For 1990-2009 cars

## Body Side Outer Panel Replacement Sedan/Wagon

### Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

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 related panels and components.
4. Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

Important: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the body side panel.

Important: If the body side panel is being replaced the roof outer panel and the roof side rail reinforcement must be replaced to allow the replacement of the center pillar structural reinforcement insert.

7. Remove the roof outer panel. Refer to Roof Outer Panel Replacement .
8. Remove the damaged body side outer panel.

### 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. Drill 8 mm (5/16 in.) plug weld holes as necessary along locations noted from original panel.
2. Prepare all mating surfaces as necessary.

Important: Ensure that the urethane adhesive does not contact the lower hinge adjustment plate, or block the sunroof drain hose channel.

3. Apply 3M Pinchweld Urethane Primer P/N 08686 (or equivalent) to the structural reinforcement insert. Allow the primer to dry for 5-10 minutes.
4. Apply 3M Fast Cure Autoglass Urethane P/N 08690 (or equivalent) to the primed areas of the structural reinforcement insert.
5. Attach all the structural reinforcement inserts to the body side panel inner.
6. Position the roof side rail reinforcement to the center pillar.
7. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
8. Position the body side panel to the vehicle using 3-dimensional measuring equipment. Clamp the body side panelinto place.
9. Plug weld accordingly.
10. Install the roof outer panel. Refer to Roof Outer Panel Replacement .
11. Clean and prepare all welded surfaces.
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 repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
14. Install all related panels and components.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
16. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.