5 door models

• Install the new rear panel and clamp it with vice-grips.

NOTE: Apply the spot sealer to the welding surface when spot welding.

• Check the rear panel position using the body dimensional drawings.

5 door models

A. New Rear panel

Saloon models

A. New Rear panel

6. Tack weld the new rear panel

• Weld the clamped sections for temporary installation.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

7. Open and close the boot lid to check for proper installation.

NOTE: Make sure the boot lid locks securely.

Position the rear panel in its correct position with the rear bumper and tail light installed.

8. Perform the main welding.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

• Make 20% to 30% more spot welds than there were holes drilled.

9. Finish the welded area.

• Level the welded areas with a disc sander, then even out high areas with a hammer being careful not to deform them.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

• Even out the spot welded flange area with a hammer and dolly.

10. Apply the sealer.

• Apply sealer to the rear side outer joint and around the tail light areas of the rear panel.
• Apply sealer to the rear panel and rear floor joint.

11. Apply the paint.

WARNING: 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 the skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. • Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.