2002 SUZUKI GRAND VITARA ten

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
1. Screws
1. Bolts
1. Door sealing cover
2. Adhesive1, (a)
9-4 BODY SERVICE
INSTALLATION
Reverse removal procedure to install door glass noting following
points:

Tighten glass attaching screws to specified torque. Tighten front
screw first, then rear screw.
Tightening Torque
(a): 2.5 N
.m (0.25 kg-m, 1.8 lb-ft)

When window becomes hard to raise and lower, adjust screws to
correct tilted glass as shown in figure.

Adjust equalizer of window regulator so that measurement A and
B are equal.

Secure door sealing cover with adhesive.

YH4
GRAND
VITARA
1. Window regulator lubrication point 1. Regulator mounting bolts
2. Regulator motor mounting nuts
3. Hole
BODY SERVICE 9-5
FRONT DOOR WINDOW REGULATOR
REMOVAL
1) Remove door glass, referring to steps 1) to 9) of FRONT DOOR
GLASS REMOVAL in this section.
2) Disconnect power window motor lead wire at coupler and loosen
clamp.
3) Loosen regulator mounting bolts, nuts and take out regulator
through hole as shown in left figure.
INSPECTION
1) Check regulator sliding and rotating parts for greasing.
2) Check rollers for wear and damage.
3) Check wire for damage.
INSTALLATION
Reverse removal procedure to install window regulator noting the
following point.

Tighten bolts and nuts according to the order (a, b, c / 1, 2, 3, 4)
shown in left figure.

When installing glass, check that the top part of the glass contacts
the glass run evenly and that the glass moves up and down
smoothly.
If the glass is tilted with respect to the glass run, make a fine ad-
justment with the screws.

Install door window regulator handle (if equipped) so that it has
an angle as shown in figure when glass is fully closed.

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
1. Fastener
ªaº: Approx. 5mm (0.197 in.)
1. Mark mating marks
2. Glass
3. Body
4. Molding
1. Do not apply primer
2. Primer
3. Apply primer
4. Old adhesive
1. Molding
2. Glass
BODY SERVICE 9-9
INSTALLATION
1) Using cleaning solvent, clean windshield edge where wind-
shield glass is to be adhered. (Let it dry for more than 10 min-
utes.)
2) Install new glass stoppers (2pcs.) to lower side of windshield and
new fastener to body.
When reusing wind shield, install new fastener to wind shield.
3) To determine installing position of glass to body, position glass
against body so that clearance between upper end of glass and
body is about 5 mm (0.197 in.) and clearances between each
side end (right & left) of glass and body are even. Place glass so
that lug of fastener is matched with cut in body and fit fastener.
Then mark mating marks on glass and body as shown.
Upper clearance can be adjusted by moving stoppers position.
4) Clean contact surfaces of old adhesive, paint or bare metal thor-
oughly.
If surfaces of paint or bare metal come out, apply primer for body
with caution not to apply primer 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 more than 10 minutes.
Cleaning Area
Distance from the edge of glass or molding
ªaº: 30 ± 50 mm (1.18 ± 1.97 in.)

YH4
GRAND
VITARA
1. Molding
2. Fastener
1. Molding
2. Adhesive
3. Glass
ªAº: Primer for molding
1. Rubber sucker grip
9-10 BODY SERVICE
7) Using new brush, apply sufficient amount of primer for glass
along glass surface to be adhered to body.
NOTE:

Be sure to refer to maker's instruction for proper han-
dling and drying time.

Do not apply primer on outside of ceramic coated sur-
face.

Do not touch primer coated surface.
Width ªbº: 18 ± 19 mm (0.71 ± 0.75 in.)
ªcº: 16 ± 17 mm (0.63 ± 0.67 in.)
ªdº: 24 mm (0.94 in.)
ªeº: 27 mm (1.06 in.)
8) Apply primer for molding along molding surface all around as
shown in figure.
9) Apply adhesive referring to figure at the left.
NOTE:

Start from bottom side of glass.

Be careful not to damage primer.

Height of adhesive applied to lower side should be high-
er than that of other three sides.
Upper, right and left sides
Width ªeº : Approx. 11 mm (0.43 in.)
Height ªfº : Approx. 17 mm (0.67 in.)
ªgº : Approx. 25 mm (0.98 in.)
Distance ªhº : Approx. 16 mm (0.63 in.)

Press glass against body quickly after adhesive is ap-
plied.

Use of rubber sucker grip is helpful to hold and carry
glass after adhesive is applied.

Perform steps 9) to 10) within 10 min. to ensure sufficient
adhesion.

Be sure to refer to adhesive maker's instruction for prop-
er handling and drying time.
10) Holding rubber sucker grips, place glass onto body by aligning
mating marks marked in step 3) and press it.

YH4
GRAND
VITARA
9-14 BODY SERVICE
1. Door window
regulator attaching
nuts
2. Hole
1. Window regulator lubrication points
1. Door sealing
cover
2. Adhesive
REAR DOOR WINDOW REGULATOR
REMOVAL
1) Remove door glass, refer to steps 1) to 10) of REAR DOOR
GLASS REMOVAL in this section.
2) Disconnect power window motor lead wire at coupler and clamp.
3) Remove door window regulator attaching nuts (6 pcs.), and take
out regulator through hole as shown in left figure.
INSPECTION
1) Check regulator sliding and rotating parts for greasing.
2) Check rollers for wear and damage.
3) Check wire for damage.
INSTALLATION
Reverse removal sequence to install door window regulator noting
following points.

Tighten regulator base nuts according to the order (a, b, c) shown
in figure.

Adjust door window regulator according to following procedure.
a. Loosen three nuts, two screws and two bolts.
b. Raise window fully.
c. Tighten three regulator rail nuts according to the order (d, e,
f) shown in figure and two center sash bolts A.
d. Lower window.
e. Tighten two screws B to specified torque. Tighten front screw
first, then rear.
Tightening Torque for glass attaching screws
2.5 N
.m (0.25 kg-m, 1.8 lb-ft)
f. Check that the glass moves up and down smoothly and that
the top part of the glass contacts the glass run evenly.

Securely seal door sealing cover with adhesive.

Install door window regulator handle (if equipped) so that it has
an angle as shown when glass is fully closed.

YH4
GRAND
VITARA
BODY SERVICE 9-15
1. Fastener
2. Glass
3. Molding
4. Adhesive
5. Primer
QUARTER WINDOW
REMOVAL AND INSTALLATION
Refer to ªWINDSHIELDº section as removal and installation proce-
dures and cautions are basically the same. However, note the fol-
lowing.
NOTE:

Before applying primer to glass edge, install molding ac-
cording to installing position shown in figure.

Observe following precautions when applying adhesive
along glass edge.
±Adhesive should be applied evenly especially in height.
±Be careful not to damage primer.
±Press glass against body quickly after adhesive is applied.
Height ªbº : 12 mm (0.47 in.)
Width ªdº : 16 mm (0.63 in.)
ªcº : 8 mm (0.31 in.)
Clearance ªeº : 1 mm (0.04 in.)