Underbody Outer Front Side Rail Sectioning - Suzuki XL7 2007 Service Manual

1. Drill 8-mm (5/16-in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces as necessary.
3. Apply GM-approved Weld-Thru Coating or
equivalent to all mating surfaces. Refer to "Anti-
Corrosion Treatment and Repair: ".
4. Position the front lower outer rail to the vehicle using
3-dimensional measuring equipment. Clamp the
front lower outer rail into place.
5. Plug weld accordingly.
6. Install the rear engine cradle mount.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the
repair area, as necessary. Refer to "Anti-Corrosion
Treatment and Repair: ".
9. Paint the repair area. Refer to "Basecoat/Clearcoat
Paint Systems: ".
10. Install all 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: ".
Underbody Outer Front Side Rail
Sectioning
Removal Procedure
WARNING
!
Refer to "Approved Equipment for Collision
Repair Caution: ".
1. Disable the supplemental inflatable restraint (SIR)
system. Refer to "SIR Disabling and Enabling: ".
2. Disconnect the negative battery cable. Refer to
"Battery Negative Cable Disconnection and
Connection: ".
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory
specifications. Refer to "Dimensions - Body".
5. Note the location and remove the sealers and anti-
corrosion materials from the repair area, as
necessary. Refer to "Anti-Corrosion Treatment and
Repair: ".
NOTE
Do not damage any inner panels or
reinforcements.
6. Cut the panel along the front edge of the die mark.
7. Locate and drill out all factory welds. Note the
number and location of welds for installation of the
front lower outer rail section.
8. Remove the damaged front lower outer rail.
Body Structure: 9K-33