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Installation Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Cut the replacement quarter panel in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow 11/2 times the metal thickness at the sectioning joint.
    2. Fig 1: Drilling Plug Weld Holes Along Sectioning Cut
    G04843196Courtesy of SUZUKI OF AMERICA CORP.
  2. Create two 50-mm (2-in) backing plates and one 100-mm (4-in) backing plate from the unused portion of the service part. Trim the backing plates as necessary to fit behind the sectioning joints where no reinforcements exist.
  3. Drill 8-mm (5/16-in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1 1/2 in) apart.
    Fig 2: Drilling Plug Weld Holes
    G04843197Courtesy of SUZUKI OF AMERICA CORP.
    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.
  4. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.
  5. Prepare all mating surfaces, as necessary.
  6. Apply GM approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
  7. Fit the backing plates halfway into the sectioning joints, clamp and plug weld to the vehicle.
  8. Position the quarter panel.
    Fig 3: Applying Sealers & Anti-Corrosion Materials To Repair Area
    G04843198Courtesy of SUZUKI OF AMERICA CORP.
  9. Plug weld accordingly.
    NOTE: To create a solid weld with minimum heat distortion make 25-mm (1-in) stitch welds along the seam with 25-mm (1-in) gaps between. Then go back and complete the stitch weld.
  10. Stitch the weld sectioning joint.
  11. Clean and prepare all welded surfaces.
  12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
  13. Paint and repair the area. Refer to BASECOAT/CLEARCOAT PAINT SYSTEMS .
  14. Install all related panels and components.
  15. Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
  16. Enable the SIR system. Refer to SIR DISABLING AND ENABLING .
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