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Home >> Suzuki >> 1991 >> Samurai JS >> Repair and Diagnosis >> External Pages >> Different car >> Section 56 (Body Structure) >> Repair Instructions >> MIG Welded Full Panel Replacement >> Removal Procedure
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Removal 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.
  1. Disable the SIR system. Refer to SIR DISABLING AND ENABLING .
  2. Disconnect the negative battery cable. Refer to REMOVAL PROCEDURE .
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications.
    WARNING: Refer to FOAM SOUND DEADENERS CAUTION .
  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 .
    Fig 1: Drilling Out Factory Welds
    G04843217Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Do not damage any inner panels or reinforcements.
  6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.
    Fig 2: Removing Reinforcement
    G04843218Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove the damaged part.