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

Important: When replacing panels that involve servicing of stationary glass, refer to Adhesive Installation of Stationary Windows before performing any priming or refinishing.

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 damage as possible to factory specifications. Refer to Dimensions - Body .

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

5. Note the location and 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. Perform the necessary procedures to gain access to repair. Refer to Radiator Upper Support Replacement , Upper Rail Replacement , Front Wheelhouse Replacement or to Windshield Lower Panel Replacement .



7. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.




Important: Do not damage any inner panels or reinforcements.

8. Cut the inner-upper rail.



9. Remove the damaged front inner upper rail.

1. Mark the service part at the inboard contour (1) to create a weld flange.



2. Cut the service part.




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) apart.

3. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in locations noted from the original panel.
4. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the service part. Locate these holes 40 mm (1½ in) apart.
5. Prepare all mating surfaces as necessary.
6. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces



7. Align the service part over the stepped tab.



8. Plug weld accordingly.



9. Complete the necessary procedures. Refer to Radiator Upper Support Replacement , Upper Rail Replacement , Front Wheelhouse Replacement or to Windshield Lower Panel Replacement .
10. Clean and prepare all welded surfaces.
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 repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
13. Install all related panels and components.
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.