500 SUZUKI SWIFT 2006 2.G Service Owners Manual

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Repair Instructions
Windshield Removal and InstallationS7RS0B9506001
Removal1) Clean both inside and outside of glass and around it.
2) Remove wiper arms and cowl top garnish.
3) Remove windshield side garnish.
4) Using tape, cover body surface around glass to prevent any damage.
5) Remove rear view mirror , sun visor and front pillar
trims (right & left).
6) If necessary, remove instrument panel. Refer to “Instrument Panel Removal and Installation in
Section 9C”.
7) If necessary, remove he ad lining. Refer to “Head
Lining Removal and Installation in Section 9H”.
8) Remove (or cut) windshield molding.
9) Drill hole with eyeleteer (1 ) through adhesive and let
piano string through it. 10) 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.
NOTE
Use piano string (2) as close to glass as
possible so as to prevent damage to body
and instrument panel.

11) Using knife (1), smoothen adhesive (2) remaining on body side (3) so that it is 1 – 2 mm (0.039 – 0.078
in.) thick all around.
NOTE
Before using knife (1), clean it with alcohol or
the like to remove oil from it.

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12) 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 windshield 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), position 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”: approx. 5 mm (0.197 in.) 4) Clean contact surfaces of old adhesive (4), paint or
bare metal thoroughly.
If surfaces of paint or ba re metal come out, apply
primer (2) for body with caution not to apply primer
(2) to surface of adhesive remaining on body.
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.

5) Install new molding to glass.
6) Clean glass surface to be adhered to body with clean cloth. If cleaning solvent is used, let it dry for
10 minutes or more.
Cleaning Area for windshie ld (distance from the
edge of glass or molding)
30 – 50 mm (1.18 – 1.97 in.)
7) Install new spacers (1) to windshield (2).
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1
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2
1“a”
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1. Do not apply primer 3. Apply primer
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8) Using new brush, apply sufficient amount of primer onto glass along glass edge.
NOTE
• Be sure to refer to maker’s instruction for
proper handling and drying time.
• Do not apply primer on outside of ceramic coated surface.
• Do not touch primer coated surface.

Width applied primer for windshield
“a”: 15 mm (0.59 in.)
9) Apply primer for molding along molding surface all around.
10) Apply adhesive (1) referring to figure.
NOTE
• Press glass (2) against fittings surface of body panel quickly after adhesive (1) is
applied.
• Use of rubber sucker gr ip is helpful to hold
and carry glass after adhesive (1) is
applied.
• Perform steps 8) to 9) within 10 min. to ensure sufficient 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.

Adhesive amount specifications and position for
windshield
Width “a”: Approx. 7 mm (0.27 in.)
Height “b”: Approx. 15 mm (0.59 in.)
Position “c”: Approx. 11 mm (0.43 in.) for front,
rear and upper sections
Position “d”: Approx. 35 mm (1.38 in.) for bottom
section
1. Molding
2. Windshield side garnish clip
3. 32.5 mm (1.28 in.)
“a”
1
“a”
“a”
2
3
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3. Molding
4. Windshield glass spacer
5. Windshield side garnish clip
2
2
4
1
“b” “d”
“b”
“c”
2
1
“a”
3
2
1
“b”
“c”
5
“a”
“a”
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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 po int with adhesive. If water
still leaks even after that , remove glass and start
installation procedure all over again.
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.

CAUTION!
Upon completion of installation, note the
following.
• Sudden closing of door before adhesive is completely set may cause glass to become
loose or to come off. Therefore, if door is
opened or closed before adhesive is
completely set, make sure to open all door
glasses and use proper care.
• If molding is not securely in place, hold it down with a tape until adhesive is
completely set.
• Each adhesive has its own setting time.
• Be sure to refer to its maker’s instruction, check setting time of adhesive to be used
and observe precautions to be taken
before adhesive is set.
• Refrain from driving till adhesive is completely set so as to ensure proper and
sufficient adhesion.

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Front Door Window ComponentsS7RS0B9506002
Front Door Glass Removal and InstallationS7RS0B9506003
Removal1) Remove door mirror trim (1).
2) Remove door trim mounting screws (2). 3) Remove door trim (1) as shown.
And disconnect power window switch lead wire at
coupler.
10 6
3
1
7
11
5
2 9
8
4
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1. Door glass 7. Front door sash
2. Window regulator assembly : Apply lithium grease 99000-25011 to sliding part. 8. Door glass mounting screw
: Tighten rear screw first, and then tighten front screw.
3. Glass run 9. Front door window regulator mounting screw
: Tighten rear screw first, and then tighten front screw.
4. Door trim 10. Front door outer weather-strip
5. Door sealing cover 11. Door trim bracket
6. Door panel
2 2
1
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“B”
“A”
“B”
“A”
“B”“A”
“A”
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4) Remove door trim bracket (1).
5) Remove door sealing cover (2).
6) Remove door glass mounting screws (1).
7) Remove door glass (2) while tilting it as shown.
Installation
Reverse removal procedure noting the following
instructions.
• If there is deformity for glass run, replace it with a new one.
• Tighten door glass rear mounting screw (1) first, and then tighten door glass front mounting screw (2). • Secure door sealing cover (1) with adhesive (2).
• Install front door trim.
Front door trim attaching order
(1) → (2) → (3) → (4) → (5) → (6)
Front Door Window Regulator Removal and
Installation
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Removal
1) Remove door glass referring to “Front Door Glass Removal and Installation”.
2) Disconnect power window motor lead wire at coupler.
3) Remove regulator mounting screws (1), and then remove front door window regulator (2).
1
2
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2
1
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1
2
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2
1
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“A”“A”
“A”
“A”
“A”“A”“A”
1 2
3
4
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1
1
2
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Installation
Reverse removal procedure noting the following
instruction.
• Apply grease to sliding portions of window regulator.: Grease 99000–25011 (SUZUKI Super Grease A)
• Tighten front door window regulator attaching screws. Front door window regulator screw tightening
order
(a) → (b)
Front Door Window Regulator InspectionS7RS0B9506005
Check the following parts for wear, dama ge, smooth
operation and lubrication:
• Check regulator sliding and rotating parts.
• Check rollers.
Rear Door Window ComponentsS7RS0B9506006
(a)
(b)
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9
7
3610
11
b
c
12
5 2
8
4
a
1
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1. Door glass
6. Door sash 11. Rear door inner garnish
2. Window regulator assembly : Apply lithium grease 99000-25011 to
sliding part. 7. Door panel
12. Door trim bracket
3. Glass run 8. Rear door window regulator mounting screw
: Tighten lower screw first, and then tighten upper screw. a: Sash upper mounting screw
: Tightening order: a → b → c
4. Door trim 9. Rear door outer weather-strip b, c: Sash lower mounting bolt
: Tightening order: a → b → c
5. Door sealing cover 10. Rear door partition glass.

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Rear Door Glass Removal and InstallationS7RS0B9506007
Removal1) Remove rear door inner garnish (1).
2) Remove door trim mounting screws (2).
3) Remove door trim (1) as shown. And disconnect power wi ndow switch lead wire at
coupler.
4) Remove door trim bracket (1).
5) Remove door sealing cover (2). 6) Detach rear part of glass run from door sash (1), and
remove door sash (1).
7) Remove door glass (2) as shown.
Installation
Reverse removal procedure noting the following
instructions.
• If there is deformity for glass run, replace it with a new one.
• Tighten door sash mounting screw and bolts.
Door sash mounting screw and bolt tightening
order
(a) → (b) → (c)
• Secure door sealing cover (1) with adhesive (2).
“A”
“A”
“A”
2
2 1
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“A”
“A”
“A”“A”
“A”
“A”
1
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2
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(a)
(b)
(c)
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• Install rear door trim.Rear door trim attaching order
(1) → (2) → (3) → (4) → (5) → (6)
Rear Door Window Regulator Removal and
Installation
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Removal
1) Remove door glass referring to “Rear Door Glass Removal and Installation”.
2) Disconnect power window mo tor lead wire at coupler
and loosen clamp.
3) Loosen regulator mounting screws (1), and then remove rear window regulator (2). Installation
Reverse removal procedure noting the following.
• Apply grease to sliding and rotating portions of
window regulator.
: Grease 99000–25011 (SUZUKI Super Grease A)
• Tighten rear door window regulator attaching screws. Rear door window regulator screw tightening
order
(a) → (b)
Rear Door Window Regulator InspectionS7RS0B9506009
Check the following point:
• Check regulator sliding and rotating parts.
• Check rollers for wear and damage.
“A”
1
2
3 45
6
“A”
“A”
“A”“A”
“A”
“A”
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Rear End Door Window ComponentsS7RS0B9506010
Rear End Door Glass Removal and InstallationS7RS0B9506011
Refer to “Windshield Removal and Installation” as
removal and installation procedures are basically the
same. However, note the following.
• Observe the following precautions when applying adhesive (1) along glass (2) edge.
• Adhesive (1) should be app lied evenly especially in
height.
• Be careful not to damage primer (3).
• With the position of fastener (4) properly aligned, install glass (2) on rear end door panel (5).
• Press glass against body quickly after adhesive (1) is applied.
Adhesive amount specifications and position for
rear end door glass
Height “a”: 13 mm (0.51 in.)
Width “b”: 6 mm (0.24 in.)
Width “c”: 14 mm (0.55 in.)
Position “d”: 12 mm (0.47 in.) for glass upper
section
Position “d”: 16 mm (0.63 in.) for glass bottom
section
Position “d”: 32.5 mm (1.28 in.) for glass side
sections
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1. Rear end door glass 2. Fastener
“A”
“A”
“A”
“A”
“c”“d”
“a” “b”
21
2
3
1
2
1
1
2
5
2
4
4
5
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