For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Remove all of the related panels and the components.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
- Measure from 127 mm (5 in) forward of the front rail to the hinge pillar joint.
- Cut the front rail at the marked location.
- Locate and drill out all factory welds. Note the number and location of the welds for installation of the front side upper rail.
- Remove the damaged front rail from the vehicle.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.
Important: Do not section the front rail except where indicated.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Scribe a line around the service part allowing for a 20 mm (0.79 in) overlap.
- Cut at the marked location.
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
- Prepare the overlap weld area as necessary for welding.
- Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
- Position the front rail section using 3-dimensional measuring equipment.
- Tack weld the front rail into position.
- Inspect the front rail for proper dimensions using 3-dimensional measuring equipment.
- Plug weld accordingly.
- Clean and prepare the welded surfaces.
- Install all of the related panels and components.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Paint the repaired area. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
Remove the front portion of the service part.
Clamp the front rail in place.
