SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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.

YH4
GRAND
VITARA
BODY SERVICE 9-15
1. Fastener
2. Glass
3. Molding
4. Adhesive
5. Primer
QUARTER WINDOW
REMOVAL AND INSTALLATION
Refer to ªWINDSHIELDº section as removal and installation proce-
dures and cautions are basically the same. However, note the fol-
lowing.
NOTE:

Before applying primer to glass edge, install molding ac-
cording to installing position shown in figure.

Observe following precautions when applying adhesive
along glass edge.
±Adhesive should be applied evenly especially in height.
±Be careful not to damage primer.
±Press glass against body quickly after adhesive is applied.
Height ªbº : 12 mm (0.47 in.)
Width ªdº : 16 mm (0.63 in.)
ªcº : 8 mm (0.31 in.)
Clearance ªeº : 1 mm (0.04 in.)

YH4
GRAND
VITARA
9-16 BODY SERVICE
1. Molding
2. Glass
3. Fastener
1. Molding
2. Glass
3. Primer
4. Adhesive
5. Fastener
1. Door sealing cover
BACK DOOR GLASS
REMOVAL AND INSTALLATION
Refer to ªWINDSHIELDº section as removal and installation proce-
dures and cautions are basically the same. However, note the fol-
lowing.
NOTE:

Before applying primer to glass edge, install molding ac-
cording to installing position shown in figure.

Observe following precautions when applying adhesive
along glass edge.
±Adhesive should be applied evenly especially in height.
±Be careful not to damage primer.
±Press glass against body quickly after adhesive is applied.
Height ªbº : 15 mm (0.59 in.)
Width ªcº : 8 mm (0.31 in.)
Width ªdº : 16 mm (0.63 in.)
Clearance ªeº : 1 mm (0.04 in.)

When replacing back door, coat replacement door inside
with wax for proper anticorrosive treatment. Refer to ªUN-
DER COATING / ANTI-CORROSION COMPOUND APPLICA-
TION AREAº in this section.

Apply sealing compound to peripheral of door hem area and
reinstall door sealing cover.

When weatherstrip is hardened and water leaks have devel-
oped, replace it.

YH4
GRAND
VITARA
BODY SERVICE 9-17
1. Stopper pin
1. Rags
2. Wooden piece
1. Upper hinge
mounting bolts
2. Lower hinge
mounting bolt
3. Door
4. Body
1. Front door hinge
2. Upper hinge nut (rear door)
3. Rear door hinge
BODY STRUCTURE
FRONT DOOR ASSEMBLY
REMOVAL
1) Remove front fender. Refer to ªFRONT FENDERº in this section.
2) Disconnect door harness lead wires at each coupler.
3) Remove stopper pin.
4) Support door panel using a jack with a piece of wood placed be-
tween jack and panel, as shown.
5) Remove door assembly by loosening hinge mounting bolts.
INSTALLATION
Reverse removal procedure to install door assembly, noting follow-
ing point.
NOTE:
When replacing door, coat replacement door inside with wax
for proper anticorrosion treatment.
Refer to ªUNDERCOATING / ANTI-CORROSION COMPOUND
APPLICATION AREAº in this section.

Tighten door hinge bolts (and nut) to specified torque.
Tightening torque
(a): 27 N
.m (2.7 kg-m, 19.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

Adjust door latch striker position by referring to ªFRONT DOOR
LOCK INSTALLATIONº section so that door is positioned correctly.

Adjust front door cushion so that door contacts body when closed.

After installation, open and close the door to check looseness.
Replace door open stopper pin when there is looseness.

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

YH4
GRAND
VITARA
9-18 BODY SERVICE
REAR DOOR ASSEMBLY
REMOVAL / INSTALLATION
Follow procedures for Front Door removal / installation in this sec-
tion.

YH4
GRAND
VITARA
BODY SERVICE 9-19
1. Back door panel assy
2. Back door window glass
3. Back door hinge
4. Back door / Rear gate balancer unit
1. Back door hinge
2. Back door
3. Body
BACK DOOR / REAR GATE ASSEMBLY
REMOVAL
1) Remove back door trim, and door / rear gate sealing cover, refer
to steps 1) to 4) of BACK DOOR LOCK ASSEMBLY in this sec-
tion.
2) Remove wire harness connector inside the back door / rear gate.
3) Remove back door / rear gate balancer (first at its door-side and
next at its body-side), as shown.
WARNING:
Handling of Back Door / Rear Gate Balancer (Damper)

Do not disassemble balancer because its cylinder is
filled with gas.

The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill.
Therefore, be sure to wear goggle.

When discarding removed back door / rear gate balanc-
er (damper), use a 2 to 3 mm (0.08 to 0.12 in.) drill to
make a hole as shown.

Handle balancer carefully. Do not scar or scratch ex-
posed surface of its piston rod, and never allow any
paint or oil to stick to its surface.

Do not turn piston rod with balancer fully extended.
5) Remove back door / rear gate hinge bolts and back door / rear
gate.

YH4
GRAND
VITARA
9-20 BODY SERVICE
1. Sealing cover
2. Adhesive
INSTALLATION
Reverse removal procedure to install back door / rear gate noting
following points.

Secure wiring harness.

Secure back door / rear gate sealing cover.
NOTE:
Use adhesive to seal sealing cover to back door / rear gate.

Adjust back door / rear gate latch striker position by referring
ªBACK DOOR LOCK ASSEMBLY INSTALLATIONº so that back
door / rear gate is positioned correctly.

Adjust back door / rear gate cushion so that back door / rear gate
contacts body when closed.

YH4
GRAND
VITARA
BODY SERVICE 9-21
1. Hood lock
2. Hood lock bolts
3. Match marks
1. Hood cushion
HOOD
REMOVAL
1) Remove window washer hose from hood.
2) Remove four mounting bolts to detach hood.
ADJUSTMENT

Fore-and-aft and right-and-left adjustment.
Loosen four mounting bolts for adjustment.

Hood lock adjustment
When installing hood lock, bring bolt at intersection point of match
marks and move it in vertical direction for adjustment, if neces-
sary.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

Vertical adjustment
If only one side (right or left) of hood is not level with front fender,
make it level by tightening or loosening hood cushion.
INSTALLATION
Reverse removal procedure to install hood.
INSPECTION
Check that secondary latch operates properly (check that second-
ary latch keeps hood from opening all the way even when pulling
hood release handle inside vehicle.) Also check that hood opens
and closes smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or repair hood
lock system.

YH4
GRAND
VITARA
1. Side body
2. Fender
3. Pad
1. Side body
2. Pad
3. Knife
9-22 BODY SERVICE
1. Front fender
2. Front fender lining
3. Fender attaching bolts
4. Fender lining attaching screws
FRONT FENDER
REMOVAL
1) Remove front bumper.
2) Remove fender splush guard (H25 engine).
3) Remove front fender lining.
4) Remove front fender.
INSTALLATION
1) Remove pad from side body and (or) fender, using care not to
damage painted surface.
2) Attach new pad cutting appropriately size temporarily and adjust
height with a knife so that fender becomes flush with side body.
3) Reverse removal procedure for installation.
NOTE:
If paint on fender bolt is peeled off, be sure to apply paint
again.