Recall SM - Possible Alternator Belt Tensioner Damage
TSB No. TS 09 07151RSection Title: Engine
Category: Technical
Division: Automotive
SUBJECT:
SAFETY RECALL CAMPAIGN: SM, ALTERNATOR BELT TENSIONER DAMAGE.
MODEL(S): SX-4 (RW420)
YEAR: 2009-2011
PRODUCTION RANGE: JUNE 19, 2008-OCTOBER 13, 2010
CONDITION:
The internal spring of alternator belt tensioner could break, allowing the belt to slip or derail, causing abnormal noise, and in worst cases may result in increased effort to steer the vehicle.
CORRECTION:
Suzuki dealers are required to perform an inquiry of the "Vehicle Master", confirming the recall campaign is open, then replace the alternator belt tensioner pulley, unless a replacement has been previously performed with countermeasure parts. This service will be performed at no cost to the customer for parts or labor.
PART(S) INFORMATION
WARRANTY INFORMATION
WORKFLOW
NECESSARY TOOLS
CUSTOMER SATISFACTION COURTESY
Drive Belt Inspection
Before beginning the removal process, please inspect the position of the tension indicators on the tensioner pulley, as well as the condition of the drive belt.
In cases of normal belt condition, the front tension indicator (1) (nearest the pulley) is on the right of the rear tension indicator (2), as shown in the illustration.
If indicator (1) is on the left of Indicator (2), the belt should be replaced as a general service in addition to the tensioner replacement.
If it is recommended that the belt should be replaced due to the tension indicators or the visual appearance during inspection, please contact the vehicle owner to advise them of these needs. It is the customer's responsibility to pay for the cost of the replacement belt as this is not included as part of the service recall campaign.
REPLACEMENT PROCEDURE OF THE GENERATOR BELT TENSIONER
Removal Procedure
1. Lift up vehicle.
2. Remove right-front wheel.
3. Remove front fender lower lining (1) of right side.
4. Loosen belt tension by turning the tensioner (1) clockwise with 14mm box wrench (2).
5. While keeping the tensioner in the turned position (belt loose), remove the alternator drive belt.
6. Remove the tensioner pulley bolt (1) and then pulley shield (2) and pulley (3).
7. Remove lower side bolt (1) of the tensioner body.
8. To make space for tool access:
> Detach engine harness clip (1) from bracket.
> Remove bracket bolt (2).
> Pull harness (3) aside.
9. Inserting a box wrench through water pump side, begin to loosen the upper side bolt (1) of the tensioner body, but do not back out or 6 remove the bolt.
10. To protect water pump pulley edge from being scratched or damaged, stick a piece of shop cloth (1) at the position indicated in the figure using adhesive tape before continuing to remove the bolt.
11. Rotate the water pump pulley so the adhered shop cloth is located in line behind the bolt (1).
12. Loosen the bolt (2) using an open-end wrench.
13. Remove the tensioner body along with the upper bolt (the bolt cannot be removed with the tensioner body still in place).
Installation Procedure
14. Place the NEW tensioner assembly (countermeasure part) in a soft jawed vise (1) and remove tensioner pulley bolt (2).
Note:
Take care not to fasten the tensioner too tightly in the vise. Excessive tightening of the vise jaws will deform the tensioner.
15. Disassemble the NEW tensioner assembly to separate the tensioner body (1), the pulley (2), the pulley shield (3) and the tensioner pulley bolt (4).
16. Discard the original upper bolt that secured the tensioner body, and install the new hexagon head bolt with washer (countermeasure parts).
17. Install the tensioner body (1) to the cylinder block and tighten the lower side bolt (2) of tensioner body lightly.
18. Install the NEW hexagon bolt (3) and washer (countermeasure parts) at the upper side of the tensioner body.
19. Using the hexagon bit socket and torque wrench, tighten upper side bolt (3) of tensioner body to specified torque.
20. Tighten lower side bolt (2) of tensioner body to specified torque.
TIGHTENING TORQUE
21. Install tensioner pulley (1), pulley shield (2) and tensioner pulley bolt (3).
Note:
Off-centering of the pulley shield hinders tightening of pulley bolt. Tighten pulley bolt while centering pulley shield.
22. Tighten the tensioner pulley bolt (3) to the specified torque.
Note:
When tightening the tensioner pulley bolt, turn the tensioner up to the swing end, and then apply specified torque.
TIGHTENING TORQUE
Tensioner body bolt (b): 33.5 lb-ft (45 Nm, 4.5 kgf-m)
23. Remove the portion of shop towel from the water pump pulley.
Note:
Check the water pump pulley for any abrasion caused by replacement of the tensioner and touch up as necessary.
24. Fit engine harness clamp (1) to bracket, and install bracket bolt (2).
25. While keeping the tensioner (1) in the clockwise turned position with wrench (3), install alternator drive belt (2) and then gently release the tensioner.
Note:
Do not turn the tensioner with a torque greater than 43.5 lbf-ft (59 Nm, 6.0 kgf-m). Over turning may cause damage to the tensioner.
Steps 26. and 27.
28. Install right front fender lower lining (1), making sure to properly interlocking the right side, joining with the under-cover (2).
29. Install front wheel and wheel nuts and tighten nuts gradually and equally.
30. Lower vehicle.
31. Tighten wheel nuts to the specified torque in the order shown in the figure.
Tightening order:
"1" - "2" - "3" - "4" - "5"
TIGHTENING TORQUE
32. Apply the proper campaign label to the upper radiator support in an area where it will be easily seen and identified, and record your Dealer Code in the white portion of the label.