2000 SUZUKI GRAND VITARA Led

YH4
GRAND
VITARA
1. Immobilizer Control Module
8G-4 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
IMMOBILIZER CONTROL MODULE
Immobilizer Control Module is installed to the underside of the
instrument panel at the driver's seat side.
As main functions, Immobilizer Control Module checks matching
not only between the Transponder Code transmitted from the igni-
tion key and that registered in Immobilizer Control Module (Up to
4 different Transponder codes can be registered.) but also between
the ECM/Immobilizer Control Module code transmitted from
ECM / PCM and that registered in Immobilizer Control Module. In
addition, it has an on-board diagnostic system (self-diagnosis func-
tion) which is described in ªOn-Board Diagnostic System (Self-
Diagnosis Function)º in this section.
ECM / PCM
As main functions, ECM / PCM not only checks matching of ECM/
Immobilizer Control Module code but also has an on-board diag-
nostic system (self-diagnosis function) as described in ªOn-Board
Diagnostic System (Self-Diagnosis Function)º in this section.
For installation position of ECM / PCM, refer to Section 6E1 or 6E2.
ON-BOARD DIAGNOSTIC SYSTEM
(SELF-DIAGNOSIS FUNCTION)
Immobilizer Control Module and ECM / PCM diagnose troubles
which may occur in the area including the following parts when the
ignition switch is ON.
ECM /
ECM/Immobilizer Immobilizer
Transponder code
PCM: Control Module Control
Coil antenna
code Module:
ECM/Immobilizer

Serial data link
Control Module code
circuit
Serial data link circuit

ECM / PCM
Immobilizer Control

Module

Ignition signal

YH4
GRAND
VITARA
1. Windshield glass
2. Fastener No. 1
3. Windshield molding4. Stopper
5. Fastener No. 2
9-6 BODY SERVICE
WINDSHIELD
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 the follow the proper procedure.
CAUTION:

Described in this section 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 instruc-
tions 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 corro-
sion may start from there.
Use an adhesive of above mentioned type which has following property.
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)

YH4
GRAND
VITARA
BODY SERVICE 9-19
1. Back door panel assy
2. Back door window glass
3. Back door hinge
4. Back door / Rear gate balancer unit
1. Back door hinge
2. Back door
3. Body
BACK DOOR / REAR GATE ASSEMBLY
REMOVAL
1) Remove back door trim, and door / rear gate sealing cover, refer
to steps 1) to 4) of BACK DOOR LOCK ASSEMBLY in this sec-
tion.
2) Remove wire harness connector inside the back door / rear gate.
3) Remove back door / rear gate balancer (first at its door-side and
next at its body-side), as shown.
WARNING:
Handling of Back Door / Rear Gate Balancer (Damper)

Do not disassemble balancer because its cylinder is
filled with gas.

The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill.
Therefore, be sure to wear goggle.

When discarding removed back door / rear gate balanc-
er (damper), use a 2 to 3 mm (0.08 to 0.12 in.) drill to
make a hole as shown.

Handle balancer carefully. Do not scar or scratch ex-
posed surface of its piston rod, and never allow any
paint or oil to stick to its surface.

Do not turn piston rod with balancer fully extended.
5) Remove back door / rear gate hinge bolts and back door / rear
gate.

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
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
When the welding or heating operation causes the
original galvanization or other anticorrosive materials
to be burnt, the interior and under-body panel sur-
faces must be cleaned.
Removal of residues of the burning should be carried
out carefully when the relevant place has boxtype
construction or has shape which limits the access to
the interior surfaces. In general, the following method
can be used satisfactorily for the removal of those res-
idues.Scrape the accessible places. If a standard putty knife
or scraper does not fit to the elevant place, consider
to use a more flexible scraper to a place narrowly en-
closed by sheet metals.
A jet of compressed air can remove most residues,
and is effective to limited areas.
However, this type of operation absolutely requires
eye protection.
BODY SERVICE 9-37
The metal service replacement parts (or assemblies)
are coated with electro-deposition primer.
For the proper adhesion of a paint, the following finish
process (refinish steps) becomes necessary.
1) Use wax or grease-removing solvent to clean the
part.
2) Use a wet or dry sand-paper (No. 400) to polish the
panel lightly. Do not polish it forcibly to produce any
scratch. Clean the part again.
3) If factory-applied primer coating is cut through to
the bare metal, apply metal conditioner to the bare
metal exposed to open air. As for method of use of
the metal conditioner, follow directions on the con-
tainer.
4) Apply primer-surfacer to the part completely dry
before starting sand-paper polishing. As for drying
time, follow directions advised on the primer-sur-
facer container.
5) Use a wet or dry sand-paper (No. 400) and water
to polish the panel lightly.
6) Wash the part again.
7) Apply color, coating to the part.
8) Different paints demand different drying methods.
Hence, follow directions advised on the pertinent
paint container.9) When lacquer coating (quick-drying paint coat-
ing) is applied, dry coated surface and polish it
with compound.
In the case of the melamine or acrylic coating,
compound polishing can be omitted after drying.
10) If the case of lacquer coating, wax should not be
applied to coated surface until the surface has
dried completely (for approx. two months).
Before replacing exterior parts or assemblies, check
paint conditions of all the covered or hidden interior
surfaces. If any rust scale is found at these places,
proceed as follows:
1) Use a proper wire brush, adhesive or liquid rust re-
moving agent to remove rust. As for the method of
use, follow directions advised for respecitve mate-
rials.
2) If necessary, wash parts with detergent, rinse, and
dry them.
3) Before installing exterior body parts, apply anticor-
rosive compound to all cleaner surfaces of exterior
body parts. Also, apply anticorrosive compound to
inner surfaces of exterior body parts to be
installed.
METAL REPLACEMENT PARTS FINISHING

YH4
GRAND
VITARA
1. Shim
1. Rubber cushion 1
9-62 BODY SERVICE
BACK DOOR / REAR GATE LOCK ASSEMBLY
REMOVAL
1) Remove inside handle bezel (if equipped).
2) Remove inside lock knob.
3) Remove door trim.
With inside handle bezel tilted as shown in figure, turn door trim
90 counterclockwise to remove it (if equipped with inside han-
dle).
4) Remove back door / rear gate sealing cover.
5) Remove back door / rear gate lock control rod.
Unlock back door / rear gate lock rod pin retainer and disconnect
control rod.
6) Disconnect back door lock motor lead wire (if equipped).
7) Remove lock assembly.
INSTALLATION
Reverse removal procedure to install back door / rear gate lock as-
sembly noting following points.

Back door / Rear gate latch striker.
Adjust back door / rear gate latch striker so that its center aligns
with the center of groove in back door / rear gate latch base.
To adjust back door / rear gate latch and striker with each other,
insert proper number of shims below the bottom of striker, as
shown.

Back door / Rear gate rubber cushion.
Move rubber cushion installed at the left side of back door / rear
gate to align it with its guide.