For 1990-2009 cars

## Floor Pan Assembly Pan Overlap

### Removal Procedure

1. Visually inspect and restore as much of the damage as possible.
2. Remove all related panels and components including fuel tank.
3. Remove both inner wheelhouse braces. Identify weld locations and drill through one layer of metal only.
4. Remove the following as necessary:

• | Sealers

• | Sound deadeners

• | Anti-corrosion materials

5. Apply a 1 inch (25 mm) piece of masking tape to the floor pan from the front edge of the floor pan to the rear edge of the wheelhouse, where pan mates to wheelhouse, along the entire contour of both sides of pan.
6. Cut along inboard side of tape to create weld flange.
7. Locate factory seam at front edge of crossbar, rearward of seat back.
8. Locate, mark and drill through one layer only, all factory welds which secure floor to rails. Note the number and location of welds for installation of the floor service panel.
9. Remove the damaged floor section.

### Preparation for Installation

1. Lay 20 mm ( ¾ in) masking tape along the contour of the floor pan service apart where it will mate to the wheelhouse.
2. Cut along the inboard side of the tape and remove unused portion of the floor pan.
3. On rear section of the floor pan service part, from end of wheelhouse to tail panel, create a 25 mm (1 in) downward-turned flange.
4. Drill 8 mm (5/16 in) plug weld holes as necessary, noted from original locations in floor pan.

### Installation Procedure

1. Prepare mating surfaces with suitable weld-through primer.

Important: Carefully bend but do not crease the front corners of the floor pan to allow it to fit inside floor pan compartment.

2. Position the service floor pan.
3. Check for proper fit using 3-dimensional measuring.
4. Clamp in place.
5. Plug weld accordingly.
6. Install both dynamic inner wheelhouse braces.
7. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

8. Apply approved anti-corrosion primer.
9. Apply body sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations.
10. Install all related panels and components.