SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

BODY SERVICE 9-7
DOOR MIRROR
REMOVAL AND INSTALLATION
When removing or installing door mirror, refer to above figure.
1. Door mirror a. Mirror mount screw Tightening order : a →
b →
c
2. Inner garnish b. Mirror mount screw Tightening torque
3. Clip c. Mirror mount screw
a 4.5 N·m (0.45 kg-m)
c 4.5 N·m (0.45 kg-m)
b 4.5 N·m (0.45 kg-m)
2
“A”
“A”
1
3 “A”

9-8 BODY SERVICE
REAR DOOR GLASS (IF EQUIPPED)
1. Door glass 7. Window regulator handle 13. Glass bottom rubber
2. Window regulator assembly
: Apply lithium grease 99000-25010 to moving section.8. Rear door outer weather-strip 14. Door inside pull handle case
3. Glass run 9. Rear door inside pull handle bracket [A] : Without power window model
4. Door trim 10. Rear door inner garnish [B] : With power window model
5. Door sealing cover 11. Rear door outer garnish
6. Door sash 12. Glass bottom channel

BODY SERVICE 9-9
REMOVAL
1) Remove window regulator handle (1) (if equipped).
For its removal, pull off snap by using a cloth (2) as shown in
figure.
2) Remove inside handle bezel (1).
3) Remove door inside pull handle case fitting screw.
4) Remove rear door inner garnish.
5) Remove door trim (1).
With inside handle bezel (2) tilted as shown in figure, turn
door trim 90° counterclockwise to remove it.
And disconnect power window switch lead wire at coupler (if
equipped).
6) Remove door inside pull handle bracket.
7) Remove door sealing cover (1).
2
1
1

9-10 BODY SERVICE
8) Remove rear door outer garnish (1).
9) Remove outer weather-strip (2).
Lower window all the way down. Then, use a tape-wrapped
putty knife (or screwdriver) to pry off outer weather-strip.
10) Detach rear part of glass run (1) from sash (2) and remove
sash (2) by removing 2 screws (3).
11) Loosen window regulator mounting screws (5).
12) When removing door glass (4), turn door glass 90° counter-
clockwise to remove it.
INSTALLATION
Reverse removal procedure to install door glass noting the follow-
ing instructions.
If there is deformity for glass run, replace new one.
Tighten bottom channel attaching screws. Tighten rear
screw first, and then tighten front screw.
Glass fitted position of bottom channel (1) is as shown in fig-
ure.
Glass fitted position of bottom channel
“a” : 201.9 - 204.9 mm (7.95 - 8.07 in.)
Secure door sealing cover (1) with adhesive (2). NOTE:
When removed outer weather-strip (2) from door panel
(3), be careful not to deformation for outer weather-strip
(2).
2 3
1
4
1
23
5
4
1
2

BODY SERVICE 9-11
Install door window regulator handle (1) so that it has a 45°
±12.5° angle when glass is fully closed.
REAR DOOR WINDOW REGULATOR
REMOVAL
1) Remove door glass (3) referring to “REAR DOOR GLASS” in
this section.
2) Loosen regulator mounting screws (1) and take out regulator
through hole (2) as shown.
INSPECTION
Check the following point :
Check regulator sliding and rotating parts for greasing (1).
Check rollers (2) for wear and damage.
INSTALLATION
Reverse removal procedure to install window regulator noting the
following instruction.
When glass run (1) is installed, fit glass run convex part (2)
to door panel cut part (3) and door sash (4).
A : Front
3
3
2
1

9-12 BODY SERVICE
WINDOW SHIELD
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 follow the proper procedure.
Use an adhesive of above mentioned type which has the following property.
Glass adhesive 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)
1. Windshield glass 3. Stopper 5. Side spacer
2. Windshield molding 4. Center spacer Do not reuse.
CAUTION:
Described in this section is the glass replacement by using 3 types of primers and 1 type of adhe-
sive made by YOKOHAMA (one component urethane adhesive to be used with primer in combina-
tion). When using primer and adhesive made by other manufacturers, be sure to refer to handling
instructions 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 cor-
rosion may start from there.

BODY SERVICE 9-13
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 “INSTRU-
MENT PANEL” in this section.
6) If necessary, remove head lining. Refer to “HEAD LINING” in
this section.
7) Remove (or cut) windshield molding.
8) Drill hole with eyeleteer (1) through adhesive and let piano
string through it.
9) Cut adhesive all around windshield (1) with piano string (2).
When using tool, windshield knife (3), to cut adhesive, be
careful not to cause damage to windshield. Use wire to cut
adhesive along lower part of windshield.
10) Using knife (1), smoothen adhesive (2) remaining on body
side (3) so that it is 1 to 2 mm thick all around.
NOTE:
Use piano string (2) as close to glass as possible so as to
prevent damage to body and instrument panel.
NOTE:
Before using knife (1), clean it with alcohol or the like to
remove oil from it.

9-14 BODY SERVICE
11) When reusing windshield, remove the adhesive (1) from it,
using care not to damage primer coated surface (2).
INSTALLATION
1) Using cleaning solvent, clean windshield edge where wind-
shield glass is to be adhered. (Let it dry for more than 10
minutes.)
2) Install new glass stoppers (1) (2 pieces) to lower side of
windshield.
3) To determine installing position of glass (1) to body (2), posi-
tion glass against body so that clearance between upper end
of glass (1) and body (2) is approximately 5 mm (0.197 in.)
and clearances between each side end (right & left) of glass
(1) and body (2) are even. Then mark mating marks on glass
(1) and body (2) as shown. Upper clearance can be adjusted
by moving glass stoppers position.
Windshield clearance
“a” : 5 mm (0.197 in.)
4) Clean contact surfaces of old adhesive (4), paint or bare
metal thoroughly.
If surfaces of paint or bare metal come out, apply primer (2)
for body with caution not to apply primer (2) to surface of
adhesive remaining on body.
1
“a” “a”
11
2 2
NOTE:
Be sure to refer to primer maker’s instruction for
proper handling and drying time.
Do not touch body and old adhesive surfaces where
glass is to be adhered.
1. Do not apply primer
3. Apply primer

BODY SERVICE 9-15
5) Install new molding (1) to glass (2).
6) Clean glass surface to be adhered to body with clean cloth. If
cleaning solvent is used, let it dry for more than 10 minutes.
Cleaning Area for windshield (distance from the edge of
glass or molding)
“a” : 30 - 50 mm (1.18 - 1.97 in.)
7) Install new spacer (1) to glass (2).
8) Using new brush, apply sufficient amount of primer for glass
along glass surface to be adhered to body.
Width applied primer for windshield
“a” : 22 mm (0.87 in.)
“b” : 15 mm (0.59 in.)
“a”
“a”1
1 2
2
2
1
12
NOTE:
Be sure to refer to maker’s instruction for proper han-
dling and drying time.
Do not apply primer on outside of ceramic coated sur-
face.
Do not touch primer coated surface.
1. Molding
2. Fastener
3. Spacer

9-16 BODY SERVICE
9) Apply primer for molding along molding surface all around.
10) Apply adhesive (1) referring to figure.
Adhesive amount specifications and position for wind-
shield
Width “a” : Approx. 7 mm (0.27 in.)
Height “b” : Approx. 15 mm (0.59 in.)
Position “c” : Approx. 10 mm (0.39 in.) for front, rear and
upper sections
Position “d” : Approx. 17 mm (0.67 in.) for bottom section.
11) Holding rubber sucker grips (1), place glass onto body by
aligning mating marks marked in step 3) and press it.
12) Check for water leakage by pouring water over windshield
through hose. If leakage is found, dry windshield and fill
leaky point with adhesive. If water still leaks even after that,
remove glass and start installation procedure all over again. NOTE:
Press glass (2) against fittings surface of body panel
quickly after adhesive (1) is applied.
Use of rubber sucker grip is helpful to hold and carry
glass after adhesive (1) is applied.
Perform steps 8) to 9) within 10 min. to ensure suffi-
cient adhesion.
Be sure to refer to adhesive maker’s instruction for
proper handling and drying time.
Start from bottom side of glass (2).
Be careful not to damage primer.
3. Molding
3
2
1
1“b”
“b”“b” “a”
“c”
“d”“c”
2
2
2
3
3
1
“a”“a”
NOTE:
Do not use high pressure water.
Do not blow compressed air directly at adhesive
applied part when drying.
Do not use infrared lamp or like for drying.