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: Identifying Front Compartment Front Side Lower Inner Rail Section

Courtesy of SUZUKI OF AMERICA CORP.

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.
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.
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 .
Slide the replacement service part behind the original panel at the sectioning joint.
Position the front lower inner rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower inner rail into place.

Fig 2: Clamping Front Lower Inner Rail
Courtesy of SUZUKI OF AMERICA CORP.
Plug weld accordingly.
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.
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 .