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 if necessary. Refer to Anti-Corrosion Treatment and Repair .
- Note structural adhesive locations.
- Measure down 220 mm (8 5/8 in) from the edge of the door opening. Create a cut line.
- Cut the panel where sectioning is to be performed.
- Locate, mark, and drill out all the necessary factory welds.
- Remove the damaged front pillar.
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Warning: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.
Note: Do not damage any inner panels or reinforcements.
Note: Note the number and location of the factory welds for installation of the center pillar.
Installation Procedure
- Measure the service part 30 mm (1 3/16 in) longer than the original reinforcement to allow for an overlap.
- Cut the service part at this sectioning location.
- Cut the service part in the corners as shown and step the tabs inward to allow the service part to fit under the original reinforcement.
- Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original reinforcement. Locate these holes 13 mm (½ in) from the edge and spaced 40 mm (1½ in) apart.
- Drill 8 mm (5/16 in) plug weld holes in the service reinforcement as necessary in the locations noted from the original panel.
- Prepare all mating surfaces, as necessary.
- Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
- Apply structural adhesive Lord 108 to locations noted in the removal procedure.
- Align service part on the vehicle using 3-dimensional measuring equipment.
- Plug weld accordingly.
- To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch weld along the seam with 25 mm (1 in) gaps between them. Repeat and complete the stitch weld.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area if necessary. Refer to Anti-Corrosion Treatment and Repair .
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
- Install all 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).
