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.

WARNING: Refer to APPROVED EQUIPMENT FOR COLLISION REPAIR CAUTION .

NOTE: Before beginning the repair, refer to METAL PANEL BONDING for proper adhesive applicator preparations and general information.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR DISABLING AND ENABLING .
Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION .
Remove all related panels and components.
Repair as much of the damage as possible to factory specifications. Refer to DIMENSIONS - BODY .
Remove the door assembly. Refer to REAR DOOR REPLACEMENT .

Fig 1: Drilling Rear Side Door Outer Panel
Courtesy of SUZUKI OF AMERICA CORP.
Locate and drill out all factory welds. Note the number and location of welds at the upper window frame and the mirror locations.

Fig 2: Grinding Edges Of Door Outer Panel
Courtesy of SUZUKI OF AMERICA CORP.
Grind the edges of the door outer panel to separate the outer door panel from the door shell.

Fig 3: Removing Sealers And Anti-Corrosion Materials
Courtesy of SUZUKI OF AMERICA CORP.

WARNING: Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.
Remove the outer door panel.
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR .

Fig 4: Identifying Edges Of Door Shell
Courtesy of SUZUKI OF AMERICA CORP.
Straighten the edges of the door shell.