Recall - Windshield/Quarter Glass/Rear Door Glass
Section Title: Body, Cab and AccessoriesTSB No. TS 25 06147
Division: Automotive
Category: Technical
SUBJECT:
SAFETY CAMPAIGN "KW" STATIONARY GLASS REPLACEMENT
MODEL(S):
XL7
YEAR:
2007
AFFECTED VIN(S):
ATTACHED VIN LIST
CONDITION:
Stationary glass is not properly bonded to the vehicle body.
CAUSE:
The wrong primer may have been used when the body was prepared for the glass installation.
CORRECTION:
In stock vehicles:
Based on factory representative inspections conducted at each dealership remove and replace the glass identified by the inspector; any or all windshield quarter windows and back door window. Suzuki recommends the use of a certified glass installer. Where glass repair is sublet provide this bulletin to the installer. If inspection confirms that the vehicle does not require repairs reassemble the vehicle and prepare for normal sales inventory.
Customer vehicles:
Replace windshield side quarter windows and back door window following the instructions in this bulletin. These vehicles will be listed in the affected VIN list. Suzuki recommends the use of a certified glass installer. Where glass repair is sublet provide this bulletin to the installer.
IMPORTANT:
Carefully review the supplemental glass removal instructions below. Refer to the service manual for a complete list of tools, supplies and vehicle trim removal and installation procedures. URETHANE AND PRIMER INSTRUCTIONS IN THIS SUPPLEMENT REPLACE THE INSTRUCTIONS PUBLISHED IN THE SERVICE MANUAL FOR THE WINDSHIELD, BACK DOOR WINDOW AND QUARTER WINDOWS.
PART(S) INFORMATION:
WARRANTY CLAIM INFORMATION:
CONTACT WARRANTY HELPLINE FOR ASSISTANCE WITH CLAIM SUBMISSION. ONLY GENUINE SUZUKI GLASS IS TO BE USED FOR THIS REPAIR. CLAIMS OR REPAIRS WITH NON-SUZUKI GLASS WILL BE DENIED
Refer to Service Campaign bulletin SC-37 for further information.
Supplemental instructions to the stationary glass replacement procedures.
1. Cut out glass holding cut out tool to edge of glass.
2. Prepare window opening by cutting excess urethane from body.
2.1 During cut out process, pull and peel all loose (not securely bonded) urethane away
2.2 Examine and check, (a second time) for securely bonded urethane, removing any loose urethane.
2.3 Where urethane is securely bonded, skim cut the urethane leaving 0.5 mm (.02 in) to 2.0 mm (.08 in) on the flange.
2.4 Cut urethane to remove any ridges, notches, or divots.
2.5 Clean any loose pieces of urethane from opening.
3. Repair of body bonding surface.
3.1 Locate any areas where the primerlurethane did not adhere to the paint surface.
3.2 If residual primer exists adjacent to area the bonding area, remove and de-gloss with 200 grit automotive grade sandpaper.
3.3 Clean the bonding surface using a low lint paint shop quality rag dampened with 99% Isopropyl Alcohol (IPA) and allow to dry.
3.4 Shake container of black (9985757, YH RC-5OKE) or equivalent body primer 5 minutes prior to use.
3.5 Apply black body primer to areas where urethane did not adhere and as needed adjacent to skim cut bead. Apply to any exposed metal on the flange. DO NOT APPLY BLACK PRIMER TO ANY EXISTING URETHANE.
3.6 Allow black body primer to dry a minimum 2 minutes prior to installing glass.
Glass Preparation
1. Glass must be clean, dry and free of contaminates prior to primer application.
1.1 Wipe glass with a clean, low lint, paint shop quality rag and 99% Isopropyl Alcohol (I PA), prior to black glass primer application.
1.2 Re-wipe interior side black ceramic bonding surface (frit) with a clean, low lint, paint shop quality rag and 99% Isopropyl Alcohol (IPA), in preparation for black glass primer application, (9982279, YH MS-90) or equivalent.
2. Allow IPA to dry prior to application of black glass primer.
3. Apply black glass primer, (9982279, YH MS-90) or equivalent to glass using original/provided dimensions and locations.
NOTICE:
The glass primer application must be continuous and streak free in the bonding area.
3.1 Re-apply black glass primer if a second coat is necessary.
Urethane Application
1. Apply a continuous bead of urethane adhesive (9985397, YH WS-70FK) or equivalent over the previously applied glass primers. The bead should be a minimum of 14 mm (.55 in) high and 8 mm (.3 in) wide at the base, in the shape of a blunt triangle.
NOTICE:
Use of an alternative method of urethane application, "bead applied to body," is not recommended. At no time should application of the urethane to the glass and installation of the glass exceed 5 minutes.
2. Install glass to vehicle within the 5 minute limit.
3. If this time is exceeded, scrape/remove urethane and reapply for new installation.
4. Upon installation, check left / right positioning (centering) and lightly press glass into position.
5. Clean any excess urethane adhesive on visible surfaces by wiping immediately with a paint shop quality rag dampened with VM&P Naphtha or equivalent.
6. Position glass to ensure that rear edge of upper reveal molding does not have a gap to the roof surface, by shifting the windshield upward.
7. If required, use masking tape to hold the molding to the body during urethane cure.
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