Campaign KQ - Water Pump Pulley Inspection

FORENZA

Section Title: Engine
TSB No.TS10 01257

Division: Automotive
Category: Technical

SUBJECT:
CUSTOMER SATISFACTION CAMPAIGN "KQ" WATER PUMP PULLEY INSPECTION

MODEL(S):
FORENZA, FORENZA WAGON, RENO (RQ420)

YEAR:
2004~2OO5

AFFECTED VIN(S):
KL5JJ52Z44K046750~KL5JD56ZX5K237477

NOTE:
VINs to inspected do not include all units in the affected VIN range. If the vehicle owner does not present the Owner Notification Letter, please check vehicle history on Suzuki Connect to verify if the VIN is affected or not.

CONDITION:
The timing belt may be rubbing the inner flange of the old-style water pump. This may cause the inner flange to separate which could result in engine damage.

CAUSE:
The inner flange of the old-style water pump is spot welded together. If the timing belt is applying pressure to the inner flange, it may break at the spot welds.

CORRECTION:
Please inspect the alignment of the timing belt on the water pump pulley according to the attached instructions. Only check vehicles within the VIN range shown above. Use the attached instructions for inspection and replacement.

WARRANTY:
Please refer to the Campaign Bulletin SC-35 for claim submission instructions and labor times.





PART(S) INFORMATION:

Parts Description





Old-style pump

Sintered flange is on the outer side, and the welded flange is on the inner side. Also note the impeller is steel.





New-style pump

The new-style pump has the sintered flange on the inner side. The welded flange is on the outer side. Also note the impeller is plastic. The new pump comes with a new seal. If this type of pump is already installed in the vehicle being inspected DO NOT REPLACE. Your inspection is complete.

The new design allows the belt to contact the rear part of the flange.

NOTE:
If the welded flange is on the outer side, as noted in the above part description, the inspection is complete. Also if the welded flange is on the outer side it is NOT necessary to remove the pump to check for a plastic impeller. This vehicle passes the inspection. Re-assemble and place the "KQ" sticker as described in step 14.

Inspection Procedure





1. Check for "KQ" sticker on the radiator core support. If sticker is found, this campaign has already been done. Do not continue. If not found, continue to step 2.





2. Record the radio station presets.

3. Place the vehicle in "Park" and apply the parking brake.

4. Disconnect the battery.

5. Remove the air cleaner assembly by removing the two indicated bolts and loosening the outlet hose clamp. Slip the outlet hose off of the air cleaner then lift the air cleaner out of the engine compartment.





6. Support the engine with the Engine Assembly Support Fixture DW11O-060 and X-28467-560 Engine Assembly Support Channel or an equivalent engine support assembly.





7. Remove the engine mount bracket nut on the frame side first. Then raise the engine until the bracket starts to raise. You will see the stud retract into the bracket.

8. Remove the remaining two nuts and bolt and remove the bracket.





9. Use a wrench to turn the tensioner bolt clockwise, compressing the tensioner, and releasing the tension on the serpentine accessory drive belt. Remove the belt.





10. Remove the timing belt cover by releasing the three tabs at the top of the cover. Then remove the three bolt indicated. Then tip the cover towards the fender to clear the engine mount bracket and slide the cover up and out.





11. Inspect the timing belt position on the water pump pulley.

NOTE:
If the welded flange is on the outer side, as as described previously, the inspection is complete. Re-assemble, this vehicle passes the inspection. Place the "KQ" sticker as described in step 15. If not continue to step 12.





12. Use a feeler gauge to measure the gap between the rear flange and the edge of the timing belt. If it is less than 0.3 mm or the rear flange is broken or missing, continue to step 13. If it is equal to or more than 0.3 mm no further action is required. Reassemble the timing belt cover and the other removed components. Reconnect the battery and reprogram the radio presets.

13. If the gap is less than 0.3mm follow the appropriate service manual procedure to replace the water pump and the timing belt with the part numbers indicated above. Be sure to align the water pump notch correctly when installing the pump. If the notch is not aligned correctly it will not be possible to correctly adjust the timing belt tension.





14. Reconnect the battery and reprogram the radio presets.

15. Write your dealer number on the "KQ" sticker and affix the "KQ" sticker to the core support. Campaign is complete.





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