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: Section as required from 127 mm (5 in) forward of rail assembly upper outer to hinge pillar joint.

1. Note amount and location of spot welds.
2. Remove sealer and drill spot welds from:

2.1. | Engine compartment assembly side

2.2. | Rail engine compartment upper inner

3. Clean all weld seams with a wire brush. Prime and seal all repair areas.
4. Apply permanent underbody sealant.

Important: Ensure that proper corrosion proctection processes are used on all repair areas.

5. Prime with two-part catalyzed primer.
6. Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.
7. Create joint forward of rear hole in brace forward of front body hinge pillar.
8. Clean surface for welding and grind primer off new part at connecting points. Apply 3M® Weld-Thru Coating P/N 05913 (or equivalent) to all areas to be welded.
9. Cut new part allowing a 20 mm (0.79 in) overlap. Punch holes for plug welding as required. Use old part as guide.
10. Before installing new part, apply 3M® Underseal brand rubberized undercoating sealer P/N 08833 (or equivalent) around baffle.
11. Measure and align. Clamp in place.
12. Use MIG to plug weld.