Recall - Poor Windshield Mounting Adhesion

Division: Automotive
Category: Technical

Section Title: Body
TSB No. TS 03 06253

SUBJECT:
SAFETY RECALL CAMPAIGN: EC, FMVSS 212 WINDSHIELD MOUNTING,
POOR ADHESION

MODEL(S):
AERIO RH420

YEAR:
2002 - 2003

NOTE:
THE SPECIFIC VINS HAVE BEEN IDENTIFIED AND THE OWNERS OF THE SPECIFIC VEHICLES HAVE BEEN NOTIFIED BY LETTER.

CONDITION:
Certain vehicles may not comply with FMVSS 212 (Windshield mounting) due to poor adhesion of top-coat paint and primer-coat paint.

CAUSE:
Over-baked paint

CORRECTION:
Perform the attached inspection procedure with the inspection kit sent to your dealership to make initial determination if vehicle has low enough paint adhesion to qualify for A.S.M.C. representative test inspection and final disposition. Additional kit components are available through Hotline.





1. Remove windshield wiper arms and cowl grille as shown.
Caution
Use care when removing cowl grille to prevent damage to it.





2. Measure 4 in. from right "A" pillar and apply 2 in. masking tape to windshield with outside edge of tape at the 4 in mark.





3. Measure 10 in. from left "A" pillar and apply 2 in. masking tape to windshield with outside edge of tape at the 10 in mark.





4. Before placing template in position, clean painted surface with a suitable cleaner such as rubbing alcohol. Place applicable template for initial check at the 4 in. mark as shown.





5. Insert razor knife into groove and cut painted surface with enough force to cut through the paint. Repeat for other groove to make 2 lines.
Note:
Before cutting, break tip of razor knife to use a new sharp tip for every new vehicle procedure. Follow razor knife instructions for proper break off method.
Note:
When cutting paint, try not to cut all the way through to the metal surface.





6. Reverse the template upside-down.





7. Repeat the cutting to draw a small square.





8. Place scotch tape over the square drawn by the cuts. Press down to ensure that tape is firmly applied to surface.





9. Remove scotch tape by using a quick pulling motion with tape held at a 45 degree angle. Evaluate the peeled paint condition by referring to the boundary sample.
If paint peel condition indicates the need for the second inspection test by ASMC because the test results are not good, stop here and contact your dealership's Suzuki District Service and Parts Manager who will arrange for the second test.





If paint peel condition indicates good paint adhesion continue to next steps.
Note:
If either or both test area(s) do not pass this initial test/inspection, save the tape evidence and place on the hard copy of your repair order.





10. To repair cuts after the inspection process spread a small amount of 3M SCOTCH-GRIP # 4475 PLASTIC ADHESIVE on the cuts flatly by using a plastic paddle applicator. Note: Follow warnings and cautions on adhesive label and ensure that the cuts are covered by the glue.





11. Place black tape on top of adhesive to cover cuts. Repeat steps (4) to (11) for left side of vehicle. Remove masking tape and reinstall cowl grille and windshield wiper arms





12. Install the Blue EC Recall Campaign sticker to the flat surface on the upper radiator support just next to the hood latch and bumper. This will identify that the inspection has been completed.