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

Removal Procedure

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

  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.

    6. Note: Do not damage any inner panels or reinforcements.


    Object Number: 1823915 Size: SH
  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.

    8. Object Number: 1823918 Size: SH
  8. Remove the damaged rear rail lower - section

Installation Procedure

    Object Number: 1823959 Size: SH

    Note: 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. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.

  1. Drill out welds between the front and rear panels of the service rail.

    2. Object Number: 1823920 Size: SH
  2. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  3. Prepare all mating surfaces as necessary.
  4. Apply GM--approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.

    5. Object Number: 1823922 Size: SH
  5. Position the rear rail lower - rear section, rear rail upper, and No. 5 crossbar to the vehicle using 3-dimensional measuring equipment. Clamp the parts into place.

    6. Object Number: 1823926 Size: SH
  6. Plug weld accordingly.
  7. Clean and prepare all welded surfaces.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Install all related panels and components.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  12. Enable the SIR system. Refer to SIR Disabling and Enabling