Mount SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual

YH4
GRAND
VITARA
BODY SERVICE 9-25
a. Front bumper
b. 1st mounting
c. Suspension frame
d. Front strut
e. Suspension arm
f. 2nd mounting
g. ù20 zig hole
h. Zig hole
i. 3rd mounting
j. Lower rod
k. Upper rod
l. Lateral rod
m. Rear shock absorber
n. 4th mounting
o. Fuel tank
p. Fuel tank
q. Lower roda ± g : 1315 mm (51.77 in.)
a ± g' : 1534 mm (60.39 in.)
b ± g : 1243 mm (48.94 in.)
b ± g' : 1518 mm (59.76 in.)
c ± g : 1377 mm (54.21 in.)
c ± g' : 1105 mm (43.50 in.)
d ± g' : 1319 mm (51.93 in.)
d ± f : 874 mm (34.41 in.)
e ± g : 525 mm (20.67 in.)
e ± g' : 857 mm (33.74 in.)
f ± g' : 927 mm (36.50 in.)
h ± i : 178 mm (7.01 in.)
h ± j : 133 mm (5.24 in.)
h ± k : 325 mm (12.80 in.)
h ± l : 674 mm (26.54 in.)h ± m : 803 mm (31.61 in.)
h ± n : 1161 mm (45.71 in.)
h ± o : 1184 mm (46.61 in.)
h ± p : 1190 mm (46.85 in.)
i ± q : 999 mm (39.33 in.)
j ± q : 997 mm (39.25 in.)
k ± q : 824 mm (32.44 in.)
l ± q : 1130 mm (44.49 in.)
m ± q : 1258 mm (49.53 in.)
n ± q : 1483 mm (58.39 in.)
o ± q : 1349 mm (53.11 in.)
p ± q : 1334 mm (52.52 in.)
For 4 door model
g' ± q : 1275 mm (50.20 in.)
g ± q : 1534 mm (60.39 in.)
For 2 door model
g' ± q : 995 mm (39.17 in.)
g ± q : 1310 mm (51.57 in.)
UNDER BODY DIMENSIONS

YH4
GRAND
VITARA
Hole to hole distance
ªa ± gº : 276 mm (10.87 in.)
ªa ± kº : 1000 mm (39.37 in.)
ªb ± b'º : 1302 mm (51.26 in.)
ªb ± gº : 730 mm (28.74 in.)
ªc ± c'º : 668 mm (26.30 in.)
ªc ± eº : 414 mm (16.30 in.)
ªc ± gº : 406 mm (15.98 in.)
ªc ± jº : 1029 mm (40.51 in.)
ªc ± kº : 1000 mm (39.37 in.)
ªd ± d'º : 1302 mm (51.26 in.)
ªd ± eº : 189 mm (7.44 in.)
ªd ± c'º : 1016 mm (40.00 in.)
ªd ± gº : 672 mm (26.46 in.)
ªd ± kº : 968 mm (38.11 in.)
ªe ± e'º : 1456 mm (57.32 in.)ªf ± f'º : 1550 mm (61.02 in.)
ªf ± hº : 299 mm (11.77 in.)
ªf ± jº : 811 mm (31.93 in.)
ªg ± kº : 854 mm (33.62 in.)
ªh ± h'º : 1339 mm (52.72 in.)
ªh ± j'º : 1504 mm (59.21 in.)
ªh ± jº : 677 mm (26.65 in.)
ªh ± kº : 927 mm (36.50 in.)
ªi ± i'º : 1344 mm (52.91 in.)
ªi ± jº : 391 mm (15.39 in.)
ªi ± kº : 760 mm (29.92 in.)
ªj ± j'º : 1348 mm (53.07 in.)
ªj ± kº : 676 mm (26.61 in.)
ªl ± jº : 961 mm (37.83 in.)
ªl ± kº : 1018 mm (40.08 in.)
a. Front bumper installation clip hole
b (b'). Front bumper installation hole
c (c'). Headlight installation hole
d (d'). Headlight installation resin nut hole
e (e'). Headlight installation hole
f (f'). Front fender installation hole
g. Center member installation hole
h (h'). Fender installation reference hole
i (i'). Fender installation hole
j (j'). Fender installation reference hole
k. Garnish installation clip hole
l. Mounting installation hole
9-26 BODY SERVICE
BODY DIMENSIONS
4 door model, 2 door model

YH4
GRAND
VITARA
1. (a)
1. (a)
1
11
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1. Bolt
BODY SERVICE 9-33
INSTRUMENTATION AND DRIVER INFORMATION
INSTRUMENT PANEL
WARNING:
See WARNING at the beginning of this section.
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) Remove console box.
4) Remove glove box and column hole cover.
5) Disconnect wires and cables from heater unit and blower motor
assembly.
6) Remove steering column assembly. Refer to Section 3C1.
7) Disconnect speedometer connector and remove speedometer
assembly. If equipped with air bag, disconnect wire coupler at
SDM and air bag ground terminal for air bag.
8) Remove engine hood opener.
9) Disconnect couplers which need to be disconnected for removal
for instrument panel.
10) Remove instrument panel mounting screws.
11) Remove instrument panel mounting bolt.
12) Remove instrument panel.
CAUTION:
For vehicle with Air Bag, instrument panel could not be re-
moved with SDM coupler connected and ground terminal
installed.
Use care not to damage Air Bag harness.
INSTALLATION
1) Install instrument panel by reversing removal procedure, noting
the following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to ªAIR BAG
STEERING COLUMN INSTALLATIONº in Section 3C1.
2) Adjust control cables. (Refer to Section 1A ªHEATER CON-
TROL CABLESº.)
3) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.

YH4
GRAND
VITARA
1. Seat cushion
2. Seat back
3. Reclining assy (RH side)
4. Reclining assy (LH side)
5. Seat adjuster (RH outside)
6. Seat adjuster (RH inside)
7. Seat adjuster (LH outside)
8. Seat adjuster (LH inside)
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1. Cover
2. Coupler(b)
9-34 BODY SERVICE
SEAT
FRONT SEAT
REMOVAL
1) Disconnect lead wire(s) at coupler (if equipped). Remove four
mounting bolts fixing front seat to seat rail to remove front seat.
2) Disassemble and repair seat as necessary.
INSTALLATION
Reverse removal procedure to install front seat.
Torque to specifications, as shown.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

YH4
GRAND
VITARA
1. Seat cushion
2. Seat back
3. Seat auto lock release handle
4. Seat hinge male
5. Hinge male cover
BODY SERVICE 9-35
REAR SEAT
REMOVAL
1) Remove four mounting bolt to remove seat cushion.
2) Remove four mounting bolts to remove seat back.
3) Disassemble and repair seat as necessary.
INSTALLATION
Reverse removal procedure to install rear seat.
Torque to specifications, as shown.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

YH4
GRAND
VITARA
9-36 BODY SERVICE
Sealer is applied to the specific joints of a vehicle dur-
ing production. The sealer is intended to prevent dust
from entering the vehicle and serves also as an anti-
corrosion barrier. The sealer is applied to the door and
hood hem areas and between panels. Correct and re-
seal the originally sealed joints if damaged. Reseal
the attaching joints of a new replacement panel and
reseal the hem area of a replacement door or hood.
Use a quality sealer to seal the flanged joints, overlap
joints and seams. The sealer must have flexible char-
acteristics and paintability after it's applied to repair
areas.
For the sealer to fill open joints, use caulking material.
Select a sealer in conformance with the place and
purpose of a specific use. Observe the manufactur-
er's label-stand instructions when using the sealer.
In many cases, repaired places require color painting.
When this is required, follow the ordinary techniques
specified for the finish preparation, color painting and
undercoating build-up.
Rust proof wax, a penetrative compound, is applied
to the metal-to-metal surfaces (door and side sill in-
sides) where it is difficult to use ordinary undercoating
material for coating. Therefore, when selecting the
rust proof wax, it may be the penetrative type.
During the undercoating (vinyl coating) application,
care should be taken that sealer is not applied to the
engine-related parts and shock absorber mounting or
rotating parts. Following the under coating, make
sure that body drain holes are kept open.
he sequence of the application steps of the anti-corro-
sion materials are as follows:
1) Clean and prepare the metal surface.
2) Apply primer.
3) Apply sealer (all joints sealed originally).
4) Apply color in areas where color is required such
as hem flanges, exposed joints and under body
components.
5) Apply anticorrosion compound (penetrative wax).
6) Apply undercoating (rust proof material).
PAINT AND COATINGS
ANTI-CORROSION TREATMENT
WARNING:
Standard shop practices, particularly eye
protection, should be followed during the per-
formance of the below-itemized operations to
avoid personal injury.
As rust proof treatment, steel sheets are given corro-
sion resistance on the interior and / or exterior.
These corrosion resistance steel sheet materials are
called one of two-side galvanized steel sheets.
It is for the sake of rust protection that these materials
are selected and given a variety of treatments as de-
scribed blow.
1) Steel sheets are treated with cathodic electroprim-
er which is excellent in corrosion resistance.
2) Rust proof wax coatings are applied to door and
side sill insides where moisture is liable to stay.
3) Vinyl coating is applied to body underside and
wheel housing inside.
4) Sealer is applied to door hem, engine compart-
ment steel sheet-to-steel sheet joint, and the like
portions to prevent water penetration and resulting
in rust occurrence.
In panel replacement or collision damage repair, leav-
ing the relevant area untreated as it is in any operation
which does disturb the above-mentioned rust proof
treatment will cause corrosion to that area. Therefore,
it is the essential function of any repair operation to
correctly recoat the related surfaces of the relevant
area.
All the metal panels are coated with metal condition-
ers and primer coating during vehicle production. Fol-
lowing the repair and / or replacement parts installa-
tion, every accessible bare metal surface should be
cleaned and coated with rust proof primer. Perform
this operation prior to the application of sealer and
rust proof wax coating.

YH4
GRAND
VITARA
1. Spot light
2. Head lining
3. Sunvisor assemblies
4. Room light
5. Trim
6. Assist grips
1. Sliding roof motor
2. Mounting screw
1. Motor assy
2. Hole (body)
3. Hole (cam)
9-66 BODY SERVICE
SLIDING ROOF MOTOR / RELAY
REMOVAL
1) Remove head lining, refer to HEAD LINING REMOVAL in this
section.
2) Disconnect coupler and remove sliding roof motor assembly by
removing 3 screws.
CAUTION:
After removing sliding motor assembly, do not move
guide and link.
INSTALLATION
For installation, reverse removal procedure, noting following point.
Before installing, connect coupler and push the CLOSE side of the
slide switch.

YH4
GRAND
VITARA
(A)ªA5º(A)
AIR BAG SYSTEM 10B-17
TABLE A ± ªAIR BAGº WARNING LAMP COMES ªONº STEADY (Page 2 of 2)
Fig. for STEP 2 Fig. for STEP 3
Special Tool
(A): 09932-76010
NOTE:
Upon completion of inspection and repair work, perform following items.
1) Reconnect all air bag system components, ensure all components are properly mounted.
2) Repeat ªAir Bag Diagnostic System Check Flow Tableº, referring to p.10B-11 to confirm that the trouble
has been corrected.

YH4
GRAND
VITARA
(A)ªA5º
1. Combination meter connector (16p)
2. ªY / Gº wire terminal1. Connection detection pin
AIR BAG SYSTEM 10B-19
TABLE B ± ªAIR BAGº WARNING LAMP DOES NOT COME ªONº (Page 2 of 2)
STEPACTIONYESNO
41) Remove combination meter, referring to
SECTION 8C.
2) Check proper connection to combination
meter at terminal for ªAIR BAGº warning lamp
and to SDM at terminal ªA5º.
3) If OK then check resistance between ªY / Gº
wire terminal of combination meter connector
(16p) and ªA5º terminal of SDM connector.
4) Is resistance 1
or less?Go to step 5.Repair high resistance
or open in ªBIº or ªY / Gº
wire circuit (between
combination meter and
SDM).
51) Measure voltage from ªA5º terminal of SDM
connector to body ground with ignition switch
ON.
2) Is it 9 V or more?Repair short from ªBIº or
ªY / Gº wire circuit
(between combination
meter and SDM) to
power circuit.Go to step 6.
61) Remove and inspect ªAIR BAGº bulb.
2) Is bulb good?Substitute a known-good
combination meter and
recheck.Replace bulb.
Fig. for STEP 2 Fig. for STEP 3 and 5
Fig. for STEP 4
Special Tool
(A): 09932-76010
NOTE:
Upon completion of inspection and repair work, perform following items.
1) Reconnect all air bag system components, ensure all components are properly mounted.
2) Repeat ªAir Bag Diagnostic System Check Flow Tableº, referring to p.10B-11 to confirm that the trouble
has been corrected.

YH4
GRAND
VITARA
(A)
AIR BAG SYSTEM 10B-21
TABLE C ± ªAIR BAGº WARNING LAMP FLASHES (Page 2 of 2)
Fig. for STEP 2
Special Tool
(A): 09932-76010
NOTE:
Upon completion of inspection and repair work, perform following items.
1) Reconnect all air bag system components, ensure all components are properly mounted.
2) Repeat ªAir Bag Diagnostic System Check Flow Tableº, referring to p.10B-11 to confirm that the trouble
has been corrected.