Underbody Rear Side Rail Replacement Sedan

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



3. Remove all related panels and components.
4. Repair as much of the damaged area as possible. Refer to Dimensions - Body .
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.



6. Remove the filler rocker inner panel (1).
7. Remove the door wheel house extension (2).

Important: There is a hidden weld under the wheelhouse and the brace opening.

8. Locate and drill out all the necessary factory welds.



9. Pry back the rear of the floor pan to access the spot welds at the front of the rail assembly.



10. Remove the rear rail.

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.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces for welding as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

Important: The service part includes a rear wheelhouse extension and a filler rocker inner panel. The rear rail can not be installed with the rear wheelhouse and filler rocker inner panel.

4. Drill out the spot welds.



5. Remove the rear wheel house extension and filler rocker inner panel.



6. Position the rear rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.



7. Plug weld accordingly.



8. Install the rear wheelhouse extension (1) to the rear rail (2).



9. Install the rear rocker inner panel (1).
10. Clean and prepare all of the welded surfaces.
11. Install all of the related panels and components.
12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
13. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
15. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.

Underbody Rear Side Rail Replacement Extended Sedan

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



3. Remove all related panels and components.
4. Repair as much of the damaged area as possible. Refer to Dimensions - Body .
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
6. Remove the inner and outer quarter panel to access the welds from the rail to the inner rocker panel area. Refer to Quarter Outer Panel Sectioning or to Quarter Inner Panel Replacement .
7. Remove the filler rocker reinforcement inner panel.



8. Remove the shock reinforcement wheel house extension (1).



9. Locate and drill out all the necessary factory welds under the inner rocker reinforcement.



10. Locate and drill out all necessary factory welds to remove the five bar (1).



11. Remove the rear rail.

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.

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces for welding as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

Important: The service part includes a rear wheelhouse extension.




4. Position the rear rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.



5. Plug weld accordingly.



6. Install the five bar (1).



7. Install the rear rocker inner panel reinforcement (1).
8. Install the quarter panel.
9. Install the inner panel.
10. Install all of the related panels and components.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
14. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.