SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
ªaº: 30 mm (1.18 in.)
ªbº: 100 mm (3.94 in.)
ªAº: Apply undercoating (PVC, 400
m or more)
ªBº: Additional applying of under coating
ªBº: (for 5 door vehicle without splush guard)
ªCº: Apply PVC chip resistant material (200
m or more)1. Side body outer
2. Side sill inner
3. Main floor
4. Front fender
5. Front wheel housing
6. Frame
7. Dash panel
8. Center floor
9. Rear floor
Vehicle produced in CAMI
VIEW : Z
BODY SERVICE 9-53

YH4
GRAND
VITARA
9-54 BODY SERVICE
ªaº: 240 mm (9.45 in.)
ªbº: 20 mm (0.79 in.)
ªcº: 40 mm (1.57 in.)
ªdº: 134 mm (5.28 in.)
ªeº: 177 mm (6.97 in.)
ªAº: Black paintªAºªeº
Vehicle produced in CAMI

YH4
GRAND
VITARA
BODY SERVICE 9-55
B ± BC ± C
2 DOOR MODEL

YH4
GRAND
VITARA
9-56 BODY SERVICE
BADC
ªaº: 30 mm (1.18 in.)
ªbº: 100 mm (3.93 in.)
ªAº: Apply undercoating (PVC, 400
m or more)
ªBº: Additional applying of under coating
ªBº: (for 5 door vehicle without splush guard)
ªCº: Apply PVC chip resistant material (200
m or more)1. Side body outer
2. Side sill inner
3. Main floor
4. Front fender
5. Front wheel housing
6. Frame
7. Dash panel
8. Center floor
9. Rear floorB ± B
A ± A
C ± C
VIEW : Z

YH4
GRAND
VITARA
BODY SERVICE 9-57
ªaº: 240 mm (9.45 in.)
ªbº: 20 mm (0.79 in.)
ªcº: 40 mm (1.57 in.)
ªdº: 134 mm (5.28 in.)
ªeº: 177 mm (6.97 in.)
ªAº: Black paintVIEW : A
VIEW : B
VIEW : C
VIEW : D

YH4
GRAND
VITARA
9-58 BODY SERVICE
PLASTIC PARTS FINISHING
Paintable plastic parts are ABS plastic parts.
Painting
Rigid or hard ABS plastic needs no primer coating.
General acrylic lacquers can be painted properly over hard ABS
plastic in terms of adherence.
1) Use cleaning solvent for paint finish to wash each part.
2) Apply conventional acrylic color lacquer to part surface.
3) Follow lacquer directions for required drying time. (Proper dry-
ing temperature range is 60 to 70
C).
Reference
Plastic parts employ not only ABS (Acrylonitrile Butadiene Styrene)
plastic but also polypropylene, vinyl, or the like plastic. Burning test
method to identify ABS plastic is described below.
1) Use a sharp blade to cut off a plastic sliver from the part at its
hidden backside.
2) Hold sliver with pincers and set it on fire.
3) Carefully observe condition of the burning plastic.
4) ABS plastic must raise readily distinguishable back smoke while
burning with its residue suspended in air temporarily.
5) Polypropylene must raise no readily distinguishable smoke
while burning.

YH4
GRAND
VITARA
BODY SERVICE 9-59
1. Door latch
2. Outside handle
3. Inside handle bezel
4. Latch striker
1. Door opening control rod pin retainer
2. Door opening control rod
3. Door lock control rod
3
SECURITY AND LOCKS
FRONT DOOR LOCK ASSEMBLY
REMOVAL
1) Raise window all the way up.
2) Remove door trim and door sealing cover, refer to steps 1) to 6)
of FRONT DOOR GLASS REMOVAL in this section.
3) Remove door opening control rods.
Unlock door lock rod pin retainer and disconnect control rod.
4) Remove door lock control rod.
5) Disconnect door lock motor lead wire (if equipped).
6) Remove lock assembly.

YH4
GRAND
VITARA
9-60 BODY SERVICE
1. Door latch
2. Door latch striker
3. Shaft
1. Door latch striker
2. Body
3. Door4. Front side
5. Shim
INSTALLATION
To install front door lock, reverse removal procedure, noting follow-
ing.

Door latch striker.
Move door latch striker up or down so its center aligns with the
center of groove ªAº on the door, as shown.
NOTE:
Striker should be moved vertically and placed level. Do not
adjust door lock.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)

Move door latch striker sideways to adjust door surface flush with
body surface, as shown.
In order to correctly obtain door latch striker position in the fore-
and-aft direction, increase or decrease number of shims inserted
between body and striker to adjust it.
Dimension ªaº: 10.9 ± 12.9 mm (0.43 ± 0.5 in.)
ªbº: 3.4 ± 5.4 mm (0.13 ± 0.21 in.)
NOTE:
Apply oil or grease to striker joints periodically.

YH4
GRAND
VITARA
BODY SERVICE 9-61
1. Outside handle
2. Inside handle bezel
3. Latch assembly
4. Latch striker
1. Door opening rod pin
2. Door opening control rod
REAR DOOR LOCK ASSEMBLY
REMOVAL
1) Remove door trim and door sealing cover, refer to steps 1) to 4)
of REAR DOOR GLASS REMOVAL in this section.
2) Remove door opening control rod and door lock control rod.
3) Remove lock assembly.
INSTALLATION
Reverse removal sequence to install rear door lock, noting points
mentioned in ªFRONT DOOR LOCK ASSEMBLYº.

YH4
GRAND
VITARA
1. Shim
1. Rubber cushion 1
9-62 BODY SERVICE
BACK DOOR / REAR GATE LOCK ASSEMBLY
REMOVAL
1) Remove inside handle bezel (if equipped).
2) Remove inside lock knob.
3) Remove door trim.
With inside handle bezel tilted as shown in figure, turn door trim
90 counterclockwise to remove it (if equipped with inside han-
dle).
4) Remove back door / rear gate sealing cover.
5) Remove back door / rear gate lock control rod.
Unlock back door / rear gate lock rod pin retainer and disconnect
control rod.
6) Disconnect back door lock motor lead wire (if equipped).
7) Remove lock assembly.
INSTALLATION
Reverse removal procedure to install back door / rear gate lock as-
sembly noting following points.

Back door / Rear gate latch striker.
Adjust back door / rear gate latch striker so that its center aligns
with the center of groove in back door / rear gate latch base.
To adjust back door / rear gate latch and striker with each other,
insert proper number of shims below the bottom of striker, as
shown.

Back door / Rear gate rubber cushion.
Move rubber cushion installed at the left side of back door / rear
gate to align it with its guide.