Important

WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by
these signal words.

WARNING:
Indicates a potential hazard that could result in death or injury.

CAUTION:
Indicates a potential hazard that could result in vehicle damage.

NOTE:
Indicates special information to make maintenance easier or instructions clearer.

WARNING:
This service manual is intended for authorized SUZUKI dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual. Improper repair may result in injury to the
mechanic and may render the vehicle unsafe for the driver and passengers.

WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System :
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer.
Refer to “Air Bag System Components and Wiring Location View” under “General Description” 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 “Service Precautions” under
“On-Vehicle Service” 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.
• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) module, sensing and diagnostic
module (SDM), seat belt pretensioner (if equipped) beforehand to avoid component damage or
unintended activation.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
 Foreword
This SUPPLEMENTARY SERVICE MANUAL is a supplement to APV series SERVICE MANUAL and SUPPLE-
MENTARY SERVICE MANUAL and has been prepared exclusively for the following applicable model.

Applicable model : CARRY (Truck Model)

When servicing a vehicle, refer to this supplementary service manual first. And for any section, item or descrip-
tion not found in this service manual, refer to MANUALS below.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.

Related Manual

Manual Name Manual Number

APV Service Manual 99500B61J00N01E
APV/CARRY Wiring Diagram Manual 99512B61J20N015

SERVICE 4W DEPARTMENT

© COPYRIGHT INDOMOBIL SUZUKI INTERNATIONAL 2005

 Table of Contents
SUSPENSION
Front Suspension 3D 3D
Rear Suspension 3E 3E
ENGINE
Engine Fuel 6C 6C
Exhaust System 6K 6K
BODY SERVICE 9 9
 FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION
NOTE:
• All front suspension fasteners are an important attaching part in that it could affect the perfor-
mance of vital parts 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 nec-
essary. Do not use a replacement part of lesser quality or substitute design. Torque values must be
used as specified during reassembly to assure proper retention of this part.
• Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.
3D

CONTENTS
General Description ........................................3D-2 Strut Assembly Components ........................3D-3
Front Suspension Construction .....................3D-2 Strut Assembly Removal and Installation .....3D-3
On-Vehicle Service..........................................3D-3 Tightening Torque Specification ...................3D-5
3D-2 FRONT SUSPENSION

General Description
Front Suspension Construction

1. Strut assembly 7. Stabilizer joint Do not reuse. 45 N·m (4.5 kg-m, 32.5 50 N·m (5 kg-m, 36.0 lb-
lb-ft) ft)
2. Stabilizer bar 8. Tie rod 82 N·m (8.2 kg-m, 59.5 95 N·m (9.5 kg-m, 68.5 25 N·m (2.5 kg-m, 18.0
lb-ft) lb-ft) lb-ft)
3. Steering knuckle 9. Wheel hub 45 N·m (4.5 kg-m, 32.5 50 N·m (5 kg-m, 36.0 lb- 50 - 80 N·m (5 - 8 kg-m,
lb-ft) ft) 36.0 - 58.0 lb-ft)
4. Wheel 10. Suspension frame 250 N·m (25 kg-m, 100 N·m (10 kg-m, 72.0 55 N·m (2.5 kg-m, 18.0
181.0 lb-ft) lb-ft) lb-ft)
5. Suspension control arm 11. Compression rod 85 N·m (8.5 kg-m, 61.5 53 N·m (5.3 kg-m, 38.5
lb-ft) lb-ft)
6. Vehicle body [A] : Forward 95 N·m (9.5 kg-m, 68.5 43 N·m (4.3 kg-m, 31.0
lb-ft) lb-ft)
 FRONT SUSPENSION 3D-3

On-Vehicle Service
Strut Assembly Components

1. Strut nut: 7. Bump stopper 13. E-ring

2. Strut lock washer 8. Coil spring 45 N·m (4.5 kg-m, 32.5 lb-ft)

3. Strut support 9. Shock absorber 82 N·m (8.2 kg-m, 59.5 lb-ft)

4. Strut bearing 10. Strut support nut. 95 N·m (9.5 kg-m, 68.5 lb-ft)

5. Coil spring upper seat 11. Strut bracket nut [A] Forward
6. Coil spring seat 12. Strut bracket bolt

Strut Assembly Removal and Installation

Removal
1) Disconnect negative cable at battery.
2) Hoist vehicle, allowing front suspension to hang free.
3) Remove wheel, referring to “Wheel Removal And Installa-
tion” in Section 3F.

4) Remove Caliper (1) with carrier (2).

CAUTION:
• Hang removed caliper with wire hook (3) or the like so
as to prevent brake hose (4) from bending and twisting
excessively or being pulled.
• Don’t operated brake pedal with pads removed.
3D-4 FRONT SUSPENSION

5) Remove E-ring (1) securing brake hose and take brake hose
off strut bracket as shown.
6) Remove stabilizer bar joint nut from strut.
7) Remove strut bracket bolts (2).

8) Remove glove box (for LH strut).

9) Remove strut support nuts (1).

NOTE:
Support strut so that it will not fall off.
10) Remove strut assembly.

Installation
Install strut assembly by reversing removal procedure, noting the
following instructions.
• Insert strut bracket bolts (1) from backward as shown.
• Tighten all fasteners to specified torque.
Tightening torque
Strut bracket nut (a): 95 N·m (9.5 kg-m, 68.5 lb-ft)
Strut support nut (b):45 N·m (4.5 kg-m, 32.5 lb-ft)
Strut nut (c): 82 N·m (8.2 kg-m, 59.5 lb-ft)
Joint nut (d): 50 N·m (5.0 kg-m, 36.5 lb-ft)

CAUTION:
• Don’t twist brake hose when installing it.
• Install E-ring (3) as far as it fits to bracket (2) as shown
in figure.
• Tighten wheel bolts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kg-m, 61.5 lb-ft)
• After installation, confirm front wheel alignment referring to
“Preliminary Checks Prior to Adjusting Front Wheel Align-
ment” in Section 3A.
 FRONT SUSPENSION 3D-5

Tightening Torque Specification

Tightening torque
Fastening part
N•m kg-m lb-ft
Brake caliper bolt 85 8.5 61.5
Compression rod front nut 50 5.0 36.0
Compression rod rear nut 50 - 80 5.0 - 8.0 36.0 - 58.0
Control arm stud bolt 53 5.3 38.5
Suspension arm bolt 100 10.0 72.0
Strut nut 82 8.2 59.5
Strut support nut 45 4.5 32.5
Wheel bearing lock nut 250 25.0 181.0
Strut bracket nut 95 9.5 68.5
The rod end nut 45 4.5 32.5
Suspension frame bolt 95 9.5 68.5
The rod end stud bolt 43 4.3 31.0
Stabilizer bar joint nut 50 5.0 36.0
Stabilizer bar mounting bracket bolt 25 2.5 18.0
Compression rod bracket bolt 55 5.5 40.0
Wheel nut 85 8.5 61.5
3D-6 FRONT SUSPENSION
 REAR SUSPENSION 3E-1

SECTION 3E

REAR SUSPENSION
WARNING:
When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec-
tion 0A.

NOTE:
• All suspension fasteners are an important attaching part in that it could affect the performance of
vital parts 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
3E
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of this part.
• Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage
to the part may result.

CONTENTS
General Description ........................................3E-2 Rear Axle Housing Removal and
Leaf Spring Components ..............................3E-3 Installation..................................................... 3E-8
Leaf Spring Removal and Installation ...........3E-4 Tightening Torque Specifications ............... 3E-10
3E-2 REAR SUSPENSION

General Description
The rear suspension is a leaf spring type, consisting of leaf springs, axle housing, axle shafts and bump stopper.
Both front and rear ends of the leaf spring are connected to the body through bushings.
The axle housing is installed on the right and left leaf springs by means of spring seats and U bolts.
The two shock absorbers (right & left) are installed with their lower ends attached to the spring seats and the
upper ends to the vehicle body, all through rubber bushings.

1. Rear shock absorber 10. Rear bump stopper 80 N·m (8.0 kg-m, 58.0 lb-ft)

2. Leaf spring 11. Leaf spring seat 50 N·m (5.0 kg-m, 36.5 lb-ft)

3. Leaf spring front bushing 12. Reinforcement plate 45 N·m (4.5 kg-m, 32.5 lb-ft)

4. Shackle pin 13. Brake drum 25 N·m (2.5 kg-m, 18.0 lb-ft)

5. Shackle plate 14. Rear axle shaft 85 N·m (8.5 kg-m, 61.5 lb-ft)

6. Shackle pin No.1 bushing 15. Rear wheel bearing 115 N·m (11.5 kg-m, 83.0 lb-ft)

7. Shackle pin No.2 bushing 16. Rear axle shaft oil seal Do not reuse.
: Apply Lithium grease 99000-25010 to oil seal lip.

8. U-bolt 17. Rear axle housing

: Apply water tight sealant 99000-31090 to joint of brake
back plate and rear axle housing.
9. Leaf spring center bolt 18. Brake back plate
 REAR SUSPENSION 3E-3

Leaf Spring Components

For left-side leaf spring

F Vehicle front side 5. Shackle plate 10. Leaf spring front nut 50 N·m (5.0 kg-m, 36.5 lb-ft)

1. U-bolt 6. Shackle nut 11. Leaf spring seat 80 N·m (8.0 kg-m, 58.0 lb-ft)

2. Rear bump stopper 7. Shackle pin No.1 bushing 12. U-bolt nut 115 N·m (11.5 kg-m, 83.0 lb-ft)

3. Leaf spring 8. Shackle pin No.2 bushing 13. Axle housing

4. Shackle pin 9. Leaf spring front bolt 14. Reinforcement plate
3E-4 REAR SUSPENSION

Leaf Spring Removal and Installation

Removal

1) Hoist vehicle. ln this operation, garage jack or hoist (1) must

not be positioned against rear suspension related parts.
When garage jack is used, place safety stands under chas-
sis to support raised body.

NOTE:
2
Don’t let rear axle housing hang on brake hose, or pipe. If
it occurs, hose or pipe may be damaged. To prevent it,
always hold rear axle housing (2) of raised vehicle with
safety stand (1).
1

2) Remove rear wheel.

3) Remove parking brake cable clamp (1).

3 4) Loosen U-bolt nuts (1), and then remove u-bolts (2), rein-
forcement plates (5) and rear bump stopper (3).
4. Rear axle housing

1
 REAR SUSPENSION 3E-5

5) Loosen shackle nuts (1), and then remove shackle pin (2)
and shackle plate (3).

2
3

6) Remove leaf spring front bolt (1) and nut (2), and then
remove leaf spring (3).

1
3

Installation

NOTE:
Right and left leaf spring assemblies are not the same.
As a guide for their proper installation.

• Refer to NOTE on page 3E-1 of this section.

• Install the leaf spring by reversing removal procedure, noting
the following.

1) Press-fit shackle pin No.1 bushing (1) to vehicle, and

1
shackle pin No.2 bushing (2) to leaf spring (3).
Some water or soapy water applied to bushes will make
1 work easier.

NOTE:
2
Never apply any kind of oil to bushes.

3
3E-6 REAR SUSPENSION

2) Insert leaf spring front bolt (1) from out side of the vehicle
toward inside.
2
3. Vehicle inside

1
3

3) Install shackle pins (1) from center of the vehicle toward out-
side.
4) Install shackle plate (2).
3, (a)
NOTE:
Install shackle pin and shackle plate so that their narrow
side comes to the upper side as shown.
1
2
4
5) Tighten shackle pin nuts (3) and spring front nut (2) to speci-
2, (b) fied torque in unladen state.
2 Tightening torque
Shackle nut (a): 50 N·m (5.0 kg-m, 36.5 lb-ft)
Leaf spring front nut (b): 80 N·m (8.0 kg-m, 58.0 lb-ft)
4
4. Vehicle outside

6) Securely fit leaf spring center bolt and nut (1) in the hole (2)
4
of leaf spring seat (3) and axle housing (4).

2
1

7) Install rear bump stopper (1) on rear axle housing observing

following instructions.
• Position rear bump stopper so that its hole (2) is directed
toward vehicle front.
• Make clearances at front “b” and rear “a” of bump stopper
equal.
 REAR SUSPENSION 3E-7

8) Install U-bolts (2) and reinforcement plates (5), then tighten

U-bolt nuts (1) to specified torque.

NOTE:
Tighten 4 U-bolt nuts uniformly so that measurement “a”
is the same among the 4.
Tightening torque
U-bolt nut (a): 115 N·m (11.5 kg-m, 83.0 lb-ft)
3. Bump stopper
4. Rear axle housing

9) Connect parking brake cable clamp (1).

Tightening torque
Parking brake cable bolt (a): 9.0 N·m (0.9 kg-m, 6.5 lb-ft)
1

(a)

10) Install wheel (1) and tighten wheel nuts (2) to specified
torque.
Tightening torque
Wheel nut (a): 85 N·m (8.5 kg-m, 61.5 lb-ft)

11) Lower hoist.

3E-8 REAR SUSPENSION

Rear Axle Housing Removal and Installation

Removal

1) Hoist vehicle (place hoist under chassis) and remove rear

wheels.
2) Remove rear axle shafts (right & left) referring to Steps 2) –
9) of “Rear Axle Shaft and Wheel Bearing Removal and
Installation” in this section.
3) Remove rear axle shaft oil seal referring to “Rear Axle Shaft
Oil Seal Removal and Installation” in this section.
4) Disconnect brake pipes (3) from flexible hoses (2) and
remove E-rings (1).
5) Remove brake pipe clamps and pipes from axle housing.
3
2

6) Before removing propeller shaft, give match marks (1) on

joint flange and propeller shaft (2) as shown.
7) Remove propeller shaft.

8) For jobs hereafter, support rear axle housing by using floor

jack (1) under axle housing (2).

9) Remove rear differential from rear axle housing referring to

“Rear Differential Disassembly and Reassembly” in Section
7F.
 REAR SUSPENSION 3E-9

10) Remove U-bolts (2), reinforcement plates (5) and bump

stopper (3).
11) Remove rear axle housing (4).
1. U-bolt nut

Installation
Install removed parts in reverse order of removal, noting the fol-
lowing.
1) Securely fit leaf spring center bolts (1) and nuts in the hole of
rear axle housing (2) and spring seats.

2) Install bump stopper (3), reinforcement plates (5) and U-

bolts (2). For details referring to “Leaf Spring Removal and
Installation” in this section.
3) Tighten U-bolt nuts (1) to specified torque.
Tightening torque
U-bolt nut (a): 115 N·m (11.5 kg-m, 83.0 lb-ft)
4. Rear Axle Housing

4) Install rear differential to rear axle housing referring to “Rear

Differential Dismounting and Remounting” in Section 7F.
5) Refill rear axle housing (differential) with new gear oil refer-
ring to “Rear Differential Gear Oil Change” in Section 7F.
6) Install propeller shaft (1) to joint flange aligning match marks
(2) and tighten shaft nuts to specified torque.
Tightening torque
Propeller shaft nut (a): 50 N·m (5.0 kg-m, 36.5 lb-ft)
3E-10 REAR SUSPENSION

7) Connect brake flexible hoses (1) to bracket on axle housing

and secure it with E-ring (2).
8) Connect brake pipe (3) to brake flexible hose and tighten
3 brake pipe flare nut (4) to specified torque.
1
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kg-m, 11.5 lb-ft)
2

4, (a)

9) Install rear axle shaft oil seal referring to “Rear Axle Shaft Oil
Seal Removal and Installation” in this section.
10) Install rear axle shafts, brake shoes, brake drums and
wheels referring to steps 5) to 13) of “Rear Axle Shaft and
Wheel Bearing Removal and Installation” in this section.
11) Depress brake pedal with about 300 N (30 kg, 66 lbs) load
three to five times so as to obtain proper drum-to-shoe clear-
ance.
12) Upon completion of all jobs, pull parking brake lever with
about 200 N (20 kg, 44 lbs) load five to seven times so as to
obtain proper drum-to-shoe clearance.
Adjust parking brake cable (for adjustment, refer to “Parking
Brake Inspection and Adjustment” in Section 5).
13) Lower hoist.
14) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
15) Perform brake test (foot brake and parking brake).
(For brake test, refer to “Road Testing Brakes” in Section 5.)
16) Check each installed part for oil leakage.

Tightening Torque Specifications

Tightening torque
Fastening part
N•m kg-m lb-ft
Rear shock absorber nut 45 4.5 32.5
Leaf spring front nut 80 8.0 58.0
Shackle nut 50 5.0 36.5
U-bolt nut 115 11.5 83.0
Parking brake cable bolt 9.0 0.9 6.5
Brake back plate nut 25 2.5 18.0
Brake pipe flare nut 16 1.6 11.5
Parking cable cap nut 9.0 0.9 6.5
Propeller shaft nut 50 5.0 36.5
Wheel nut 85 8.5 61.5
 ENGINE FUEL 6C-1

SECTION 6C

ENGINE FUEL 6C

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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).

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the service manual
mentioned in the FOREWORD of this manual.

CONTENTS
General Description ....................................... 6C-1 Fuel System Components............................ 6C-2
On-Vehicle Service......................................... 6C-2

General Description
The main components of the fuel system are fuel tank, fuel pump assembly (with fuel filter, fuel level gauge, fuel
pressure regulator and tank pressure control valve), fuel feed line.
For the details of fuel flow, refer to “General Description” in Section 6E.
6C-2 ENGINE FUEL

On-Vehicle Service
Fuel System Components

1. Fuel tank 9. Fuel tank inlet valve 17. Neck hose (if equipped)
2. Fuel pump assembly 10. Fuel filler neck protector 18. Fuel vapor hose-1 (if equipped)
3. Breather hose 11. Tank cover 19. Fuel vapor hose-2 (if equipped)
4. Fuel tank filler hose 12. Fuel pump gasket Do not reuse.

5. Fuel filler cap 13. Fuel tank bolt 23 N·m (2.3 kg-m, 17.0 lb-ft)

6. Fuel feed pipe 14. Fuel pump assembly bolt 11 N·m (1.1 kg-m, 8.0 lb-ft)

7. Fuel return pipe 15. Fuel filler neck assembly

8. Wire harness for fuel pump 16. Clip

For fuel tank system
1. Pipe
2. Hose
3. Clamp
4. Fuel filler hose clamp screw
5. Vehicle forward
6. Vehicle rightward
7. Vehicle inward
8. Trim, fuel filler cap guard
9. Match trim end with line L
“a”: 3 – 7 mm (0.12 – 0.27 in.)
“b”: 25 – 30 mm (0.98 – 1.18 in.)
“c”: 20 mm (0.79 in.) min.
ENGINE FUEL 6C-3
“d”: 5 – 12 mm (0.20 – 0.47 in.)
“e”: 35 mm (1.38 in.) min.
“f”: 35 – 40 mm (1.38 – 1.57 in.)
“g”: 30 – 35 mm (1.18 – 1.38 in.)
“h”: 5 – 10 mm (0.20 – 0.39 in.)
2 N·m (0.2 kg-m, 1.5 lb-ft)
6C-4 ENGINE FUEL
 EXHAUST SYSTEM 6K-1

SECTION 6K

EXHAUST SYSTEM
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the service manual
mentioned in the FOREWORD of this manual.

6K

CONTENTS
On-Vehicle Service..........................................6K-2 Exhaust System Components....................... 6K-2
6K-2 EXHAUST SYSTEM

On-Vehicle Service
Exhaust System Components

WARNING:
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

1. Exhaust manifold 6. Exh. pipe seal ring 11. Exh. pipe mounting cover 50 N·m (5.0 kg-m, 36.0 lb-ft)

2. Exhaust manifold gasket 7. Exh. pipe spring 12. Heat protector screw 45 N·m(4.5 kg-m, 32.5 lb-ft)

3. Exh. manifold upper cover 8. Exhaust pipe (Euro 2) 13. Muffler Do not reuse

4. Exh. manifold lower cover 9. Exhaust pipe (Euro 3) 14. Muffler mounting
5. Oxygen sensor (if equipped) 10. Muffler mounting 15. Exh pipe seal ring
 BODY SERVICE 9-1

SECTION 9

BODY SERVICE
NOTE:
• For the descriptions (items) not found in this section, refer to the same section of the service man-
ual mentioned in the FOREWORD of this manual.
• Fasteners are important attaching parts in that they could affect the performance of vital compo-
nents 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 specified during reassembly to assure proper retention of these parts.

CONTENTS
Glass, Windows and Mirrors............................ 9-2
Cabin Back Window Removal and Installation 9-2
Seat..................................................................... 9-5
Front Seat ....................................................... 9-5
Seat Back Removal and Installation ............... 9-6
Seat Cushion Removal and Installation .......... 9-8
Body Structure ................................................ 9-10
Front Door Components................................ 9-10
Deck Components ........................................ 9-11
Body Dimensions .......................................... 9-11
Under body................................................ 9-12
Panel Clearance ........................................... 9-13
Paint and Coatings ......................................... 9-15
Sealant Application Areas............................. 9-15
Under Coating Application Areas.................. 9-19 9
Required Service Material .............................. 9-20
9-2 BODY SERVICE

Glass, Windows and Mirrors

Cabin Back Window Removal and Installation

1. Cabin back window weatherstrip

2. Cabin back window glass

Removal

1) Remove back window guard bars (1).

2) Stick clotch tape (2) onto back window glass and cabin back
panel as shown, to prevent back window glass from drop-
ping during removal operation.

3) From the interior, lift weatherstrip (2) by using a screw driver

(1) or the like and detach it from cabin back panel edge.
4) Remove back window glass (3) together with weatherstrip
from cabin back panel.
 BODY SERVICE 9-3

Installation

1) Wipe clean cabin back panel where weatherstrip was

mounted to be free from dust or dirt.

2) Fit weatherstrip (2) around back window glass (1).

NOTE:
Position the weatherstrip’s end-to-end joint at the central
bottom portion of the glass. Because the position is bet-
ter in the viewpoint of seal ability.

3) Fit a cord (1) into weatherstrip’s cabin back panel channel to

wrap around weatherstrip.

NOTE:
To assemble weatherstrip easily, put out cord downward
as shown in figure.

4) Place back window glass together with weatherstrip (3) and

cord (1) onto cabin back panel lower edge (2) as shown in
the figure.
9-4 BODY SERVICE

5) Mount weatherstrip onto cabin back panel edge.

NOTE:
With a help of another operator to press on back window
glass from outside, pull the cord from inside in the
direction of arrow as shown in the figure. This will make
the installation smoothly.

1 - 2 - 3: Installation order

6) To settle the glass in place, tap it by fist from the outside.

7) Install back window guard bars (1).

CAUTION:
To prevent removed part from being rusted, paint the
scratch or peel portion before reinstallation.
 BODY SERVICE 9-5

Seat
Front Seat
Front seats construction are different between the driver and passenger seat.
Driver seat is a removable seat cushion (pop up type). Seat back and seat cushion both are can be raised for
easy access to the engine compartment from driver side.
Passenger seat back is a fixed seat cushion. The passenger seat cushion can be raised without raising the seat
back to access to the engine compartment from passenger side.

1. Cushion assy 3. Head restraint assy 5. Lock assy.

2. Back assy 4. Cushion stopper band 6. Panel comp.
9-6 BODY SERVICE

Seat Back Removal and Installation

Removal

1) Remove seat back reffering to the procedure below:

• For driver seat back, pull strap loop (1) to release seat back
lock. Then lift seat back and loosen seat back screws (2) to
remove seat back.

• For passenger seat back, remove screws (2). Then remove

seat back (3) by pulling up until lead of seat back free from
bracket (4) as shown.

2) Remove rings (1) that hold seat back cover (trim) by using
snap ring opener (2), and then remove seat back cover.

Installation

1) Correct the rings (1) which have been deformed during

removal procedure to the shape as shown in the figure.
 BODY SERVICE 9-7

2) Fit seat back cover (trim) over seat back cushion and fasten
it with the rings (1). The rings should be positioned with even
spaces and fastened with equal, appropriate tension to avoid
wrinkle.
2. Plier

3) Install seat back reffering to the procedure below:

• For driver seat back, install seat back and tighten screws (2)
then push seat back until it locks securely.

• For passenger seat back, install seat back (3) by inserting

lead of seat back into bracket (4) and then tighten seat back
screws (2).
9-8 BODY SERVICE

Seat Cushion Removal and Installation

Removal

1) Operate seat cushion lock lever (1) to unlock the seat.

2) Remove seat cushion reffering to the procedure below:
• For driver seat cushion, with seat back held lifted, remove
seat cushion attaching bolts (2).
• For passenger seat cushion, detach the carpet and then
remove passenger seat cushion attaching bolts.

3) Remove seat panel insulator (3) from seat riser panel (2),
then seat riser panel from seat cushion (1).

4) Remove rings (1) that hold seat cushion cover (trim) by

using snap ring opener (2), and then remove seat cushion
cover.

Installation

1) Correct the rings (1) which have been deformed during

removal procedure to the shape as shown in the figure.
 BODY SERVICE 9-9

2) Fit seat cushion cover (trim) over seat cushion and fasten it
with the rings (1). The rings should be positioned with even
spaces and fastened with equal, appropriate tension to avoid
wrinkle.
2. Plier

3) Install seat riser panel (2) to seat cushion (1) and panel insu-
lator (3) to seat riser panel. Then, install seat cushion sub
assembly to the cabin and tighten the attaching bolts and
screws to specified tightening torque.
Tightening torque
Seat cushion bolt (a): 23 N·m (2.3 kg-m, 26.5 lb-ft)
Seat riser panel screw (b): 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
9-10 BODY SERVICE

Body Structure
Front Door Components

1. Door panel 6. Door sealing cover

2. Door hinge 7. Weatherstrip door inner
: Apply lithium grease 99000-25010 to rotating part
: Apply sealant 99000-31110 to contact face
3. Door open stopper 8. Trim front door
4. Front door hinge bolt 9. Handle grip
5. Weatherstrip door opening 26 N·m (2.6 kg-m, 19.0 lb-ft)
 BODY SERVICE 9-11

Deck Components

1. Deck floor panel 4. Lock handle 7. Cushion 10. Protector

2. Rear gate panel 5. Deck front panel 8. Stopper 11. Stopper

3. Side gate panel 6. Pillar upper cover 9. Cap 8.5 N·m (0.85 kg-m, 6.0 lb-ft)

Body Dimensions

NOTE:
All measurement point are on the outer surface of the panel.
9-12 BODY SERVICE

Under body

a. Extreme front jig hole on side member

b (b’). Front frame rear jig hole
c (c’). Center frame front jig hole
d (d’). Center frame rear jig hole
e (e’). Rear frame, rear jig hole

Hole to hole distance

a-a’ : 810.0 mm (31.89 in) b-c’ : 917.2 mm (36.11 in) c’-d’ : 798.7 mm (31.44 in)
a-b : 959.4 mm (37.77 in) b’-c : 894.9 mm (35.23 in) d-d’ : 1065.0 mm (41.93 in)
a-b’ : 1247.8 mm (49.13 in) b’-c’ : 335.0 mm (13.19 in) d-e : 1270.0 mm (50.00 in)
a’-b : 1263.3 mm (49.74 in) c-c’ : 876.0 mm (34.49 in) d-e’ : 1657.4 mm (65.25 in)
a’-b’ : 959.4 mm (37.77 in) c-d : 798.7 mm (31.44 in) d’-e : 1657.4 mm (65.25 in)
b-b’ : 810.0 mm (31.89 in) c-d’ : 1253.3 mm (49.34 in) d’-e’ : 1270.0 mm (50.00 in)
b-c : 332.7 mm (13.10 in) c’-d : 1253.3 mm (49.34 in) e-e’ : 1065.0 mm (41.93 in)
 BODY SERVICE 9-13

Panel Clearance
9-14 BODY SERVICE

Panel to panel distance

g: 2.6 - 4.6 mm m: 2.4 - 4.4 mm r2: 5.0 - 8.0 mm
(0.10 - 0.18 in.) (0.09 - 0.17 in.) (0.20 - 0.31 in.)
h: 1.0 - 3.0 mm n: 5.0 - 7.0 mm r3: 5.5 mm (0.22 in.)
(0.04 - 0.12 in.) (0.20 - 0.28 in.)
i: 0.5 - 2.0 mm o: 5.5 - 7.5 mm s: 2.5 - 5.5 mm
(0.02 - 0.08 in.) (0.22 - 0.30 in.) (0.10 - 0.22 in.)
j: 2.7 - 3.7 mm p: 6.1 - 8.1 mm t1: 1662 mm (65.43 in.)
(0.11 - 0.15 in.) (0.24 - 0.32 in.)
k: 4.2 - 6.2 mm q: 4.2 - 6.2 mm t2: 1581 - 1587 mm
(0.17 - 0.24 in.) (0.17 - 0.24 in.) (62.24 - 62.48 in.)
l: 5.5 - 7.5 mm r1: 8.5 - 10.5 mm t3: 19.4 - 21.4 mm
(0.22 - 0.30 in.) (0.33 - 0.41 in.) (0.76 - 0.84 in.)
 BODY SERVICE 9-15

Paint and Coatings

Sealant Application Areas

“A” : Apply sealant flat “C” : Brush “E” : Wipe away excess
“B” : Apply sealant “D” : Apply sealant brush “F” : Be free from sealant
9-16 BODY SERVICE

“A” : Apply sealant flat “C” : Brush

“B” : Apply sealant “G” : 5 mm min. without sealant
 BODY SERVICE 9-17

“A” : Apply sealant flat “I” : Wipe up area without swell 2. Min 10mm between aa~bb
“B” : Apply sealant “J” : Be free from protrude of sealant Min 5mm between dd~ee
“E” : Wipe away excess “K” : Flat between gg~hh Flat between cc~dd, ee~ff
“H” : Cannot be opened 1. Sealant
9-18 BODY SERVICE

“A” : Apply sealant flat “C” : Brush

“B” : Apply sealant “H” : Cannot be opened
 BODY SERVICE 9-19

Under Coating Application Areas

a, b, c, d : Apply undercoating (400 µm min) View U: Do not apply under coating View X: Do not apply under coating
e : Apply anti-chip coat (300 µ or more) View V: Do not apply under coating
f : Fading zone (0 - 300µ) View W: Do not apply anti-chip coat
9-20 BODY SERVICE

View T: Do not apply under coating (LH only)

Required Service Material

Material Recommended SUZUKI product Use
Lithium grease SUZUKI SUPER GREASE A • Window regulator
(99000-25010) • Door hinge
Sealant SUZUKI BOND No. 1215 • Hood hinge
(99000-31110) • Door hinge
 Prepared by
PT. INDOMOBIL SUZUKI INTERNATIONAL

1st Ed. May 2005

Printed in Indonesia

Printing: June 2005 48