front SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual

YH4
GRAND
VITARA
Operation
Terminal Front Door
Rear Door
Back Door (except Canvas Top Model)
LOCK
UNLOCK
LOCK
UNLOCK
LOCK
UNLOCK
8D-22 WINDOWS, MIRRORS, SECURITY AND LOCKS
POWER DOOR LOCK ACTUATOR
1) Disconnect power door lock actuator coupler.
2) Connect 12 V battery positive and negative terminals to the door
lock actuator terminals shown below and check operation.
If it does not operate as specified in table below, replace door
lock actuator.
UNLOCKLOCK
2

3


YH4
GRAND
VITARA
Hard Top Model
Canvas Top Model
LOAD2 LOAD1
1. Heater wire
2. Thermostat
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-33
FRONT SEAT HEATER (IF EQUIPPED)
SEAT HEATER SWITCH (DRIVER AND PASSENGER SIDE)
INSPECTION
1) Confirm that ignition switch is OFF position.
2) Pull out seat heater switch from front center console box.
3) Disconnect seat heater switch coupler.
4) Check for continuity between terminals at each switch position
as shown below. If check result is not as specified, replace.
SEAT HEATER WIRE
INSPECTION
1) Confirm that seat heater switch is OFF position.
2) Disconnect two couplers of seat heater under the seat cushion.
(If seat under tray is equipped, pull out coupler between tray and
seat cushion.)
3) Check for continuity between terminals as shown below.
If not continuity, replace faulty seat heater.
Hard Top Model
Seat heater circuit in seat back
Between a and b
Between b and d
Between c and e
Seat heater circuit in seat cushion
Between f and g
Canvas Top Model
Seat heater circuit in seat back
Between A And B
Seat heater circuit in seat cushion
Between C and D
Between D and F
Between E and G

YH4
GRAND
VITARA
9
BODY SERVICE 9-1
GLASS, WINDOWS AND MIRRORS9- 2 . . . . .
Front Door Glass 9- 2. . . . . . . . . . . . . . . . . . . . .
Front Door Window Regulator 9- 5. . . . . . . . . .
Windshield 9- 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Glass 9-12. . . . . . . . . . . . . . . . . . . . .
Rear Door Window Regulator 9-14. . . . . . . . . .
Quarter Window 9-15. . . . . . . . . . . . . . . . . . . . . .
Back Door Glass 9-16. . . . . . . . . . . . . . . . . . . . .
BODY STRUCTURE9-17 . . . . . . . . . . . . . . . . . . .
Front Door Assembly 9-17. . . . . . . . . . . . . . . . .
Rear Door Assembly 9-18. . . . . . . . . . . . . . . . . .
Back Door / Rear Gate Assembly 9-19. . . . . . . .
Hood 9-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Fender 9-22. . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper 9-23. . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper 9-24. . . . . . . . . . . . . . . . . . . . . . . .
Under Body Dimensions 9-25. . . . . . . . . . . . . . .
Body Dimensions 9-26. . . . . . . . . . . . . . . . . . . . .
INSTRUMENTATION AND DRIVER
INFORMATION9-33 . . . . . . . . . . . . . . . . . . . . . . .
Instrument Panel 9-33. . . . . . . . . . . . . . . . . . . . .
SEAT9-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seat 9-34. . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat 9-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
PAINT AND COATINGS9-36 . . . . . . . . . . . . . . . .
Anti-Corrosion Treatment 9-36. . . . . . . . . . . . . .
Metal Replacement Parts Finishing 9-37. . . . .
Plastic Parts Finishing 9-58. . . . . . . . . . . . . . . . .
SECURITY AND LOCKS9-59 . . . . . . . . . . . . . . . .
Front Door Lock Assembly 9-59. . . . . . . . . . . . .
Rear Door Lock Assembly 9-61. . . . . . . . . . . . .
Back Door / Rear Gate Lock Assembly 9-62. . .
Key Coding 9-63. . . . . . . . . . . . . . . . . . . . . . . . . .
SUNROOF / CONVERTIBLE TOP9-64 . . . . . . . . .
Sliding Roof (if equipped) 9-64. . . . . . . . . . . . . .
Canvas Top And Topbow Frames 9-71. . . . . . .
EXTERIOR AND INTERIOR TRIM9-72 . . . . . . .
Floor Carpet 9-72. . . . . . . . . . . . . . . . . . . . . . . . .
Head lining 9-73. . . . . . . . . . . . . . . . . . . . . . . . . .
Roof Trim (2 Door Model) 9-75. . . . . . . . . . . . . .
Side Moldings (if equipped) 9-77. . . . . . . . . . . .
Splash Guard (if equipped) 9-78. . . . . . . . . . . .
Roof Rail (if equipped) 9-79. . . . . . . . . . . . . . . .
Roof Molding 9-79. . . . . . . . . . . . . . . . . . . . . . . .
Luggage Under Box 9-80. . . . . . . . . . . . . . . . . .
SECTION 9
BODY SERVICE
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

When body servicing, if shock may be applied to air bag system component parts, remove those parts
beforehand. (Refer to Section 10B.)
NOTE:
Fasteners are important attaching parts in that they could affect the performance of vital components and
systems, and / or could result in major repair expense. They must be replaced with one of the same part
number of with an equivalent part if replacement becomes necessary.
Do not use a replacement part of lesser quality or substitute a design. Torque values must be used as spe-
cified during reassembly to assure proper retention of these parts.
CONTENTS

YH4
GRAND
VITARA
6. Door trim
7. Door hinge
8. Door open stop
9. Door sealing cover
10. Window regulator handle (if equipped) 1. Door glass
2. Weatherstrip
3. Opening weatherstrip
4. Window regulator
5. Glass run
9-2 BODY SERVICE
GLASS, WINDOWS AND MIRROR
FRONT DOOR GLASS

YH4
GRAND
VITARA
1. Screws
1. Bolts
1. Door sealing cover
2. Adhesive1, (a)
9-4 BODY SERVICE
INSTALLATION
Reverse removal procedure to install door glass noting following
points:

Tighten glass attaching screws to specified torque. Tighten front
screw first, then rear screw.
Tightening Torque
(a): 2.5 N
.m (0.25 kg-m, 1.8 lb-ft)

When window becomes hard to raise and lower, adjust screws to
correct tilted glass as shown in figure.

Adjust equalizer of window regulator so that measurement A and
B are equal.

Secure door sealing cover with adhesive.

YH4
GRAND
VITARA
1. Window regulator lubrication point 1. Regulator mounting bolts
2. Regulator motor mounting nuts
3. Hole
BODY SERVICE 9-5
FRONT DOOR WINDOW REGULATOR
REMOVAL
1) Remove door glass, referring to steps 1) to 9) of FRONT DOOR
GLASS REMOVAL in this section.
2) Disconnect power window motor lead wire at coupler and loosen
clamp.
3) Loosen regulator mounting bolts, nuts and take out regulator
through hole as shown in left figure.
INSPECTION
1) Check regulator sliding and rotating parts for greasing.
2) Check rollers for wear and damage.
3) Check wire for damage.
INSTALLATION
Reverse removal procedure to install window regulator noting the
following point.

Tighten bolts and nuts according to the order (a, b, c / 1, 2, 3, 4)
shown in left figure.

When installing glass, check that the top part of the glass contacts
the glass run evenly and that the glass moves up and down
smoothly.
If the glass is tilted with respect to the glass run, make a fine ad-
justment with the screws.

Install door window regulator handle (if equipped) so that it has
an angle as shown in figure when glass is fully closed.

YH4
GRAND
VITARA
1. Windshield glass
2. Fastener No. 1
3. Windshield molding4. Stopper
5. Fastener No. 2
9-6 BODY SERVICE
WINDSHIELD
The front windshield is installed by using a special type of adhesive (that is, one component urethane adhesive
used with primer). For the Windshield replacement, it is important to use an adhesive which provides sufficient
adhesion strength and the follow the proper procedure.
CAUTION:

Described in this section is the glass replacement by using 3 types of primers and 1 type of adhesive
made by YOKOHAMA (one component urethane adhesive to be used with primer in combination).
When using primer and adhesive made by other manufacturers, be sure to refer to handling instruc-
tions supplied with them. Negligence in following such procedure or misuse of the adhesive in any
way hinders its inherent adhesive property. Therefore, before the work, make sure to read carefully
the instruction and description given by the maker of the adhesive to be used and be sure to follow
the procedure and observe each precaution throughout the work.

Should coated surface be scratched or otherwise damaged, be sure to repair damaged part, or corro-
sion may start from there.
Use an adhesive of above mentioned type which has following property.
Shearing strength: 40 kg / cm
2 (569 lb / in2) or more
Adhesive materials and tools required for removal and installation.

One component urethane adhesive and primers used in combination (for one sheet of windshield).
Adhesive (470 g (15.7 oz.))
Primer for glass (30 g (1.0 oz.))
Primer for body (30 g (1.0 oz.))
Primer for molding (30 g (1.0 oz.))

Eyeleteer

Piano string

Windshield knife

Brush for primer application (2 pcs.)

Knife

Rubber sucker grip

Sealant gun (for filling adhesive)

Putty spatula (for correcting adhered parts)

YH4
GRAND
VITARA
1. Eyeleteer
1. Piano string
2. Windshield
3. Windshield knife
BODY SERVICE 9-7
REMOVAL
1) Clean both inside and outside of glass and around it.
2) Remove wiper arms and garnish.
3) Using tape, cover body surface around glass to prevent any
damage.
4) Remove rear view mirror, sunvisor, and front pillar trims (right
& left).
5) If necessary, remove instrument panel. Refer to ªINSTRU-
MENT PANELº in this section.
6) If necessary, remove head lining. Refer to ªHEAD LININGº in
this section.
7) If necessary, remove roof trim. Refer to ªROOF TRIMº in this
section.
8) Remove (or cut) windshield molding all around until windshield
edge comes out.
9) Drill hole with eyeletter through adhesive and let piano string
through it.
10) Cut adhesive all around windshield with piano string.
When using tool to cut adhesive, be careful not to cause dam-
age to windshield. Use wire to cut adhesive along lower part of
windshield.
NOTE:
Use piano string as close to glass as possible so as to pre-
vent damage to body and instrument panel.

YH4
GRAND
VITARA
1. Glass
2. Screw
1. Glass run
2. Center sash
3. Partition glass
1. Screw
2. Partition glass
3. Center sash
1. Door outer
weatherstrip
2. Screw
1. Door sealing
cover
2. Adhesive
1
BODY SERVICE 9-13
5) Remove outer weatherstrip.
CAUTION:
Using a tape-wrapped putty knife (or tape-wrapped
screwdriver), pry off weatherstrip. Use of an unwrapped
tool will cause damage to painting.
6) Remove glass fitting screws. Then down door glass.
7) Detach rear part of glass run from center sash.
8) Remove door center sash (by removing two screws with door
glass lowered all the way down).
9) When remove partition glass, slide to front to remove it.
10) Take out glass.
INSTALLATION
Reverse removal sequence to install door glass.
However, be careful of following points.

Securely seal door sealing cover with adhesive.

When weatherstrip is hardened, water leak may develop. In such
case, replace it with new one.

YH4
GRAND
VITARA
9-14 BODY SERVICE
1. Door window
regulator attaching
nuts
2. Hole
1. Window regulator lubrication points
1. Door sealing
cover
2. Adhesive
REAR DOOR WINDOW REGULATOR
REMOVAL
1) Remove door glass, refer to steps 1) to 10) of REAR DOOR
GLASS REMOVAL in this section.
2) Disconnect power window motor lead wire at coupler and clamp.
3) Remove door window regulator attaching nuts (6 pcs.), and take
out regulator through hole as shown in left figure.
INSPECTION
1) Check regulator sliding and rotating parts for greasing.
2) Check rollers for wear and damage.
3) Check wire for damage.
INSTALLATION
Reverse removal sequence to install door window regulator noting
following points.

Tighten regulator base nuts according to the order (a, b, c) shown
in figure.

Adjust door window regulator according to following procedure.
a. Loosen three nuts, two screws and two bolts.
b. Raise window fully.
c. Tighten three regulator rail nuts according to the order (d, e,
f) shown in figure and two center sash bolts A.
d. Lower window.
e. Tighten two screws B to specified torque. Tighten front screw
first, then rear.
Tightening Torque for glass attaching screws
2.5 N
.m (0.25 kg-m, 1.8 lb-ft)
f. Check that the glass moves up and down smoothly and that
the top part of the glass contacts the glass run evenly.

Securely seal door sealing cover with adhesive.

Install door window regulator handle (if equipped) so that it has
an angle as shown when glass is fully closed.