For 1990-2009 cars

### Removal Procedure

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

Note: Sectioning of the front upper rails is not recommended.

3. Remove all related panels and components.
4. Restore as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area if necessary. Refer to Anti-Corrosion Treatment and Repair.
6. Locate, mark, and drill out all factory welds attaching the outer rail.
7. Remove the damaged outer rail.

### Installation Procedure

1. Prepare the mating surfaces as necessary.
2. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.

Note: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in).

3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panels.
4. Temporarily position the outer rail on the vehicle.
5. Verify the location using 3-dimensional measuring equipment.
6. Plug weld accordingly.
7. Clean and prepare the welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area if necessary. Refer to Anti-Corrosion Treatment and Repair.
9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
10. Install all of the related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
12. Enable the SIR system. Refer to SIR Disabling and Enabling.