Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSUZUKI2010KIZASHI FWD L4-2.4LREPAIR AND DIAGNOSISBODY AND FRAMESERVICE PRECAUTIONS
2010 Suzuki Kizashi FWD L4-2.4L
Body and Frame: Service Precautions
2010 Suzuki Kizashi FWD L4-2.4LSECTION Service Precautions
Precautions For Body Structure
Operation
WARNING: Wear clothing and protective items suitable for operation. Before attempting any body repair, be sure to disconnect negative (-) cable at battery. When using the body frame repair device for pulling-out operation, avoid standing in front of the pulling chain. Secure the chain with the safety wires. Whenever a repair work near the fuel tank using frames or sparkes, be sure to remove the fuel tank from the vehicle and prevent the removed fuel tank from fuel leakage.
High-Strength Steel
CAUTION:
- When body panels made of high-strength steel having the tensile strength more than 590 MPa damaged or deformed, be sure to replace them with new spare panels in repair work. Because such high-strength steel panels will remarkably loose it strength by cutting, heating and welding.
- Refer to Sheet Metal Specification for tensile strength of steel panels.
Body Panel Repair
CAUTION:
- The number of spot welded points should be increased by 20 to 30% in number from original welding points. The numbers and locations of the welding points in the drawings shows the original spot welding.
- Although the spot welding is recommended in the repair procedure, you shall adopt the plug welding when the panel thickness for welding points exceed the performance of your spot welding device.
- Select hole diameter for plug welding referring to following table according to panel thickness and type of steel panel.
* dia. 10.0 (dia. 0.39 in.) or more for parts using high-tensile steel panel
- Refer to Sheet Metal Specification for types and thickness of steel panels.
- Prior to welding, always remove paint layer and plating from body panels at every welding points in order to prevent incomplete welding. Also, always apply the welding primer/spot sealer to prevent rust on welding points.
- When installing new parts, refer "Body Dimensions" and Panel Clearance.
- After repairing body panels, be sure to apply seam sealer, cavity protection, underbody coating and anti-corrosion compound to all areas originally protected by the manufacture referring to Sealant Application Areas, Undercoating Application Areas and Anti-Corrosion Compound Application Area.
Foamed Material Filling Area Repair
CAUTION:
Follow instructions below when repairing body part filled with foamed material because such foamed material may start fire when heated.
- Do not heat or cut panels with gas torch or the like.
- Use a fire-free tools such as air-saw when cutting panels.
- Remove foamed material close to welding part before welding.
Operation
WARNING: Wear clothing and protective items suitable for operation. Before attempting any body repair, be sure to disconnect negative (-) cable at battery. When using the body frame repair device for pulling-out operation, avoid standing in front of the pulling chain. Secure the chain with the safety wires. Whenever a repair work near the fuel tank using frames or sparkes, be sure to remove the fuel tank from the vehicle and prevent the removed fuel tank from fuel leakage.
High-Strength Steel
CAUTION:
- When body panels made of high-strength steel having the tensile strength more than 590 MPa damaged or deformed, be sure to replace them with new spare panels in repair work. Because such high-strength steel panels will remarkably loose it strength by cutting, heating and welding.
- Refer to Sheet Metal Specification for tensile strength of steel panels.
Body Panel Repair
CAUTION:
- The number of spot welded points should be increased by 20 to 30% in number from original welding points. The numbers and locations of the welding points in the drawings shows the original spot welding.
- Although the spot welding is recommended in the repair procedure, you shall adopt the plug welding when the panel thickness for welding points exceed the performance of your spot welding device.
- Select hole diameter for plug welding referring to following table according to panel thickness and type of steel panel.
* dia. 10.0 (dia. 0.39 in.) or more for parts using high-tensile steel panel
- Refer to Sheet Metal Specification for types and thickness of steel panels.
- Prior to welding, always remove paint layer and plating from body panels at every welding points in order to prevent incomplete welding. Also, always apply the welding primer/spot sealer to prevent rust on welding points.
- When installing new parts, refer "Body Dimensions" and Panel Clearance.
- After repairing body panels, be sure to apply seam sealer, cavity protection, underbody coating and anti-corrosion compound to all areas originally protected by the manufacture referring to Sealant Application Areas, Undercoating Application Areas and Anti-Corrosion Compound Application Area.
Foamed Material Filling Area Repair
CAUTION:
Follow instructions below when repairing body part filled with foamed material because such foamed material may start fire when heated.
- Do not heat or cut panels with gas torch or the like.
- Use a fire-free tools such as air-saw when cutting panels.
- Remove foamed material close to welding part before welding.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.