For 1990-2009 cars

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 engine compartment rail may be sectioned in the area specified. Repair and restore as much structure as possible before cutting and preparing joint for welding. Do not section reinforcements. The following conditions for repair MUST be met.

No wrinkles or distortions in post repair rail surfaces may exceed 2 mm (5/64 in.) up or down in deflection of the rail surface or structure from the original location.

1. Note amount and location of spot welds. The joint is located forward of the front of dash lower panel.
2. Remove sealer and drill spot welds from:

2.1. | Engine compartment rail extension

2.2. | Front end assembly

2.3. | Engine compartment side outer

2.4. | Front bumper bar

Notice: Do not damage the inner reinforcements.

Drill 8 mm (5/16 in) plug weld holes as necessary in the location 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 weld. Switch weld along the entire joint. Make 25 mm (63/64 in) gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. Refer to "Spaceframe Sectioning -- General Notes."

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.