1987 SUZUKI GRAND VITARA Service Repair Manual

[Door lock inside handle]
Fit the inside handle, adjusting the clearance
between inside open lever @I and outside open
lever @I of the door lock to 0 - 2 mm (0 -
0,079 in) by moving the inside handle remote
control rod @ in the arrow direction given in
below figure.
After installation, give it a trial and check if its
play felt then is appropriate.
8. Inside open lever
9. Outside open lever
10. Control rod
11. Door lock striker“B” :0 - 2 mm (0 - 0.079 in.)
Fig. 20-1-21
[Door lock rod pin]
Fix the lock rod with rod pin securely as illust-
rated below.
Rod pin
Fig. 20-1-22
[Door lock striker]
Increase or decrease striker spacers fitted in “A”
position behind the striker to adjust dimensions
to below values as shown in below figure.
After adjustment, check the difference in level
between the door and
there is difference by
striker to right or left.
body and adjust when
moving the door lock
Clearance3.0 mm
(0.12 in.)Spacer fitting position “A”r
Striker
Door lock base\JIA4Yl
y <1 Door inner panelDimension
H 12.7-14.7mm(0.499 - 0.579 in.)
Fig. 20-1-23
Move the striker base up and down so that
striker shaft aligns with the center of the groove
of the door lock (the clearance between the shaft
of door lock striker and lock base is 1.0 mm
(0.04 in.)) in the vertical direction.
CAUTION:
l The striker should be placed vertically.
l Do not adjust the door lock.
Door lock cam
Fig. 20-1-24
20-7

20-2. WINDSHIELD
The windshield glass is bonded to the window panel (body) with weatherstrip in position. When replacing
the glass, it is necessary to perform correct operation and adhesive selection so that adequate bonding
strength can be obtained.
1. Windshield glass2. Windshield weatherstrip
Fig. 20-2-1
CLEANING
1) After removing the glass, remove the urethane
gum sticking to the glass and window panel
(body).
Fig. 20-2-2
NOTE:
When removing the urethane gum from the
window panel (body), apply a masking tape
along the edge of the gummed surface to protect
the painted surface from damage.
1. Urethane gum
Fig. 20-2-3
2. Use cleaning solvent to clean the glass and
window panel (body).
NOTE:
The use of alcohol or thinner when cleaning may
adversely affect some kinds of adhesives in
terms of bonding strength, resulting in that it is
impossible to obtain adequate strength for glass
installation. So, be careful sufficiently about the
selection of the cleaning solvent
20-8

INSTALLATION
The installation sequence is shown in the Block Diagram below.
SolventcleaningDrying\rr05 Assembly
SolventDrying
4
-8-9F10-11B12
TemporaryinstallationInstallation(Cord drawing)Bondingagentfilling
Oozecleaning
Solventwipingcleaning
1) As for the cleaning, use cleaning solvent.
The use of alcohol or thinner adversely affects
some kinds of adhesives in terms of bonding
strength. Hence, use sufficient care to select
proper cleaning solvent.
2) When cleaning the weatherstrip, apply a 3 kg
or more pressure on a clean cloth to wipe and
clean it.
3) After cleaned with solvent, each item should
not be touched by hand fouled with grease,
etc.
4) Make a glass-and-weatherstrip assembly,
Thereafter, carefully keep the assembly free
from dust to assemble it to the window panel
(body) as soon as possible.
5) Glass installation
When assembling the glass into the weather-
strip’s glass channel, and when assembling the
glass-and-weatherstrip assembly to the window
panel (body) soapy water must not be used as
lubricant. If the installation is felt hard, use
cleaning solvent as lubricant,
1, Soapy water
Fig. 20-2-4
l When installing the glass-and-weatherstrip
assembly to the window panel (body), pre-
viously fit a cord into the weatherstrip’s
body flange channel.
l Start the installation from the central bottom
portion of the glass.
l Position the glass-and-weatherstrip assembly
in the window panel (body) opening with a
helper applying pressure by palm from the
outside. Then, pull the weatherstrip over the
flange with the cord to install the assembly
into position.
Fig. 20-2-5
l To settle the glass
from the outside.
in place, tap it by palm
6) As for the bondingagent, use urethan-based
bonding agent having the strength as shown
below:
ISeparating StrengthAt least 6 kg/l/2 in
wideI
Shearing StrengthAt least 10 kg/cm2I
20-9

7) Fill bonding agent completely between the
glass and the weatherstrip and also between
the window panel (body) and the weather-
strip.
To confirm this condition, bonding agent
should be oozed out of position.
1. Windshield glass2. Windshield weatherstrip
3. Adhesive4. Window panel (body)
Fig. 20-2-6
CAUTlOlU:
l Bonding agent should be of the type
which conforms to the material of the
weatherstrip, having the above-mentioned
strength. Also it must not affect the
painted surface, weatherstrip or glass.
l Until when the bonding agent is so com-
pletely dried that its strength can be ob-
tained sufficiently, the relevant vehicle
should not be driven. As for the drying
time, follow the direction suggested by
the manufacturer of the relavant bonding
agent.
8) Oozed bonding agent should be wiped and
cleaned with solvent completely.
20-10

20-3. BACK DOOR (APPLICABLE TO HARD TOP VEHICLE)
1.Back door panel9.Outside handle2.Door balancer 10.Outside handle rod3.Back window glass11.Back door lock4.Window weatherstrip12.Control rod5.Door upper hinge13.Door lock key set6.Door lower hinge14.Door lock striker7.Service hole lid15.Door stop female8.Door weatherstrip16.Door stop male
DOOR LOCK AND STRICKER ADJUSTMENT
Door Outside Open Rod
When installing open rod @ onto outside open
handle 0, adjust clearances “A” to 0 - 2 mm
(0 - 0.079 in) and “B” to 2 mm (0.079 in) as
shown in Fig. 20-3-2 by turning adjusting joint
Co
NOTE:
Don’t push down push plate (4) when installing
the rod.
After installing the open rod, give the outside
handle a trial and check if its play felt then is
appropriate.
“B”2mm
(0.079 in)
Release cancel lever
“A”
O-2mm
(0 - 0.079in)
Fig. 20-3-2
20-11
Fig. 20-3-1

Door Lock Stricker
After reinstalling the door lock striker or door
lock which was once removed, adjust dimension
“C” in Fig. 20-3-3 to 1.0 mm (0.04 in) by mov-
ing the striker up and down.
Door lock armopen position
Fig. 20-3-3
To position the door lock striker correctly in
the front and rear direction, adjust dimension
“D” to 5.5 mm (0.22 in) as shown in Fig. 20-3-4
by increasing or decreasing spacers fitted in “E”
position behind the striker.
After adjustment, check the difference in level
between the door and body and adjust when
there is a difference by moving the door lock
striker to right or left.
CAUTION:
Do not adjust the door lock.
t---l
31.0-320mm
Door inner panel(1.22 - 1 26 in)
Striker fitting
/ surface
’ Spacer fitting
position “E”
Handling of Back Door Balancer.
WARNING:
l Handle the balancer carefully. Do not
scar or scratch the exposed surface of
its piston rod, and never allow any paint
or oil to stick to the surface.
l Do not disassemble the balancer because
its cylinder is filled with high pressure
Qas.
l Do not put it into the fire.
l Do not store it where it gets hot.
l When discarding the removed back door
balancer, envelop it, as illustrated, with
a vinyl bag. Then, use a 2 to 3 mm (0.08
to 0.12 in) drill to make a hole, as shown,
from above through the bag into the
balancer and let gas out.
It-10 mm (0.4 in)
Fig. 20-3-5
5.5 mm
(0.22 in)Fig. 20-3-4
20-12

20-13

21-1.COMBINATION METER..................................
21-2.HEAD LIGHT..........................................
21-3.TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT.......
21-4.WINDSHIELD WIPER MOTOR.............................
21-5.WATER TEMPERATURE METER AND GAUGE...............
21-6.FUEL LEVEL METER AND GAUGE........................
21-7.BRAKE WARNING LAMP ...............................
21-8.OIL PRESSURE LAMP..................................
4 WHEEL DRIVE LAMP.................................
21-10. SEAT BELT WARNING LAMP/BUZZER.....................
...................
...~I-I
.....
21-14. .............................................
21-15. WIRING HARNESS ROUTING............................
21-16. WIRING DIAGRAM....................................
SECTION 21
BODY ELECTRICAL EQUIPMENT
CONTENTS
21-9.
21-11. MAIN SWITCH KEY WARNING BUZZER
21-12. ILUMINATION CONTROLLER..............................................
21-13. REAR DEFOGGER ( hard-top )......................................
FUSE BOX
21-2
21-4
21-7
21-9
21-11
21-12
21-13
21-14
21-15
21-15
21-16
21-16
21-16
21-18
21-19
21-22
21-1