GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2007 🢒 XL-7 FWD 🢒 Body Repair 🢒 Collision Repair 🢒 Rear Rail Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
  4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    5. Object Number: 1825784 Size: SH

    Important: Do not damage any inner panels or reinforcements.

  5. Locate and drill out all factory welds on the number 4 bar and the floor reinforcement. Note the number and location of the welds for installation.

    6. Object Number: 1825786 Size: SH
  6. Remove the number 4 bar and the floor reinforcement.

    7. Object Number: 1825789 Size: SH
  7. Locate and drill out all factory welds on the outer rail reinforcement. Note the number and location of the welds for installation.

    8. Object Number: 1825791 Size: SH
  8. Remove the rail reinforcements from the vehicle.

    9. Object Number: 1825792 Size: SH
  9. Locate and drill out all factory welds on the rear rail. Note the number and location of the welds for installation.

    10. Object Number: 1825794 Size: SH
  10. Remove the damaged rear rail from the vehicle.

Installation Procedure

    Object Number: 1825796 Size: SH

    Important: 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. Replace the weld-thru adhesive with an additional spot weld between each factory spot weld.

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

    4. Object Number: 1825798 Size: SH
  4. Position the rear rail lower to the vehicle using 3-dimensional measuring equipment. Clamp the rear rail lower into place.
  5. Plug weld accordingly.
  6. Position the outer rail reinforcements, #4 bar, and floor reinforcements using 3-dimensional measuring equipment. Clamp the components into place.
  7. Plug weld accordingly.
  8. Clean and prepare all welded surfaces.
  9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  10. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
  11. Install all related panels and components.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  13. Enable the SIR system. Refer to SIR Disabling and Enabling .