For 1990-2009 cars only
Removal Procedure
- Remove all related panels and components.
- Visually inspect and restore as much of the damage as possible to the factory specifications.
- Remove all sealers and anti-corrosion materials as necessary.
- Locate, mark and drill out all factory welds attaching the upper rail outer panel. Note the number of welds for installation of the service panel.
- Remove the damaged panels as necessary.
Important: The fender brackets are formed and pierced during vehicle assembly. The service parts are pre-drilled and will need to be located and shimmed accordingly, use three dimensional measuring equipment.
Important: There are a number of welds attaching the rear of the upper inner rail to the cowl panel extension and the strut tower cap (1). These welds can be accessed with the outer panels removed (2). Due to the limited access for welding, care must be taken when deciding the side of the panel from which to drill (3).
Sectioning the Upper Inner Rail
- Create a 50 mm (2 in) overlap in front of the strut tower (1).
- Measure 50 mm (2 in) forward from the cowl panel extension and mark a line.
- Cut the damaged rail square to the vehicle (2).
- Drill 8 mm (5/16 in) holes for plug welding.
- Cut the service rail long enough to overlap the remaining portion of the original rail 50 mm (2 in) (3).
- Position the service rail under the remaining portion of the original rail to create a 50 mm (2 in) overlap.
- Check for proper fit and plug weld accordingly.
Installation Procedure
- Prepare mating surfaces and check for proper fit of the upper rail service panels.
- Drill 8 mm (5/16 in) holes in the service panels for plug welding at the locations noted from the original panels.
- Check the position of the front fender mounting bracket location (1), use three dimensional measuring equipment.
- Plug weld accordingly.
- Install the upper tie-bar top panels to the upper rail assembly (2) and the radiator support assembly.
- Plug weld accordingly.
- Clean and prepare welded surfaces.
- Apply sealers and anti-corrosion materials, as necessary.
- Prime with two-part catalyzed primer.
- Install all related panels and components.
