Important: The hinge pillar inner reinforcement (1) can be used as backing plate when sectioning the outer door frame (2) at the front hinge pillar.

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, including the quarter panel.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

4. 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 Coating.



5. Remove all related panels and components.
6. Visually inspect and repair as much of the damage as possible to factory specifications.
7. Remove sealers and anti-corrosion materials as necessary.
8. Align template provided with the service part.
9. Mark and cut the hinge pillar for sectioning.

Important: Do not damage any inner panels or reinforcements.

10. Perform all other sectioning procedures as necessary.
11. Locate, mark, and drill out all factory welds attaching the lower front door hinge pillar. Note the number and location of welds for installation of the service part.



12. Remove damaged front lower hinge pillar.
13. Remove foam (1) from the lower portion of the hinge pillar.

1. Rough cut the service part to match the damaged section of the door frame opening and discard the unused portion of the service part.
2. The modified service panel (1) should be trimmed to allow a gap of one and one-half times the metal thickness at the joint between the service part and the factory part.
3. Drill 8 mm (5/16 in) holes for plug welding in the service part 13 mm (½ in) from the sectioning joint edge.
4. Drill 8 mm (5/16 in) holes for plug (2) welding in the service panel (1) as necessary in the locations noted from the original panel.
5. Prepare mating surfaces as necessary.
6. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces
7. Align the service part to the vehicle.
8. Use three-dimensional measuring equipment to inspect the fit. Refer to Dimensions - Body .
9. Plug weld accordingly.
10. Complete the sectioning by welding the joint gap closed with 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps alternately.
11. Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.



12. Install closed cell two-part expandable foam in the service door frame opening hinge pillar as necessary to replace the original foam air baffle (1).
13. Clean and prepare welded surfaces.
14. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
15. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
16. Install all related panels and components.
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
18. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.