Rear Rail Replacement - Suzuki XL7 2007 Service Manual

9K-54 Body Structure:
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.
4. 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.
5. Prepare all mating surfaces, as necessary.
6. Apply GM approved Weld-Thru Coating or
equivalent to all mating surfaces. Refer to "Anti-
Corrosion Treatment and Repair: ".
7. Fit the backing plates halfway into the sectioning
joints, clamp and plug weld to the vehicle.
8. Position the quarter panel.
9. Plug weld accordingly.
NOTE
To create a solid weld with minimum heat
distortion make 25-mm (1-in) stitch welds
along the seam with 25-mm (1-in) gaps
between. Then go back and complete the
stitch weld.
10. Stitch the weld sectioning joint.
11. Clean and prepare all welded surfaces.
12. Apply the sealers and anti-corrosion materials to the
repair area, as necessary. Refer to "Anti-Corrosion
Treatment and Repair: ".
13. Paint and repair the area. Refer to "Basecoat/
Clearcoat Paint Systems: ".
14. Install all related panels and components.
15. Connect the negative battery cable. Refer to "Battery
Negative Cable Disconnection and Connection: ".
16. Enable the SIR system. Refer to "SIR Disabling and
Enabling: ".

Rear Rail Replacement

Removal Procedure
WARNING
!
Refer to "Approved Equipment for Collision
Repair Caution: ".
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: ".
3. Repair as much of the damage as possible to factory
specifications. Refer to "Dimensions - Body".
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: ".