For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Remove all related panels and components.
- Restore as much of the damage as possible.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Locate, mark, and drill out all factory welds attaching the outer rail.
- Remove the damaged outer rail.
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Note: Sectioning of the front upper rails is not recommended.
Installation Procedure
- Prepare the mating surfaces as necessary.
- Apply Weld-Thru Coating to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panels.
- Temporarily position the outer rail on the vehicle.
- Verify the location using 3-dimensional measuring equipment.
- Plug weld accordingly.
- Clean and prepare welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
- Install all of the related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Enable the SIR system. Refer to SIR Disabling and Enabling.
Note: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in).
