Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 511

9J-3 Hood / Fenders / Doors: 

Front Door Assembly Components

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Front Door Assembly Removal and Installation

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Removal

1) Remove front fender referring to “Front Fender 

Components”.

2) Disconnect door harness lead wires at each coupler.
3) Remove door open stopper (1).

4) Support door panel (1) using a jack (2) with rags (3) 

and a piece of wood (4) placed between jack (2) and 
panel (1) as shown.

5) Remove door assembly (1) by loosening hinge 

mounting bolts (2).

2

2

1

(a)

4

(a)

4

(a)

5

3

(b)

7

(b)

(b)

7

6

I5JB0A9A0005-01

1. Door panel

5. Door open stopper bolt

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

 

 2. Door hinge

: Apply lithium grease 99000-25010 to rotating part.
: Apply sealant 99000-31110 to contact face.

6. Front door opening weather-strip

3. Door open stopper

7. Front door hinge bolt (door side)

4. Front door hinge bolt (body side)

: 27 N

⋅m (2.7 kgf-m, 19.5 lb-ft)

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2

1

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Hood / Fenders / Doors:  9J-4

Installation
Reverse removal procedure to install door assembly 
noting the following instructions.
• When replacing door, coat replacement door inside 

with wax for proper anti-corrosion treatment. Refer to 
“Sealant Application Areas in Section 9L”.

• Apply sealant to contact face “A” of hinge (1) and 

apply grease to rotating part “B” of hinge (1).

“A”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)
“B”:  Grease 99000–25010 (SUZUKI Super Grease 
A)

• Tighten hinge bolt to specified torque.

Tightening torque
Door hinge mounting bolt (body side) (a):  27 N·m 
(2.7 kgf-m, 19.5 lb-ft)
Door hinge mounting bolt (door side) (b):  23 N·m 
(2.3 kgf-m, 17.0 lb-ft)

• When door open stopper (1) is installed, make sure 

punch mark (2) is upward.

Door open stopper installing direction
Left side door: L punch mark is upward
Right side door: R punch mark is upward

• Tighten door open stopper bolt (3) to specified torque.

Tightening torque
Door open stopper bolt (a):  27 N·m (2.7 kgf-m, 
19.5 lb-ft)

• Adjust door latch striker position referring to “Front 

Door Lock Assembly Removal and Installation in 
Section 9F”.

• Adjust front door cushion so that door becomes flush 

with side body.

• After installation, open and close the door to check 

looseness. 

Rear Door Assembly Components

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1

(a)

(b)

(b)

“A”

“A”

“B”

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I4RS0A9A0008-01

2

2

(a)

4

(a)

4

(a)

7

(a)

5

(a)

(a)

7

3

1

6

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1. Door panel

4. Rear door hinge bolt

7. Rear door hinge nut

9J-5 Hood / Fenders / Doors: 

Rear Door Assembly Removal and Installation

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Refer to “Front Door Assembly Removal and Installation” as removal and installation procedures are basically the 
same. However, note the following.
• Tighten rear door hinge bolts and nuts to specified torque referring to “Rear Door Assembly Components”.

Rear End Door Assembly Components

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 2. Door hinge 

: Apply lithium grease 99000-25010 to rotating part.
: Apply sealant 99000-31110 to contact face.

5. Door open stopper bolt

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

3. Door open stopper

6. Rear door opening weather-strip

A

A

A

A

A

A

A

A

A

A

A

E

E

E

A

A

A

A

A

A

A

A

1

2

4

5

5

6

(a)

3

3

I5JB0A9A0009-01

1. Rear end door panel assembly

4. Rear end door balancer

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

2. Rear end door window glass

5. Rear end door trim

 

 3. Rear end door hinge

: Apply lithium grease 99000-25010 to door hinge 
moving section.
: Apply sealant 99000-31110 to contact face.

6. Rear end door opening wether-strip

Hood / Fenders / Doors:  9J-6

Rear End Door Assembly Removal and 
Installation

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Removal

1) Remove rear end door trims (1).
2) Remove spare tire.
3) Disconnect rear end door harness coupler (2) and 

washer hose (3).

4) Remove rear end door balancer (4).
5) Remove door hinge bolts (5) and remove rear end 

door assembly (6).

WARNING

!

 

Handling of Rear End Door Balancer 
(Damper)
• Handle balancer carefully. Do not scar or 

scratch exposed 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.

• Do not disassemble balancer (1) because 

its cylinder is filled with gas.

Discarding of Rear End Door Balancer 
(Damper)
• The gas itself in balancer is harmless but it 

may issue out of the hole together with 
chips generated by the drill (2). Therefore, 
be sure to wear goggle when drilling.

• Using a 2 to 3 mm (0.08 to 0.12 in.) drill (2), 

make a hole to remove gas inside as 
shown before discarding.

 

Installation
Reverse removal procedure noting the following.
• Tighten rear end door hinge bolts and balancer nut to 

specified torque referring to “Rear End Door 
Assembly Components”

• Secure wiring harness (1).

• Adjust door latch striker position by referring to “Rear 

End Door Lock Assembly Removal and Installation in 
Section 9F”.

• Adjust door cushion so that door contacts body when 

closed.

• Apply sealant to contact face “A” of door hinge (1) and 

apply grease to rotating part “B” of hinge (1).

“A”:  Sealant 99000–31110 (SUZUKI Bond 
No.1215)
“B”:  Grease 99000–25010 (SUZUKI Super Grease 
A)

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

E

E

A

1

1

1

1

2

3

4

5

5

6

E

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1

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“A”

“A”

“B”

“B”

1

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