For 1990-2009 cars

Sedan shown, wagon similar

Coupe shown

Three door coupe (RAD) shown

Important: Only the outer rocker panel may be sectioned in the areas specified. Repair and restoration of as much structure as possible before cutting and preparing the joint for welding is imperative. No reinforcements may be sectioned. The outer rocker panel may be sectioned at the center of the front or rear door opening. It may not be sectioned in areas under the center pillar stamping attach points or at least 100 mm (4 in) rearward of the rear vertical edge of the front body hinge pillar.

1. Note the amount and location of the spot welds.
2. Remove the sealer and drill spot welds from the areas necessary to place the joint in the areas specified.
3. Cut the service part along the joint area. DO NOT damage the inner reinforcements.
4. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
5. Apply a permanent underbody sealant.

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

6. Prime with a 2-part catalyzed primer.
7. 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.
8. Perform any additional procedures as necessary to remove unused areas of the service part.
9. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section.
10. Construct a joint reinforcement 100 mm (3-15/16 in) long to back up and reinforce the joint. Unused sections of the service part can be modified to fit behind the joint area.
11. Clean the surface for welding and grind the ELPO 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.
12. Use 8 mm (5/16 in) plug welds. Refer to Space Frame Sectioning .
13. Stitch weld along the entire joint. Make 25 mm (1 in) gaps between, then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.

Sedan shown, wagon similar