1998-2003 Suzuki Alto 4 Door Body Service User Manual
MyCarUserManual.com
USER MANUALS FOR EVERY MAKE & MODEL

Body Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

9
BODY SERVICE 9-1
SECTION 9
BODY SERVICE
CONTENTS
FRONT AND REAR DOOR 9- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Glass and Window Regulator 9- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Glass and Window Regulator 9- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Lock 9- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door 9-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR QUARTER WINDOW 9-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BACK DOOR 9-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Door Balancer 9-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Latch Striker 9-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT 9-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seat 9-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Seat 9-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY DIMENSION 9-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE MOLDING 9-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AND REAR DOOR
FRONT DOOR GLASS AND WINDOW REGULATOR
1. Door panel
2. Door glass
3. Door outer weatherstrip
4. Door inner weatherstrip
5 Door sealing cover
6. Door trim
7. Inside handle bezel
8. Door armrest
9. Winder regulator handle
10. Door inside handle
11. Window regulator
Apply SUZUKI SUPER GREASE A
(99000-25010) to moving section.
12. Door upper hinge
13. Door lower hinge
14. Window regulator handle snap
15. Glass bottom channel
REMOVAL
1) Remove inside handle bezel.
2) Remove door armrest.
3) Remove window regulator handle (1).
D Pull off the snap with a cloth (2) in position to remove the regu-
lator handle (1).
4) Remove door trim.
5) Remove door sealing cover.
6) Remove door outer weatherstrip.
D Fully lower the window. Then, use a tapewrapped putty knife
(1) (or like a screwdriver) to pry off the weatherstrip (2).
9-2 BODY SERVICE
7) Remove glass bottom channel attaching screws (1).
8) Take out the door glass together with the bottom channel.
9) Detach the glass from the bottom channel.
10) Loosen door window regulator attaching screws (six places)
and take out the regulator through the hole “A”.
INSPECTION
D Check the window regulator gear for wear or damage.
D Check the window regulator spring for weakened condition.
INSTALLATION
Reverse the removal sequence to install the door window regulator
and door glass. However, be careful of the following points.
1) Apply SUZUKI SUPER GREASE A (99000-25010) to the slid-
ing parts.
BODY SERVICE 9-3
2) When installing the glass to the bottom channel (1), coat the
channel with soapy water to tap it with a plastic hammer.
Glass-fitted position of the bottom channel is as shown.
For 3-door model
For 5-door model
3) When you feel hard to raise and lower the door glass, it is pos-
sible that the glass is tilted toward the door sash. If this is the
case, adjust the equalizer of the window regulator so that the
measurements A and B are equal to each other.
1. Equalizer screws
4) Securely seal the door sealing cover (1) with adhesive (2).
9-4 BODY SERVICE
5) After installing the door outer weather strip, securely fix its
rear end with adhesive.
1. Front door outer weather strip rear end
6) Install the door window regulator handle (1) so that it has a 45_
angle when the glass is fully closed, as illustrated below.
BODY SERVICE 9-5
REAR DOOR GLASS AND WINDOW
REGULATOR
REMOVAL
1) Remove inside handle bezel.
2) Remove door armrest.
1. Door panel
2. Door glass
3. Door outer weatherstrip
4. Door inner weatherstrip
5. Door sealing cover
6. Door trim
7. Inside handle bezel
8. Door armrest
9. Window regulator han-
dle
10. Door inside handle
11. Window regulator
Apply SUZUKI SUPER
GREASE A (99000-
25010) to moving sec-
tion.
12. Door upper hinge
13. Door lower hinge
14. Window regulator
handle snap
15. Glass bottom channel
16. Door center sash
17. Partition glass
3) Remove window regulator handle (1).
D Pull off the snap with a cloth (2) in position to remove the regu-
lator handle (1).
4) Remove door trim.
5) Remove door sealing cover.
6) Remove door outer weatherstrip.
D Fully lower the window. Then, use a tapewrapped putty knife
(1) (or like a screwdriver) to pry off the weatherstrip (2).
9-6 BODY SERVICE
7) Remove door center sash (4) (by removing two screws (1) with
the door glass lowered all the way down).
8) Remove partition glass (3).
2. Door glass
9) Putting the regulator arm roller (2) out of the bottom channel
(3), take out the door glass (1) together with the bottom chan-
nel.
1. Door glass
10) Detach the glass from the bottom channel.
11) Loosen door window regulator attaching screws (1) (four
places) and take out the regulator through the hole “A”.
INSPECTION
D Check the gear for wear or damage.
INSTALLATION
Reverse. the removal sequence to install the window regulator
and door glass. However, be careful of the following points.
1) Apply SUZUKI SUPER GREASE A (99000-25010) to the win-
dow regulator sliding parts.
BODY SERVICE 9-7
2) When installing the glass (2) to the bottom channel (1), coat
the channel with soapy water to tap it with a plastic hammer.
Glass-fitted position of the bottom channel is as shown below.
3) To install the glass, lower the regulator arm so that the regulator
arm roller (1) can go into the bottom channel (2).
4) After installing rear door outer weather strip and partition weath-
er strip, securely fix their ends specified below with adhesive.
1. Rear door outer weatherstrip front end
2. Rear door outer weatherstrip rear end
3. Partition weatherstrip rear end
5) Securely seal the door sealing cover (1) with adhesive (2).
6) Install the door window regulator handle (1) so that it has a 45_
angle when the glass is fully closed, as illustrated below.
9-8 BODY SERVICE
DOOR LOCK
1. Outside handle
2. Door lock key cylinder
3. Door inside handle
4. Door latch ass’y
5. Door latch striker
6. Door rear sash
1. Outside handle
2. Inside handle bezel
3. Door inside handle
4. Door latch ass’y
5. Door latch striker
Rear door lock
Front door lock
BODY SERVICE 9-9
REMOVAL
1) Remove inside handle bezel.
2) Remove door armrest.
3) Remove window regulator handle.
Pull off the snap with a cloth to remove the regulator handle.
4) Remove door trim.
5) Remove door sealing cover.
6) Remove front door rear sash. (Applicable to front door only)
7) Remove door inside handle and door latch ass’y.
After disconnecting each joint of control link, remove the door
inside handle and door latch ass’y.
1. Plain screw driver
INSTALLATION
Be careful of the following items to reverse the removal sequence
to install the front door lock.
1) Door outside opening rod
When installing the opening rod (1) to the outside handle (2),
turn the joint (3) to adjust the distance “A” to 0 to 2 mm as illus-
trated.
NOTE:
Do not push down the opening link 6 when adjusting and
installing the opening rod.
4. Adjusting joint snap
5. Front door latch ass’y
6. Opening link
A: 0 – 2 mm
9-10 BODY SERVICE
2) Door lock inside handle
When fitting the door inside handle in position, move the inside
handle (control link (2)) toward the arrows-pointed directions
to adjust to 0 to 2 mm (0 to 0.08 in.) the clearance “B” between
the inside opening lever (1) and the outside opening lever (or
door lock opening lever pin) (3).
Front Door Lock
4. Front door latch striker
B: 0 – 2 mm
Rear Door Lock
4. Door latch ass’y
B: 0 – 2 mm
3) Door lock rod pin
Use the door lock rod pin (1) to securely fix the door lock rod as
illustrated.
4) Door latch striker
Move the door latch striker (2) up and down so that its shaft (3)
approximately aligns with the center of the groove “C” of the
door latch (1).
NOTE:
The striker should be placed level and moved vertically. Do
not adjust the door latch.
1. Door latch
BODY SERVICE 9-11
Move the door latch striker (3) sideways to adjust to 0 mm the
door surface-to-body surface difference with the door closed.
1. Body
2. Door
4. Front side
In order to correctly obtain the door latch striker (1) position in
the fore-and-aft direction, increase or decrease the number of
spacers inserted between the body and the striker to adjust it.
The dimension “D” should be adjusted to 12.6 to 14.6 mm
NOTE:
Apply oil or grease to the striker joints periodically.
2. Shim
3. Door
4. Front side
5. Body
D: 12.6 – 14.6mm
DOOR
1. Upper hinge
2. Lower hinge
3. Door
4. Body
“A” : Oil point
REMOVAL
1) Remove the stopper pin upward by tapping with hammer.
9-12 BODY SERVICE
2) Support the door panel using a jack with a piece of wood placed
(2) between the jack and the panel.
3) Remove the door assembly by loosening the hinge mounting
bolts.
1. Rags
INSTALLATION
Reverse the removal sequence to install the front door.
D When the weatherstrip is hardened, water leak may develop. In
this case, replace it if possible.
D After installing, adjust the door latch striker position by referring
to previous page so that the door is positioned correctly.
BODY SERVICE 9-13
REAR QUARTER WINDOW
NOTE:
D If the weatherstrip is hardened, water leak may develop. In
this case, renew the weatherstrip if possible.
1. Glass
2. Weatherstrip
For 5-door model
NOTE:
D After installing the glass, securely fix the weather strip up-
per front end (A) with adhesive.
9-14 BODY SERVICE
BACK DOOR
1. Back door window glass
2. Back door window weatherstrip
3. Back door panel
4. Back door opening weatherstrip
5. Back door trim
6. Back door sealing cover
7. Back door balancer
8. Back door lock cylinder
9. Back door latch ass’y
10. Back door latch striker
11. Back door latch striker spacer
12. Back door hinge
BACK DOOR BALANCER
WARNING:
Handling of Back Door Balancer (Damper)
D Do not disassemble balancer because its cylinder is
filled with gas.
D 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.
D Do not turn piston rod with balancer fully extended.
D When discarding removed back door balancer (damp-
er), use a 2 to 3 mm (0.08 to 0.12 in.) drill to make a hole
as shown.
D 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.
DOOR LATCH STRIKER
When adjusting the door latch striker (2), adjust the door latch strik-
er (2) so that striker shaft approximately aligns with the center of
the groove of the door latch (1).
3. Shim
BODY SERVICE 9-15
To adjust the door latch and the striker with each other in the door
up-and-down direction, insert a proper number of shims below the
bottom of the striker as illustrated.
1. Shim
9-16 BODY SERVICE
SEAT
FRONT SEAT
1. Headrestraint assembly
2. Front seat back
3. Front seat cushion
4. Front seat inside adjuster
5. Front seat outside adjuster
6. Front seat reclining assembly
7. Reclining cover
8. Reclining knob
9. Front seat frame
10. Front seat assembly bolt
11. Front seat adjuster bolt
12. Front seat back fixing screw
13. Front seat reclining bolt
: Tightening Torque
REMOVAL AND INSTALLATION
Refer to above figure when removing and installing or disassembling and assembling front seat.
Make sure to tighten each bolt as specified in above figure.
(Right and left sides are symmetrical.)
BODY SERVICE 9-17
REAR SEAT
[A]: Bench type
[B]: Separate type
1. Rear seat back
2. Rear seat cushion
3. Right rear seat back
4. Left rear seat back
5. Knob
6. Rear seat back lock assembly
7. Rear seat back lock striker
8. Rear seat back striker cover
9. Rear seat back hinge
10. Rear seat center hinge
[A]
[B]
REMOVAL AND INSTALLATION
Refer to above figure when removing and installing or disassembling and assembling rear seat.
9-18 BODY SERVICE
BODY DIMENSION
NO.
MEASUREMENT
POSITION
LENGTH, MM (in.) NO.
MEASUREMENT
POSITION
LENGTH, MM (in.) NO.
MEASUREMENT
POSITION
LENGTH, MM (in.)
1
2
3
4
5
6
7
M – m
M – Q
O – m
M – O
O – o
P – p
R – m
804 (31.65)
910 (35.83)
1123 (44.21)
552 (21.73)
1189 (46.81)
1050 (41.34)
790 (31.10)
8
9
10
11
12
13
14
15
16
17
S – s
T – t
U – u
V – v
S – T
S – U
S – V
T – U
T – V
U – V
930 (36.61)
1176 (46.30)
1176 (46.30)
1172 (46.14)
987 (38.86)
725 (28.54)
891 (35.08)
818 (32.20)
487 (19.17)
387 (15.24)
T(t) DETAIL V(v) DETAIL o(O) DETAIL
m(M) DETAIL
BODY SERVICE 9-19
NO.
MEASUREMENT
POSITION
LENGTH, MM (in.) NO.
MEASUREMENT
POSITION
LENGTH, MM (in.) NO.
MEASUREMENT
POSITION
LENGTH, MM (in.)
18
19
20
21
22
23
24
25
26
27
28
A – a
A – b
A – C
A – B
B – b
C – c
C – b
C – d
C – E
D – E
D – d
840 (33.07)
1148 (45.20)
472 (18.58)
608 (23.94)
1162 (45.75)
780 (30.71)
970 (38.19)
853 (33.58)
790 (31.10)
544 (21.42)
524 (20.63)
29
30
31
32
33
34
35
36
37
38
39
40
41
D – F
E – F
G – H
I – i
I – J
I – K
I – L
J – j
J – L
J – K
K – k
K – L
L – l
666 (26.22)
759 (29.88)
1195 (47.05)
1176 (46.30)
718 (28.27)
1260 (49.61)
643 (25.31)
1174 (46.22)
852 (33.54)
875 (34.45)
935 (36.81)
826 (32.52)
1179 (46.42)
G DETAIL
H DETAIL I DETAIL
9-20 BODY SERVICE
SIDE MOLDING
INSTALLATION
1) Bonding surfaces should be cleaned throughly.
2) Follow the above-illustrated bonding positions to install the side moldings.
3) If adequate adhesive force is unobtainable, use urethane adhesive.
1. Front fender molding
2. Front door molding
3. Quarter outer molding
4. Rear door molding
Unit : mm
Unit : mm
BODY SERVICE 9-21

Related Topics

Front and Rear Door Rear Quarter Window Back Door Seat Body Dimension Side Molding

Popular Owner Manuals

Audi
Audi
BMW
BMW
Citroen
Citroen
Ford
Ford
Honda
Honda
Peugeot
Peugeot