For 1990-2009 cars

### Removal Procedure

Note: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Repair as much of the damaged area as possible. Refer to Dimensions - Body.
4. Remove all related panels and components.

• | Remove the battery tray. Refer to Battery Tray Replacement.

• | Remove the headlamp. Refer to Headlamp Replacement.

• | Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement.

• | Remove the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement.

• | Remove the fuse box.

Note: Do not damage any inner panels or reinforcements.

5. Cut out the headlamp mount panel.

Note: Note the number and location of the welds for installations of the service part.

6. Locate and drill out all of the necessary factory welds.
7. Remove the damaged headlamp mount panel.

### Installation Procedure

1. Prepare new headlamp mount panel outer in the area (1).

2x slots 6x20 mm (0.2x0.8 in).

2. Apply bodywork repair through structural adhesive to body. Refer to Structural Adhesive Body Repairs.
3. Position the headlamp mount panel inner.

Note: Refer to Welded, Brazed, and Riveted Joint Specifications.

4. Spot weld the headlamp mount panel inner accordingly.
5. Apply bodywork repair through structural adhesive to body. Refer to Structural Adhesive Body Repairs.
6. Position the headlamp mount panel outer.

Note: Refer to Welded, Brazed, and Riveted Joint Specifications.

7. Spot weld the headlamp mount panel outer accordingly.
8. MIG-braze the headlamp mount panel outer.
9. Grind MIG brazed seams.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
11. Install all related panels and components.

• | Install the battery tray. Refer to Battery Tray Replacement.

• | Install the headlamp. Refer to Headlamp Replacement.

• | Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement.

• | Install the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement.

• | Install the fuse box.

12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
13. Enable the SIR system. Refer to SIR Disabling and Enabling.