For 1990-2009 cars

Important: Sedan shown; wagon similar

Important: Some parts have structural weld-thru adhesive in the joint areas. It is necessary to replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.

Important: Only the outer rocker panel may be sectioned in the areas specified. Repair and restoration of as much structure as possible before cutting and preparing joint for welding is imperative. No reinforcements may be sectioned.

1. Note amount and location of spot welds.

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.

2. Trim the parts as necessary to achieve this type of gap.
3. Clean all weld seams with a wire brush.
4. Prime and seal all repair areas. Apply permanent corrosion protection process.
5. Remove the sealer and drill spot welds from areas necessary to place joint in areas specified below door hinge welds in front body hinge pillar and on center pillar. The lock pillar performs additional procedures as necessary to remove unused areas of the service part. Drill 8mm (5/16 in) plug weld holes as necessary in the locations noted from the original section. Clean surface for welding and grind Elpo primer off new part at connecting points. Apply 3M® Weld-Thru Coating P/N 05913 (or equivalent) to all areas to be welded. Stitch weld along the entire joint. Make 25mm (1 in) gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.