For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Remove all related panels and components.
- Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Section the windshield pillar outer between the points of 100 mm (4 in) through 200 mm (8 in) when measured down from the windshield header flange.
- Section the rocker panel outer between the rear point of the down turned tab on the upper pinch weld flange and 325 mm (13 in) when measured rearward of the down turned tab.
- Locate and drill out all factory welds. Note the number and location of the welds for installation of the front hinge pillar.
- Remove the damaged front hinge pillar.
- Remove the structural reinforcement insert material and the adhesive from the inner panels.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Cut the service part to fit the remaining original panel. To ensure a secure weld, sectioning joints should have a gap of approximately one and a half times the thickness of the metal.
- Construct an 100 mm (4 in) backing plate for the rocker panel section joint, from the unused portion of the service part or the undamaged sections of the original panel. Trim the backing plate as necessary to fit behind the sectioning joint.
- Construct 50 mm (2 in) an backing plate for the windshield pillar section joint, from the unused portion of the service part or the undamaged sections of the original panel. Trim the backing plate as necessary to fit behind the sectioning joint.
- Drill 8 mm (5/16 in) plug weld holes as necessary along locations noted from original panel.
- Prepare all mating surfaces as necessary.
- Apply 3M Pinch-weld Urethane Primer P/N 08686 (or equivalent) to the structural reinforcement insert. Allow the primer to dry for 5-10 minutes.
- Apply 3M Fast Cure Autoglass Urethane P/N 08690 (or equivalent) to the primed areas of the structural reinforcement insert.
- Attach all the structural reinforcement inserts to the front hinge pillar.
- Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
- Position the front hinge pillar to the vehicle using 3-dimensional measuring equipment. Clamp the front hinge pillar into place.
- Plug weld accordingly.
- Stitch weld along both rocker and windshield pillar section joint, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between.
- Complete the stitch weld until entire joint is welded.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.Important: Ensure that the urethane adhesive does not contact the lower hinge adjustment plate, or block the sunroof drain hose channel.
