For 1990-2009 cars

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

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

2.1. | The engine compartment assembly side

2.2. | The rail engine compartment upper inner

3. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
4. Apply a permanent underbody sealant.

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

5. Prime with a 2-part catalyzed primer.
6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
7. Cut at the arrows and remove.
8. Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
9. Cut the new part allowing an additional 20 mm (0.79 in) length for the section joint.

Important: A new service part will be installed inside of the remaining portion of the original upper rail assembly.

10. Punch holes for plug welding as required. Use the old part as a guide. Punch plug weld holes in the original portion of the upper rail assembly at the section joint.
11. Before installing the new part, apply 3M® Ultrapro Urethane Seam Sealer P/N 08361, or equivalent, around the baffle.