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.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Sectioning of the front upper rails is not recommended.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panels.
- Prepare the mating surfaces as necessary.
- Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
- Position the outer rail on the vehicle. Inspect for proper fit 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 .
Important: 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).
