For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to Disabling the SIR System in SIR.
- Disconnect the negative battery cable.
- Remove all related panels and components.
- Repair as much of the damage as possible. Refer to Dimensions - Body .
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
- Locate and drill out all the necessary factory welds.
- Remove the full rail.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: The rail replacement front compartment is joined to the front longitudinal and crossmember dash lower center. It forms the base for the front suspension and is maintaining the rigidity of the front parts. Pay particular attention to the position and dimensions of the weld joints and weld carefully.
Important: This assembly is replaced at factory seams.
Important: Note the number and location of the factory welds for installation of the full rail service part.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
- Prepare all mating surfaces as necessary.
- Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
- Position the full rail service part to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.
- Plug weld accordingly.
- Clean and prepare all of the welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
- Install all of the related panels and components.
- Connect the negative battery cable.
- Enable the SIR system. Refer to Enabling the SIR System in SIR.
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.
