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Home >> Suzuki >> 2007 >> XL7 Base, AWD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Body Structure >> Repair Instructions >> Rail Replacement - Rear Section >> Removal Procedure
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Removal Procedure

WARNING: Refer to APPROVED EQUIPMENT FOR COLLISION REPAIR CAUTION .
  1. Disable the supplemental inflatable restraint (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. Refer to DIMENSIONS - BODY .
  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 .
    NOTE: Do not damage any inner panels or reinforcements.
    Fig 1: Drilling Out Factory Welds
    G04843207Courtesy of SUZUKI OF AMERICA CORP.
  6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the rear rail lower - half.
  7. Remove the No. 5 crossbar.
    Fig 2: Removing Rear Rail Lower Section
    G04843208Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove the damaged rear rail lower - section
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