Body Repair Manual

5. Set the new rear panel.
• Paint the inside of the panel with the body color.
• See Paint Repair section.
• Ventilate when spraying paint. Most paint
contains substances that are harmful if inhaled
or swallowed. Read the paint label before
opening the paint container.
• Avoid contact with 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.
• Remove the undercoat from the welding section of
the panel and expose the steel plate using a disc
sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
• Install the new rear panel and clamp it with vise-
grips.
NOTE: Apply the spot sealer to the welding surface when
spot welding.
• Check the rear panel position using the body dimen-
sionnal drawings (see section 6).
6. Tack weld the rear panel.
• Weld the clamped sections for temporary installa-
tion.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
7. Open and close the trunk lid to check for proper
installation.
NOTE: Make sure the trunk lid or tailgate locks securely.
Position the rear panel in its correct position with the rear
bumper and taillight installed.
8. Perform the main welding.
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.
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