For 1990-2009 cars only
- Note the amount and location of the spot welds.
- Remove the sealer and drill spot welds from:
- Cut the service part along the marked line as per illustration. DO NOT damage the hinge pillar reinforcement.
- Perform any additional procedures as necessary to remove the unused areas of the service part.
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section.
- Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
- Apply a permanent underbody sealant.
- Prime with a 2-part catalyzed primer.
- Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
- Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
- Measure and align the front body hinge piller outer 3/4 section. Clamp into place.
- Use a MIG to plug the weld.
- Stitch weld the entire hinge pillar sectioning joint. Make 25 mm (1 in) gaps between.
- Go back and complete the stitch weld. This will create a solid joint with a minimal heat distortion.
| 2.1. | The frame windshield side outer |
| 2.2. | The rail assembly engine compartment upper outer |
| 2.3. | The rocker panel assembly rocker outer |
Important: Cut the outer surface of the hinge pillar service part. The inner reinforcement is used as a backing plate when installing the new section.
Important: Ensure that proper corrosion protection processes are used on all repair areas.
Important: To ensure a secure weld, the sectioning joint should have a gap of approximately one and a half times the thickness of the metal. Trim the parts as necessary to achieve this.
