Installation Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Drilling Plug Weld Holes

Courtesy of SUZUKI OF AMERICA CORP.

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.

Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel.
Prepare all mating surfaces as necessary.
Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to ANTI-CORROSION TREATMENT AND REPAIR .

Fig 2: Positioning Front Lower Inner Rail To Vehicle
Courtesy of SUZUKI OF AMERICA CORP.
Position the front lower inner rail - front half to the vehicle using 3-dimensional measuring equipment. Clamp the front lower inner rail - front half into place.

Fig 3: Applying Sealers & Anti-Corrosion Materials To Repair Area
Courtesy of SUZUKI OF AMERICA CORP.
Plug weld accordingly.
Install the rear engine cradle mount.
Clean and prepare all welded surfaces.
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
Paint the repair area. Refer to BASECOAT/CLEARCOAT PAINT SYSTEMS .
Install all related panels and components.
Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
Enable the SIR system. Refer to SIR DISABLING AND ENABLING .