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HOMESERVICE MANUALSSUZUKI2013SX4 CROSSOVER, AUTOMATIC CVT TRANSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 46 (BODY STRUCTURE)REPAIR INSTRUCTIONSROOF 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: Drilling Plug Weld Holes
G04843143Courtesy of SUZUKI OF AMERICA CORP.
  1. Drill 8-mm (5/16-in) plug weld holes as necessary in locations noted from the original panel.
    NOTE: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (11/2 in) apart.
  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 2: Positioning Roof Panel To Body
    G04843144Courtesy of SUZUKI OF AMERICA CORP.
  4. With the aid of an assistant, position the roof panel to the body.
    Fig 3: Identifying Plug Weld
    G04843145Courtesy of SUZUKI OF AMERICA CORP.
  5. Plug weld accordingly.
  6. Clean and prepare all welded surfaces.
    Fig 4: Applying Sealers & Anti-Corrosion Materials To Repair Area
    G04843146Courtesy of SUZUKI OF AMERICA CORP.
  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 the windshield. Refer to INSTALLATION PROCEDURE .
  10. Install the liftgate. Refer to LIFTGATE REPLACEMENT .
  11. Install all related panels and components.
  12. Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
  13. 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.