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HOMESERVICE MANUALSSUZUKI2013SX4 CROSSOVER, AUTOMATIC CVT TRANSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 46 (BODY STRUCTURE)REPAIR INSTRUCTIONSFRONT COMPARTMENT FRONT RAIL REPLACEMENTINSTALLATION PROCEDURE
2013 Suzuki SX4 Crossover, Automatic CVT Trans

Installation Procedure

2013 Suzuki SX4 Crossover, Automatic CVT TransSECTION 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.
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 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 .
    Fig 1: Positioning Front Lower Rail To Vehicle
    G04843111Courtesy of SUZUKI OF AMERICA CORP.
  4. Position the front lower rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower rail into place.
    Fig 2: Applying Sealers & Anti-Corrosion Materials To Repair Area
    G04843112Courtesy of SUZUKI OF AMERICA CORP.
  5. Plug weld accordingly.
  6. Clean and prepare all welded surfaces.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
  8. Paint the repair area. Refer to BASECOAT/CLEARCOAT PAINT SYSTEMS .
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
  11. Enable the SIR system. Refer to SIR DISABLING AND ENABLING .
RENDER: 1.0x

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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.