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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: Grinding Door Shell Surface
G04843151Courtesy of SUZUKI OF AMERICA CORP.
  1. Using a grinding disk grind the surface of the door shell, mating the flanges to bare steel.
    Fig 2: Removing E-Coat Gloss
    G04843152Courtesy of SUZUKI OF AMERICA CORP.
  2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.
    Fig 3: Drilling Plug Weld Holes
    G04843153Courtesy of SUZUKI OF AMERICA CORP.
  3. Drill 8-mm (5/16-in) plug weld holes as necessary in the locations noted from the original panel.
    NOTE: If the location of the original plug-weld holes can not be determined, space the plug weld holes every 40 mm (1 in) apart.
  4. Clean the mating surfaces.
    Fig 4: Applying Metal Panel Bonding Adhesive To Mating Surfaces
    G04843154Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: The adhesive has a 40-50 minute working time. Do not allow the door to totally cure off the vehicle, as proper alignment of the door outer panel to the door shell will be difficult.
  5. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5) or equivalent, to both of the mating surfaces.
  6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
    Fig 5: Installing Door Outer Panel To Door Shell
    G04843155Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Do NOT pull the panels apart after being joined together. Slide the panels against each other to realign the panels.
  7. Install the door outer panel to the door shell.
  8. Clamp the door outer panel into position as required.
    Fig 6: Tapping Hem Flanges Around Door Shell
    G04843156Courtesy of SUZUKI OF AMERICA CORP.
  9. Using a hammer re-hem the hem flanges around the door shell.

    Continue to hammer in stages along the hem flanges.

  10. Using lacquer thinner remove the excess adhesive from the door panel area.
  11. Install the door to the vehicle. Inspect the door outer panel for proper alignment, adjust the alignment as required.
    Fig 7: Welding Door Outer Panel To Door Frame
    G04843157Courtesy of SUZUKI OF AMERICA CORP.
  12. Using metal-inert gas (MIG), weld the door outer panel to the door frame in the locations noted at the upper door frame.
  13. Clean and prepare all welded surfaces.
    Fig 8: Applying Fusor Super Flexible Anti-Flutter Foam-Fast Set To Door Outer Panel
    G04843158Courtesy of SUZUKI OF AMERICA CORP.
  14. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124 or equivalent in 4-5 evenly spaced locations between the door outer panel and the inner safety beam.
  15. Apply sealers and anti-corrosion materials to the repair area as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
  16. Paint the repaired area. Refer to BASECOAT/CLEARCOAT PAINT SYSTEMS .
  17. Install the door assembly. Refer to INSTALLATION PROCEDURE .
  18. Install all related panels and components.
  19. Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
  20. Enable the SIR system. Refer to SIR DISABLING AND ENABLING .
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