Door SUZUKI GRAND VITARA 2003 2.G Service Repair Manual

YH4
GRAND
VITARA
Hole to hole distance
a ± a' : 1112 mm (43.78 in.)
a ± f' : 1134 mm (44.65 in.)
a ± g' : 796 mm (31.34 in.)
a' ± f : 1156 mm (45.51 in.)
a' ± g : 824 mm (32.44 in.)
b ± d : 1229 mm (48.39 in.)
c ± d : 1324 mm (52.13 in.)
e ± e' : 1544 mm (60.79 in.)
f ± f' : 1029 mm (40.51 in.)
a (a'). Trim installation clip hole
b. Installation hole in uppermost part of upper hinge
c. Installation hole in outside part of lower hinge
d. Installation hole in uppermost part of rear gate striker
e (e'). Installation hole in outer upper section of R-COMB R (L) lamp
f (f'). Innermost end of rear floor tail member installation section
g (g'). Garnish installation clip hole
9-32 BODY SERVICE
2 door model

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. Side body inner panel
2. Rear wheel housing outer rear panel
3. Rear wheel housing panel
4. Rear floor panel
5. Tail lower member
6. Center floor panel
7. Front floor panel
8. Center floor member
9. Side sill inner panel
10. Side outer panelªAº: Apply sealant
ªBº: Brush treatment
9-38 BODY SERVICE
SEALANT APPLICATION AREA
4 door model

YH4
GRAND
VITARA
1. Side body inner panel
2. Rear wheel housing panel
3. Rear floor panel
4. Center floor panel
5. Front floor panel
6. Center floor member
7. Side sill inner panelªAº: Apply sealant
ªBº: Brush treatment
BODY SERVICE 9-47
2 DOOR MODEL

YH4
GRAND
VITARA
ªaº: 200 mm (7.87 in.)
ªbº: 100 mm (3.94 in.)
ªAº: Apply rust proof wax (hot wax 50
m or more)
ªBº: Apply rust proof wax (high viscosity wax 50
m or more)1. Side body outer
2. Side sill inner
3. Frame
4. Main floor
5. Rear fender
6. Rear wheel housing
7. Center floor
BODY SERVICE 9-51
UNDERCOATING / ANTI-CORROSION COMPOUND APPLICATION AREA
4 door model

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 IWATA
VIEW: Z
9-52 BODY SERVICE

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
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 9-59
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.