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 MANUALSSUZUKI2013SX4 CROSSOVER, AUTOMATIC CVT TRANSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 46 (BODY STRUCTURE)REPAIR INSTRUCTIONSREAR SIDE DOOR OUTER PANEL 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.

Fig 1: Grinding Surface Of Door Shell

Courtesy of SUZUKI OF AMERICA CORP.

Using a grinding disk grind the surface of the door shell, mating the flanges to bare steel.

Fig 2: Removing Gloss Of E-Coat
Courtesy of SUZUKI OF AMERICA CORP.
Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.

Fig 3: Drilling Plug Weld Holes
Courtesy of SUZUKI OF AMERICA CORP.
Drill 8-mm (5/16-in) plug weld holes as necessary in the locations noted from the original panel.
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.
Clean the mating surfaces.

Fig 4: Applying Bead Of Metal Panel Bonding Adhesive To Both Of Mating Surfaces
Courtesy of SUZUKI OF AMERICA CORP.

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.