Check the trunk locking and unlocking condition.
- Check all operation.
- Check for water leaks in the trunk compartment.
Note : Use specified check sheet for operation
check properly.