For 1990-2009 cars

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

2.1. | The frame windshield side outer

2.2. | The rail assembly engine compartment upper outer

2.3. | The rocker panel assembly rocker outer

3. Cut the service part along the marked line as per illustration. DO NOT damage the hinge pillar reinforcement.

Important: Cut the outer surface of the hinge pillar service part. The inner reinforcement is used as a backing plate when installing the new section.

4. Perform any additional procedures as necessary to remove the unused areas of the service part.
5. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section.
6. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
7. Apply a permanent underbody sealant.

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

8. Prime with a 2-part catalyzed primer.
9. 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.

Important: To ensure a secure weld, the sectioning joint should have a gap of approximately one and a half times the thickness of the metal. Trim the parts as necessary to achieve this.

10. 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.
11. Measure and align the front body hinge piller outer 3/4 section. Clamp into place.
12. Use a MIG to plug the weld.
13. Stitch weld the entire hinge pillar sectioning joint. Make 25 mm (1 in) gaps between.
14. Go back and complete the stitch weld. This will create a solid joint with a minimal heat distortion.