1998 SUZUKI GRAND VITARA tem

YH4
GRAND
VITARA
9
BODY SERVICE 9-1
GLASS, WINDOWS AND MIRRORS9- 2 . . . . .
Front Door Glass 9- 2. . . . . . . . . . . . . . . . . . . . .
Front Door Window Regulator 9- 5. . . . . . . . . .
Windshield 9- 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Glass 9-12. . . . . . . . . . . . . . . . . . . . .
Rear Door Window Regulator 9-14. . . . . . . . . .
Quarter Window 9-15. . . . . . . . . . . . . . . . . . . . . .
Back Door Glass 9-16. . . . . . . . . . . . . . . . . . . . .
BODY STRUCTURE9-17 . . . . . . . . . . . . . . . . . . .
Front Door Assembly 9-17. . . . . . . . . . . . . . . . .
Rear Door Assembly 9-18. . . . . . . . . . . . . . . . . .
Back Door / Rear Gate Assembly 9-19. . . . . . . .
Hood 9-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Fender 9-22. . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper 9-23. . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper 9-24. . . . . . . . . . . . . . . . . . . . . . . .
Under Body Dimensions 9-25. . . . . . . . . . . . . . .
Body Dimensions 9-26. . . . . . . . . . . . . . . . . . . . .
INSTRUMENTATION AND DRIVER
INFORMATION9-33 . . . . . . . . . . . . . . . . . . . . . . .
Instrument Panel 9-33. . . . . . . . . . . . . . . . . . . . .
SEAT9-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seat 9-34. . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat 9-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
PAINT AND COATINGS9-36 . . . . . . . . . . . . . . . .
Anti-Corrosion Treatment 9-36. . . . . . . . . . . . . .
Metal Replacement Parts Finishing 9-37. . . . .
Plastic Parts Finishing 9-58. . . . . . . . . . . . . . . . .
SECURITY AND LOCKS9-59 . . . . . . . . . . . . . . . .
Front Door Lock Assembly 9-59. . . . . . . . . . . . .
Rear Door Lock Assembly 9-61. . . . . . . . . . . . .
Back Door / Rear Gate Lock Assembly 9-62. . .
Key Coding 9-63. . . . . . . . . . . . . . . . . . . . . . . . . .
SUNROOF / CONVERTIBLE TOP9-64 . . . . . . . . .
Sliding Roof (if equipped) 9-64. . . . . . . . . . . . . .
Canvas Top And Topbow Frames 9-71. . . . . . .
EXTERIOR AND INTERIOR TRIM9-72 . . . . . . .
Floor Carpet 9-72. . . . . . . . . . . . . . . . . . . . . . . . .
Head lining 9-73. . . . . . . . . . . . . . . . . . . . . . . . . .
Roof Trim (2 Door Model) 9-75. . . . . . . . . . . . . .
Side Moldings (if equipped) 9-77. . . . . . . . . . . .
Splash Guard (if equipped) 9-78. . . . . . . . . . . .
Roof Rail (if equipped) 9-79. . . . . . . . . . . . . . . .
Roof Molding 9-79. . . . . . . . . . . . . . . . . . . . . . . .
Luggage Under Box 9-80. . . . . . . . . . . . . . . . . .
SECTION 9
BODY SERVICE
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

When body servicing, if shock may be applied to air bag system component parts, remove those parts
beforehand. (Refer to Section 10B.)
NOTE:
Fasteners are important attaching parts in that they could affect the performance of vital components and
systems, and / or could result in major repair expense. They must be replaced with one of the same part
number of with an equivalent part if replacement becomes necessary.
Do not use a replacement part of lesser quality or substitute a design. Torque values must be used as spe-
cified during reassembly to assure proper retention of these parts.
CONTENTS

YH4
GRAND
VITARA
BODY SERVICE 9-21
1. Hood lock
2. Hood lock bolts
3. Match marks
1. Hood cushion
HOOD
REMOVAL
1) Remove window washer hose from hood.
2) Remove four mounting bolts to detach hood.
ADJUSTMENT

Fore-and-aft and right-and-left adjustment.
Loosen four mounting bolts for adjustment.

Hood lock adjustment
When installing hood lock, bring bolt at intersection point of match
marks and move it in vertical direction for adjustment, if neces-
sary.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

Vertical adjustment
If only one side (right or left) of hood is not level with front fender,
make it level by tightening or loosening hood cushion.
INSTALLATION
Reverse removal procedure to install hood.
INSPECTION
Check that secondary latch operates properly (check that second-
ary latch keeps hood from opening all the way even when pulling
hood release handle inside vehicle.) Also check that hood opens
and closes smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or repair hood
lock system.

YH4
GRAND
VITARA
1. Side body
2. Fender
3. Pad
1. Side body
2. Pad
3. Knife
9-22 BODY SERVICE
1. Front fender
2. Front fender lining
3. Fender attaching bolts
4. Fender lining attaching screws
FRONT FENDER
REMOVAL
1) Remove front bumper.
2) Remove fender splush guard (H25 engine).
3) Remove front fender lining.
4) Remove front fender.
INSTALLATION
1) Remove pad from side body and (or) fender, using care not to
damage painted surface.
2) Attach new pad cutting appropriately size temporarily and adjust
height with a knife so that fender becomes flush with side body.
3) Reverse removal procedure for installation.
NOTE:
If paint on fender bolt is peeled off, be sure to apply paint
again.

YH4
GRAND
VITARA
BODY SERVICE 9-23
1. Front bumper
2. Screws
3. Front bumper member
4. Side marker
FRONT BUMPER
NOTE:

Fasteners are important attaching parts in that they could affect the performance of vital components
and systems, and / or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary.
Do not use a replacement part of lesser quality or substitute design. Torque values must be used as spe-
cified during reassembly to assure proper retention of these parts.

Before removing front bumper, remove fender lining and disconnect connector of side marker.

YH4
GRAND
VITARA
1. (a)
1. (a)
1
11
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1. Bolt
BODY SERVICE 9-33
INSTRUMENTATION AND DRIVER INFORMATION
INSTRUMENT PANEL
WARNING:
See WARNING at the beginning of this section.
REMOVAL
1) Disconnect negative cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) Remove console box.
4) Remove glove box and column hole cover.
5) Disconnect wires and cables from heater unit and blower motor
assembly.
6) Remove steering column assembly. Refer to Section 3C1.
7) Disconnect speedometer connector and remove speedometer
assembly. If equipped with air bag, disconnect wire coupler at
SDM and air bag ground terminal for air bag.
8) Remove engine hood opener.
9) Disconnect couplers which need to be disconnected for removal
for instrument panel.
10) Remove instrument panel mounting screws.
11) Remove instrument panel mounting bolt.
12) Remove instrument panel.
CAUTION:
For vehicle with Air Bag, instrument panel could not be re-
moved with SDM coupler connected and ground terminal
installed.
Use care not to damage Air Bag harness.
INSTALLATION
1) Install instrument panel by reversing removal procedure, noting
the following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to ªAIR BAG
STEERING COLUMN INSTALLATIONº in Section 3C1.
2) Adjust control cables. (Refer to Section 1A ªHEATER CON-
TROL CABLESº.)
3) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.

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
9-58 BODY SERVICE
PLASTIC PARTS FINISHING
Paintable plastic parts are ABS plastic parts.
Painting
Rigid or hard ABS plastic needs no primer coating.
General acrylic lacquers can be painted properly over hard ABS
plastic in terms of adherence.
1) Use cleaning solvent for paint finish to wash each part.
2) Apply conventional acrylic color lacquer to part surface.
3) Follow lacquer directions for required drying time. (Proper dry-
ing temperature range is 60 to 70
C).
Reference
Plastic parts employ not only ABS (Acrylonitrile Butadiene Styrene)
plastic but also polypropylene, vinyl, or the like plastic. Burning test
method to identify ABS plastic is described below.
1) Use a sharp blade to cut off a plastic sliver from the part at its
hidden backside.
2) Hold sliver with pincers and set it on fire.
3) Carefully observe condition of the burning plastic.
4) ABS plastic must raise readily distinguishable back smoke while
burning with its residue suspended in air temporarily.
5) Polypropylene must raise no readily distinguishable smoke
while burning.

YH4
GRAND
VITARA
BODY SERVICE 9-63
KEY CODING
KEY USAGE AND IDENTIFICATION
Key is used for ignition and door lock cylinder. Keys are cut on both
edges to make them reversible.
Key identification is obtained from five character key code stamped
on key code tag. Using this key code, key code cutting combination
can be determined from a code list (available to owners of key cut-
ting equipment from suppliers).
If key codes are not available from records or tags, key code can
be obtained from the right hand door lock cylinder (if lock has not
been replaced). Lock cylinders supplied by the factory as service
parts are unmarked.
If original key is available, key code cutting combination can be de-
termined by laying key.
IGNITION SWITCH LOCK CYLINDER
Removal / Installation
See Section 3C1, ªAIR BAG STEERING WHEEL AND COLUMNº.
ELECTRICAL DIAGNOSIS
For ignition switch electrical troubleshooting, see Section 8, ªBODY
ELECTRICAL SYSTEMº.