For 1990-2009 cars

## Rear Compartment Pan Assembly Replacement Front

Important: Sedan shown; wagon similar.

Important: Some parts have structural weld-thru adhesive in the joint areas. It is necessary to replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.

1. Note amount and location of spot welds.
2. Remove sealer and drill spot welds from:

• | Panel body side inner.

• | Rocker panel outer.

• | Quarter panel.

• | Front floor panel.

• | Wheelhousing.

3. It may be necessary to construct a lamp joint to overlap the new part over the existing floor section by 20 mm (25/32 in.). Attach at this point by installing new structural sport welds at cut line.
4. Clean all weld seams with a wire brush. Prime and seal all repair areas.
5. Apply permanent underbody sealant.

Important: Ensure that proper corrosion protection processes are used on all repair areas.

6. Prime with two-part catalyzed primer.
7. Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.
8. Clean surface for welding and grind primer off new part at connecting points. Apply 3M® Weld-Thru Coating P/N 05913 (or equivalent) to all areas to be welded.

Important: Add additional components for wagons if applicable.

9. Measure and align. Clamp in place.
10. Use MIG to plug weld.

## Rear Compartment Pan Assembly Replacement Rear

Important: Sedan shown; wagon similar.

Important: Some parts have structural weld-thru adhesive in the joint areas. It is necessary to replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.

1. Note amount and location of spot welds.
2. Remove sealer and drill spot welds from:

• | Panel body side inner.

• | Rocker panel outer.

• | Quarter panel.

• | Front floor panel.

• | Wheelhousing.

3. It may be necessary to construct a lamp joint to overlap the new part over the existing floor section by 20 mm (25/32 in.). Attach at this point by installing new structural sport welds at cut line.
4. Clean all weld seams with a wire brush. Prime and seal all repair areas.
5. Apply permanent underbody sealant.

Important: Ensure that proper corrosion protection processes are used on all repair areas.

6. Prime with two-part catalyzed primer.
7. Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.
8. Clean surface for welding and grind primer off new part at connecting points. Apply 3M® Weld-Thru Coating P/N 05913 (or equivalent) to all areas to be welded.

Important: Add additional components for wagons if applicable.

9. Measure and align. Clamp in place.
10. Use MIG to plug weld.