For 1990-2009 cars

### Removal Procedure

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.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all of the related panels and the components.
4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
5. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .

Important: Do not section the front rail except where indicated.

6. Measure from 127 mm (5 in) forward of the front rail to the hinge pillar joint.
7. Cut the front rail at the marked location.

Important: Do not damage any inner panels or reinforcements.

8. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front side upper rail.
9. Remove the damaged front rail from the vehicle.

### Installation Procedure

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.
1. Scribe a line around the service part allowing for a 20 mm (0.79 in) overlap.
2. Cut at the marked location.

Remove the front portion of the service part.

3. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
4. Prepare the overlap weld area as necessary for welding.
5. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
6. Position the front rail section using 3-dimensional measuring equipment.

Clamp the front rail in place.

7. Tack weld the front rail into position.
8. Inspect the front rail for proper dimensions using 3-dimensional measuring equipment.
9. Plug weld accordingly.
10. Clean and prepare the welded surfaces.
11. Install all of the related panels and components.
12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
13. Paint the repaired area. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
14. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.