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HOMESERVICE MANUALSSUZUKI2013SX4 CROSSOVER, AUTOMATIC CVT TRANSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 46 (BODY STRUCTURE)REPAIR INSTRUCTIONSUNDERBODY OUTER FRONT SIDE RAIL SECTIONINGINSTALLATION 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: Locating Die Mark
G04843129Courtesy of SUZUKI OF AMERICA CORP.
  1. Cut the replacement service part along the back edge of the arrow on the die mark.
    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.
  2. 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.
  3. Prepare all mating surfaces as necessary.
  4. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
  5. Slide the replacement service part behind the original panel at the sectioning joint.
  6. Position the front lower outer rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower outer rail into place.
    Fig 2: Identifying Lower Outer Rail
    G04843130Courtesy of SUZUKI OF AMERICA CORP.
  7. Plug weld accordingly.
  8. To create a solid weld with minimum heat distortion at the sectioning joint, make 25-mm (1-in) welds with 25-mm (1-in) gaps between them. Then go back and complete the stitch weld.
  9. Clean and prepare all welded surfaces.
  10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR .
  11. Paint the repair area. Refer to BASECOAT/CLEARCOAT PAINT SYSTEMS .
  12. Install all related panels and components.
  13. Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
  14. 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.