SUZUKI SX4 2006 1.G Service Workshop Manual

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Windshield Removal and InstallationS6RW0D9506002
Preparation
The 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.
CAUTION!
• Described 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
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 corrosion may start from
there.

Use the specific adhesive which has the following
property.
Glass adhesive shearing strength
40 kg/cm2 (569 lb/in2) or moreAdhesive 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)
Removal
1) Clean both inside and outside of glass and around it.
2) Remove wiper arms and cowl top garnish.
3) Using tape, cover body surface around glass to
prevent any damage.
4) Remove rear view mirror, sun visor and front pillar
trims (right & left).
5) If necessary, remove instrument panel. Refer to
“Instrument Panel Removal and Installation in
Section 9C”.
6) If necessary, remove head lining. Refer to “Head
Lining Removal and Installation in Section 9H”.
7) Remove (or cut) windshield molding.
8) Drill hole with eyeleteer (1) through adhesive and let
piano string through it.
I2RH01950040-01

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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.
NOTE
Use piano string (2) as close to glass as
possible so as to prevent damage to body
and instrument panel.

10) Using knife (1), smoothen adhesive (2) remaining on
body side (3) so that it is 1 – 2 mm (0.040 – 0.078
in.) thick all around.
NOTE
Before using knife (1), clean it with alcohol or
the like to remove oil from it.

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
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 (2) as shown.
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 5.5 mm (0.217 in.) and clearances
between each side end (right & left) of glass (1) and
body (2) are even. Then mark mating marks (3) on
glass (1) and body (2) as shown. Upper clearance
can be adjusted by moving glass stoppers position.
Windshield clearance
“a”: approx. 5.5 mm (0.217 in.)
I3RH0A950006-01
I2RH01950042-01
3. Mark
I2RH01950043-01
1
3
2
I5RW0A950002-01
2
1“a”
3
I5RW0A950003-02

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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.
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 windshield (distance from the
edge of glass or molding)
30 – 50 mm (1.19 – 1.96 in.)
7) Install new spacers (1) to windshield (2).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”: 17 mm (0.67 in.)
“b”: 20 mm (0.79 in.)
9) Apply primer for molding along molding surface all
around.
1. Do not apply primer
3. Apply primer
I2RH01950046-01
2
1I5RW0A950004-01
1. Molding
2. 40 mm (1.57 in.)
“b”2
“a”
1
“a”
1
I5RW0A950005-01

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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 grip 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. 10 mm (0.39 in.) for right,
left and upper sections
Position “d”: Approx. 50 mm (1.97 in.) for bottom
section11) 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
• Do not use high pressure water.
• Do not blow compressed air directly at
adhesive applied part when drying.
• Do not use infrared light or like for drying.

3. Molding 4. Windshield glass spacer
2
“b”
“c”
2
3
1
“a”
3
2
1
“b”
“c”
“a”
2
4
1“b”
“d”
“a”
I5RW0A950006-01
I2RH01950050-01
I2RH01950051-01

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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.

Front Pillar Window ComponentsS6RW0D9506003
Front Pillar Window Removal and InstallationS6RW0D9506004
Refer to “Windshield Removal and Installation” as
preparation, 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 applied evenly especially in
height.
• Be careful not to damage primer (3).
• Press glass against body quickly after adhesive (1) is
applied.
Adhesive amount specification and position for front
pillar window
Height “a”: 10 mm (0.39 in.)
Width “b”: 6 mm (0.24 in.)
Position “c”: 4.5 mm (0.18 in.)
Width “d”: 12 mm (0.47 in.)
Position “e”: 3.5 mm (0.14 in.)
Position “f”: 5.5 mm (0.22 in.)
Width “g”: 11.3 mm (0.44 in.)
1. Front pillar window glass
1
I5RW0A950007-02
4. Molding
“d”
“a” “b”“e”1
2 3
4
“d”
“a” “b”“c”
1 2
3
4
“d”
“f ” “a”
“b”12
3
4
“c”“g”
“a” “b”
12
3
4
I5RW0A950008-01

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Rear Quarter Window ComponentsS6RW0D9506005Rear Quarter Window Removal and InstallationS6RW0D9506006
Refer to “Windshield Removal and Installation” as
preparation, 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 applied evenly especially in
height.
• Be careful not to damage primer (3).
• Press glass against body quickly after adhesive (1) is
applied.
Adhesive amount specifications and position for
rear quarter window
Width “a”: Approx. 6 mm (0.24 in.)
Height “b”: Approx. 13 mm (0.51 in.)
Position “c”: Approx. 12 mm (0.47 in.)
Width “d”: Approx. 14 mm (0.55 in.)
Position “e”: Approx. 84 mm (3.31 in.)
1. Rear quarter window glass 2. Fastener
2
2
1
I7RW01950001-03
4. Ceramic print line
“a”
“b”
“d”“c”“e”“a”
“b” “d”
“a” “b”
“d”
“c”
“a”“b”
“d”
“c”
1
3
2
3
1
2
4
2
3
1
2
3
1
I5RW0A950010-02

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Rear End Door Window ComponentsS6RW0D9506007
Rear End Door Glass Removal and InstallationS6RW0D9506008
Refer to “Windshield Removal and Installation” as
preparation, 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 applied evenly especially in
height.
• Be careful not to damage primer (3).
• Install glass (2) on rear end door panel (5) noting the
following.
– With the position of fastener (4) properly aligned.
– With the position of ceramic mark (6) aligned to the
mark (7) of 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”: 7 mm (0.28 in.)
Width “c”: 14 mm (0.55 in.)
Position “d”: 15 mm (0.59 in.)
Position “e”: 42 mm (1.65 in.)
Position “f”: 37 mm (1.46 in.)
Position “g”: 9 mm (0.35 in.)
Position “h”: 14 mm (0.55 in.)
2
2
1
2
I5RW0A950011-02
1. Rear end door glass 2. Fastener
“A”“a”“c”“d”1
3
12
“a”
“b”“c”
“g”
“h”
1
2
3
“A”
“B”“B” “b”
5
24
15
4 2
6
572
“a” “c”
“e”
“f ”
2
31“b”
I7RW01950010-01

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Front Door Window ComponentsS6RW0D9506009
2
8
11
4
1
7
36
9
10
12
5
I7RW01950002-01
1. Door glass 5. Door sealing cover 9. Front door inner weather-strip
2. Window regulator assembly: Apply lithium
grease 99000-25011 to sliding part.6. Door panel 10. Front door outer weather-strip
3. Glass run 7. Front door sash 11. Door trim bracket
4. Door trim 8. Door glass mounting screw: Tighten rear
screw first, and then tighten front screw.12. Door mirror trim

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Front Door Glass Removal and InstallationS6RW0D9506010
NOTE
(For pinching prevention function model)
After disconnecting the power window main
switch, make sure to execute to the initial
setting, (to have the door glass closed
position learned) refer to “Power Window
Main Switch Initialization (Pinching
Prevention Function Model)”.

Removal
1) Remove door mirror trim (1).
2) Remove door trim mounting screws (2).
3) Remove door trim (1) as shown.
And disconnect connectors from power window
switch, door mirror and tweeter (if equipped).
4) Remove door inner weather-strip (3).
5) Remove door trim bracket (1).
6) Remove door sealing cover (2).7) Remove door glass mounting screws (1).
8) 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).
“A”
“A”
“A”21
2
I5RW0A950014-02
“A”
“A”
“A”
“A”“A”
“A”“A”
“A”
“A”
“A”
1I5RW0A950015-02
3
1
2I5RW0A950016-02
2
1
I5RW0A950017-03
2
1
I5RW0A950018-02
2
1
I5RW0A950019-02

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• Install front door trim.
Front door trim attaching order
(1) → (2) → (3) → (4) → (5) → (6) → (7) → (8) → (9)
Front Door Window Regulator Removal and
Installation
S6RW0D9506011
NOTE
(For pinching prevention function model)
After replacing or disconnecting the driver
side door window regulator, make sure to
execute to the initial setting, (to have the
door glass closed position learned) refer to
“Power Window Main Switch Initialization
(Pinching Prevention Function Model)”.

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).Installation
Reverse removal procedure noting the following
instruction.
• Apply grease to sliding portions of window regulator.
: Grease 99000–25011 (SUZUKI Super Grease A)
Front Door Window Regulator InspectionS6RW0D9506012
NOTE
(For pinching prevention function model)
After replacing or disconnecting the driver
side door window regulator, make sure to
execute to the initial setting, (to have the
door glass closed position learned) refer to
“Power Window Main Switch Initialization
(Pinching Prevention Function Model)”.

Check the following parts for wear, damage, smooth
operation and lubrication:
• Check regulator sliding and rotating parts.
• Check rollers.
“A”
“A”
“A”
“A”“A”
“A”“A”
“A”
“A”
“A”
3
2
4
5
6
7
8
9
1
I5RW0A950020-02
2
1I5RW0A950021-02