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Home >> Suzuki >> 2009 >> XL7 Limited, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 86 (Body Structure) >> Repair Instructions >> Front Compartment Front Rail Replacement >> Removal Procedure
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Removal Procedure

WARNING: This page is about a different car, the 2008 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR DISABLING AND ENABLING .
  2. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION
  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 .
    Fig 1: Drilling Front Compartment Front Rail
    G05471565Courtesy 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 front lower rail.
    Fig 2: Removing Damaged Front Lower Rail
    G05471566Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove the damaged front lower rail.