Replacement

Replacement

1. See Rear Floor Replacement for removal of related parts.
2. Peel off the undercoat. Heat the undercoat at the weld areas of the rear floor and rear frame with a gas torch, and peel off the undercoat with a metal spatula.

CAUTION: Be careful not to burn the fittings inside the luggage compartment when heating.

3. Remove the rear floor cross member.

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

• Centre punch around the spot weld imprints on the rear floor cross member from inside the luggage compartment.
• Drill 5 mm (0.2 in) holes through the nuggets.
• Keep the holes to a minimum since they will be used as weld holes for MIG plug welding of the new part.

A. Rear Floor Cross Member

• Centre punch around the spot weld imprints on the rear frame.
• Drill holes with a spot cutter.
• Be careful not to let them penetrate through to the rear frame.
• Prise off the part with a chisel.

4. Set the new rear floor cross member.

• Sand off undercoat from both sides of the areas to be welded to expose the steel plate.

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

• Set the new rear floor cross member in the original position properly and place a jack under the rear floor cross member for support.
• Refer to the set position body dimensional drawing for proper positioning of the rear floor cross member.
• Temporarily weld the mating surfaces with the rear frame.

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

A. New Rear Floor Cross Member

• Check the rear floor cross member is in its correct position with the fuel tank installed.