Replacing the rear floor
The dotted lines indicate the cutting lines, on the fragments the arrows indicate the cutting places. On the main view the arrows indicate the gas welding places.
Replacing the fuel tank floor (spare tire) and rear floor side members
The dashed lines indicate the cutting lines, the dots indicate the contact welding seams. In the main view, the arrows indicate the gas welding locations, and the arrows on the fragments indicate the cutting locations.
1. The replacement is carried out with the rear fenders, rear panel and rear panel reinforcement removed.
2. Use a thin chisel to cut off half of the rear. Use nippers to remove the remaining strips of metal, straighten and clean the deformed edges with an electric or pneumatic grinder (see fig. Replacing the rear floor).
3. Cut off half of the fuel tank (spare tire) from the side members and inner arches of the rear wheels (cutting lines are shown as dotted lines), remove the metal strips and smooth out the edges.
4. Use a chisel to cut off the side members from the inner arches of the rear wheels and the crossmember, remove the remaining strips of metal and clean the mounting areas.
5. Install new side members in place and gas weld them with L-62, L-68 rods in the places indicated by arrows in the figure Replacing the fuel tank floor (spare tire) and the rear floor side members.
6. Weld the central amplifier, the holder with an asbestos gasket placed under it and the main muffler mounting brackets to the bottom of the rear floor. Perform electric welding in a carbon dioxide environment with points every 40–50 mm using SV-08G1S or SV-08G2S wire with a diameter of 0.8 mm. Gas welding is allowed.
7. Install the rear floor in place and weld it with gas welding at the corners at the points indicated in the figure Replacing the fuel tank floor (spare tire) and the rear floor side members.
8. Install the reinforcement to the rear panel and weld it using carbon dioxide welding with spots every 40 mm. Install the rear panel in place and tack it to the body elements using gas welding (see subsection 10.8.5).
9. Weld the fuel tank floor (spare tire) gas welding at the points indicated in Fig. Replacing the fuel tank floor (spare tire) and the rear floor side members.
10. Perform a preliminary check of all the secured parts with the rear fenders and trunk lid hanging.
11.Eliminate assembly defects and finally weld the parts using carbon dioxide electric welding with SV-08G1S or SV-08G2S wire with a 10 mm long intermittent seam every 30 mm. Electric current 50–90 A. Gas welding with L-62 or L-68 brass rods with spots every 30–40 mm is allowed.