Glass/windows/mirrors: Removal & Installation Suzuki Aerio I

Windshield Removal and Installation

Reference: WINDSHIELD CONSTRUCTION

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1. Clean both inside and outside of glass and around it.
2. Remove wiper arms and garnish.
3. Using tape, cover body surface around glass to prevent any damage.
4. Remove rear view mirror, sun visor and front pillar trims (right & left).
5. If necessary, remove instrument panel. Refer to «INSTRUMENT PANEL REMOVAL AND INSTALLATION»(ref-251100-S22921662052007032000000) .
6. If necessary, remove head lining. Refer to «HEAD LINING REMOVAL AND INSTALLATION»(ref-251105-S28377054922007032000000) .
7. Remove (or cut) windshield molding.
8. Drill hole with eyeleteer (1) through adhesive and let piano string through it.
9. Cut adhesive all around windshield (1) with piano string (2). When using tool, windshield knife (3), to cut adhesive, be careful not to cause damage to windshield. Use wire to cut adhesive along lower part of windshield. NOTE: Use piano string (2) as close to glass as possible so as to prevent damage to body and instrument panel.
10. Using knife (1), smoothen adhesive (2) remaining on body side (3) so that it is 1 - 2 mm (0.039 - 0.078 in.) thick all around. NOTE: Before using knife (1), clean it with alcohol or the like to remove oil from it.
11. When reusing windshield, remove the adhesive (1) from it, using care not to damage primer coated surface (2).

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1. Using cleaning solvent, clean windshield edge where windshield glass is to be adhered. (Let it dry for more than 10 minutes.)
2. Install new glass stoppers (1) (2 pieces) to lower side of windshield.
3. To determine installing position of glass (1) to body (2), position glass against body so that clearance between upper end of glass (1) and body (2) is approximately 5 mm (0.197 in.) and clearances between each side end (right & left) of glass (1) and body (2) are even. Then mark mating marks on glass (1) and body (2) as shown. Upper clearance can be adjusted by moving glass stoppers position. Windshield clearance "a": approx. 5 mm (0.197 in.)
4. Clean contact surfaces of old adhesive (4), paint or bare metal thoroughly. If surfaces of paint or bare metal come out, apply primer (2) for body with caution not to apply primer (2) 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 10 minutes or more. Cleaning Area for windshield (distance from the edge of glass or molding) 30 - 50 mm (1.18 - 1.97 in.)
7. Install new spacers (1) to windshield (2).
8. Using new brush, apply sufficient amount of primer onto glass along glass edge. NOTE: Be sure to refer to primer maker's instruction for proper handling and drying time. Do not apply primer on outside of ceramic coated surface. Do not touch primer coated surface. Width applied primer for windshield "a": 15 mm (0.59 in.) "b": 22 mm (0.87 in.) "c": 6 mm (0.24 in.)
9. Apply primer for molding along molding surface all around.
10. Apply adhesive (1) referring to figure. NOTE: Press glass (2) against fittings surface of body panel quickly after adhesive (1) is applied. Use of rubber sucker grip is helpful to hold and carry glass after adhesive (1) is applied. Perform steps 8 ) to 9 ) within 10 min. to ensure sufficient adhesion. Be sure to refer to adhesive maker's instruction for proper handling and drying time. Start from bottom side of glass (2). Be careful not to damage primer. Adhesive amount specifications and position for windshield Width "a": Approx. 7 mm (0.27 in.) Height "b": Approx. 15 mm (0.59 in.) Position "c": Approx. 11 mm (0.43 in.) for front, rear and upper sections Position "d": Approx. 17 mm (0.67 in.) for bottom section
11. Holding rubber sucker grips (1), place glass onto body by aligning mating marks marked in step 3 ) and press it.
12. Check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again. NOTE: Do not use high pressure water. Do not blow compressed air directly at adhesive applied part when drying. Do not use infrared lamp or like for drying.

Front Pillar Window Removal and Installation

Refer to WINDSHIELD REMOVAL AND INSTALLATION as removal and installation procedures are basically the same. However, note the following.

1. Observe the following precautions when applying adhesive (1) along glass (2) edge.
2. Adhesive (1) should be applied evenly especially in height.
3. Be careful not to damage primer (3).
4. Press glass against body quickly after adhesive (1) is applied.

Adhesive amount specification and position for front pillar window

Height "a": 10 mm (0.39 in.)

Width "b": 6 mm (0.24 in.)

Position "c": 4.5 mm (0.18 in.)

Width "d": 12 mm (0.47 in.)

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Front Door Glass Removal and Installation

Reference: FRONT DOOR WINDOW COMPONENTS

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1. Remove inside handle bezel (1).
2. Remove inside door grip cover (2), and then remove door trim mounting bolts (3).
3. Remove door trim (1). With inside handle bezel (2) tilted toward inside, turn and remove door trim as shown. And disconnect power window switch lead wire at coupler.
4. Remove door sealing cover (1).
5. Remove outer weather-strip (1). Do not deform it when removal. Lower window all the way down. Then, use a tape-wrapped putty knife to pry off outer weather-strip.
6. Remove door glass mounting screws (1).
7. Remove door glass (2) while tilting it as shown.

Installation

Reverse removal procedure noting the following instructions.

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1. If there is deformity for glass run, replace new one.
2. Tighten door glass rear mounting screw (1) first, and then tighten door glass front mounting screw (2).
3. Secure door sealing cover (1) with adhesive (2).
4. Tighten front door outer weather-strip mounting screw as specified torque. Tightening torque Front door outer weather-strip mounting screw (a): 1.5 N.m (0.15 kg-m, 1.0 lb-ft)

Front Door Window Regulator Removal and Installation

Reference: FRONT DOOR WINDOW COMPONENTS

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1. Remove door glass referring to «FRONT DOOR GLASS REMOVAL AND INSTALLATION»(ref-251102-S00472695402007032000000) .
2. Disconnect power window motor lead wire at coupler and loosen clamp.
3. Loosen regulator mounting bolts (1) and nuts (2), and then remove front door window regulator (3).

Reference: FRONT DOOR WINDOW REGULATOR INSPECTION

Reverse removal procedure noting the following instruction.

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1. Apply grease to sliding portions of window regulator. : Grease 99000-25010
2. Tighten front door window regulator attaching bolts to proper tightening order. Front door window regulator bolt tightening order (a) --> (b) --> (c)

Rear Door Glass Removal and Installation

Reference: REAR DOOR WINDOW COMPONENTS

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1. Remove inside handle bezel (1).
2. Remove inside door grip cover (2), and then remove door trim mounting bolts (3).
3. Detach door trim mounting clips.
4. Remove door trim (1). With inside handle bezel (2) tilted toward inside, turn and remove door trim as shown. And disconnect power window switch lead wire at coupler.
5. Remove door sealing cover (1).
6. Remove outer weather-strip (1). Do not deform it when removal.
7. Loosen door glass mounting screws (1), and then drop door glass (2) from window regulator (3).
8. Detach rear part of glass run from sash (4), and remove sash by removing 2 screws (5) and bolt (6).
9. Remove door glass (2).

Reverse removal procedure noting the following instructions.

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1. If there is deformity for glass run, replace new one.
2. Tighten door glass front mounting screw (2) first, and then tighten door glass rear mounting screw (1).
3. Tighten rear door rear sash lower mounting bolt (1), and tighten rear door rear sash upper mounting screws (2, 3) as specified torque. Tightening order: (1) --> (2) --> (3) Tightening torque Rear door rear sash upper mounting screw (a): 2.5 N.m (0.25 kg-m, 1.8 lb-ft)
4. Secure door sealing cover (1) with adhesive (2).
5. Tighten rear door outer weather-strip mounting screw to specified torque. Tightening torque Rear door outer weather-strip mounting screw (a): 1.5 N.m (0.15 kg-m, 1.0 lb-ft)

Rear Door Window Regulator Removal and Installation

Reference: REAR DOOR WINDOW COMPONENTS

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1. Remove door glass referring to «REAR DOOR GLASS REMOVAL AND INSTALLATION»(ref-251102-S23920452162007032000000) .
2. Disconnect power window motor lead wire at coupler and loosen clamp.
3. Loosen regulator mounting bolts (1) and nuts (2), and then remove rear window regulator (3).

Reference: REAR DOOR WINDOW REGULATOR INSPECTION

Reverse removal procedure noting the following.

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1. Tightening order: (1) --> (2) --> (3)

Quarter Window (for Wagon Model) Removal and Installation

Refer to WINDSHIELD REMOVAL AND INSTALLATION as removal and installation procedures are basically the same. However, note the following.

1. Observe the following precautions when applying adhesive (1) along glass (2) edge.
2. Adhesive (1) should be applied evenly especially in height.
3. Be careful not to damage primer (3).
4. Press glass against body quickly after adhesive (1) is applied.

Adhesive amount specification and position for quarter window

Height "a": 16 mm (0.63 in.)

Width "b": 9 mm (0.35 in.)

Position "c": 8 mm (0.31 in.) for glass front section

Position "c": 10 mm (0.39 in.) for glass rear sections

Position "c": 12 mm (0.47 in.) for glass bottom section

Width "d": 14 mm (0.55 in.)

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Rearend Door Glass (for Wagon Model) Removal and Installation

Reference: REAREND DOOR WINDOW (FOR WAGON MODEL) COMPONENTS

Refer to WINDSHIELD REMOVAL AND INSTALLATION as removal and installation procedures are basically the same. However, note the following.

1. Observe the following precautions when applying adhesive (1) along glass (2) edge.
2. Adhesive (1) should be applied evenly especially in height.
3. Be careful not to damage primer (3).
4. With the position of fastener (4) properly aligned, install glass (2) on rearend door panel (5).
5. Press glass against body quickly after adhesive (1) is applied.

Adhesive amount specifications and position for back door glass

Height "a": 14 mm (0.55 in.)

Width "b": 7 mm (0.28 in.)

Width "c": 16 mm (0.63 in.)

Position "d": 14 mm (0.55 in.) for glass upper and side sections

Position "d": 15 mm (0.59 in.) for glass bottom section

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Back Window (for Sedan Model) Removal and Installation

Reference: BACK WINDOW (FOR SEDAN MODEL) COMPONENTS

Refer to WINDSHIELD REMOVAL AND INSTALLATION as removal and installation procedures are basically the same. However, note the following.

1. Observe the following precautions when applying adhesive (1) along glass (2) edge.
2. Adhesive (1) should be applied evenly especially in height.
3. Be careful not to damage primer (3).
4. Press glass against body quickly after adhesive (1) is applied.

Adhesive amount specifications and position for back window

Width "a": 7 mm (0.28 in.)

Height "b": 14 mm (0.55 in.)

Position "c": 6 mm (0.23 in.)

Width "d": 14 mm (0.55 in.)

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Door Mirror Removal and Installation

Reference: DOOR MIRROR COMPONENTS

When removing or installing door mirror, refer to the figure in DOOR MIRROR COMPONENTS .

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1. Remove mirror switch from door trim.
2. Check for continuity between terminals at each switch position. If check result is not as specified, replace door mirror switch.

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1. Remove door trim referring to «FRONT DOOR GLASS REMOVAL AND INSTALLATION»(ref-251102-S00472695402007032000000) .
2. Disconnect door mirror coupler (1).
3. Check that door mirror operates properly when battery voltage is applied to connector terminals.
4. Connect battery positive (+) and negative (-) terminal to the door mirror terminal as shown. If it does not follow the table's operation, replace door mirror assembly.

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1. Remove mirror heater switch from instrument panel.
2. Check for continuity between terminals at each switch position as shown. If check result is not as specified, replace switch.

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1. Remove door trim referring to «FRONT DOOR GLASS REMOVAL AND INSTALLATION»(ref-251102-S00472695402007032000000) .
2. Disconnect door mirror coupler (1).
3. Check for continuity between terminals "a" and "b". If no continuity, replace outside mirror.