For 1990-2009 cars

### 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. Section the rear rail side underbody ONLY at 185 mm forward of the rear edge of the rail.
7. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front hinge pillar.
8. Remove the damaged rear rail side underbod.

### Installation Procedure

1. Cut the service part to fit the remaining original panel. To ensure a secure weld, sectioning joints should have a gap of approximately one and a half times the thickness of the metal.

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.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
4. Position the rear rail side underbody to the vehicle using 3-dimensional measuring equipment. Clamp the front hinge pillar into place.
5. Plug weld accordingly.
6. Stitch weld along section joint, make 25 mm (1 in.) stitch welds along the seam with 25 mm (1 in.) gaps between.
7. Complete the stitch weld until entire joint is welded.
8. Clean and prepare all welded surfaces.
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
10. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
13. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.