Suzuki XL7 2007 Service Manual page 2926

9K-34 Body Structure:
Installation Procedure
1. Cut the replacement service part along the back
edge of the arrow on the die mark.
NOTE
If the location of the original plug weld holes
can not be determined, space the plug weld
holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru
adhesive. It is necessary to replace the weld-
thru adhesive with an additional spot weld
between each factory spot weld.
2. Drill 8-mm (5/16-in) plug weld holes in the service
part as necessary in the locations noted from the
original panel, and along the sectioning cut.
3. Prepare all mating surfaces as necessary.
4. Apply GM-approved Weld-Thru Coating or
equivalent to all mating surfaces. Refer to "Anti-
Corrosion Treatment and Repair: ".
5. Slide the replacement service part behind the
original panel at the sectioning joint.
6. Position the front lower outer rail to the vehicle using
3-dimensional measuring equipment. Clamp the
front lower outer rail into place.
7. Plug weld accordingly.
8. To create a solid weld with minimum heat distortion
at the sectioning joint, make 25-mm (1-in) welds with
25-mm (1-in) gaps between them. Then go back and
complete the stitch weld.
9. Clean and prepare all welded surfaces.
10. Apply the sealers and anti-corrosion materials to the
repair area, as necessary. Refer to "Anti-Corrosion
Treatment and Repair: ".
11. Paint the repair area. Refer to "Basecoat/Clearcoat
Paint Systems: ".
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to "Battery
Negative Cable Disconnection and Connection: ".
14. Enable the SIR system. Refer to "SIR Disabling and
Enabling: ".