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 Out Welds Between Front & Service Rail Rear Panels

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 out welds between the front and rear panels of the service rail.

Fig 2: Drilling Plug Weld Holes
Courtesy of SUZUKI OF AMERICA CORP.
Drill 8-mm (5/16) 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 3: Positioning Rear Rail Lower Section
Courtesy of SUZUKI OF AMERICA CORP.
Position the rear rail lower - rear section, rear rail upper, and No. 5 crossbar to the vehicle using 3-dimensional measuring equipment. Clamp the parts into place.

Fig 4: Applying Sealers & Anti-Corrosion Materials To Repair Area
Courtesy of SUZUKI OF AMERICA CORP.
Plug weld accordingly.
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