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Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 1
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
Berørte modeller: Swift AZH412 (japanprodusert 4WD), totalt 241 biler. Eiere er eller vil bli tilskrevet. Problem/symptomer: Mulig feilmontering av slangeklemme på påfyllingsslange til bensintank. Dette kan på sikt medføre at slange sprekker ved slangeklemme og gi lekkasje. I forbindelse med utvidelsen av kampanjen, er det kommet ny arbeidsbeskrivelse. Endringen ligger i detaljert beskrivelse for montering av slangen.
Tiltak: 241 biler skal ha kontrollert montering av bensinslange (se VIN liste kontroll). Disse bilene skal kun kontrolleres for korrekt montering av slange. Spesielle tilfeller: Om slangen viser seg å være skadet på grunn av feilmontering; skifte slange i henhold til arbeidsbeskrivelse ”Procedure A” side 7. Ved reklamasjon:
Kontroll av slange: Kampanjekode: AZH-2 – 1 Kontroll Symptom / Defektkode: 99-SU Arbeidsoperasjonskode: DH97A0 0,4 timer Forårsakende delenummer: 89241-71L51-RX0 Spesielle tilfeller: Kampanjekode: AZH-2 – 2 Spes.tilfeller Symptom / Defektkode: 99-SU Arbeidsoperasjonskode: DH48R8 0,5 timer Forårsakende delenummer: 89241-71L51-RX0
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 2
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
Til toppen
SWIFT (AZH412 / AZH414)
Repair Instruction for Recall Campaign
Countermeasure to Incorrect Installation of Fuel Filler Hose
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 3
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
Workflow
NOTE: * : If “99-ST” recall campaign has not been done yet, proceed to [Procedure A]
so that the correction intended by “99-ST” recall will be exactly completed before performing the new recall work.
3. Repair procedure for Fuel Filler Hose Countermeasure ………………………………………………… Page 5
1. Confirmation of Affected Vehicle ………… Page 2
2. Preparation for Fuel Filler Hose Countermeasure ………………………………………………… Page 2
[1] Confirmation of fuel residual quantity
[2] Fuel drainage
[Procedure A]
Replacement of fuel filler hose … Page 7
Indication of fuel meter: 1/2 or more
Indication of fuel meter: Less than 1/2
[4] Check of the vehicle whether “99-ST” recall campaign has already been done or not
[Procedure B] Reposition of fuel filler hose …………. Page 11
[3] Confirmation of VIN whether the vehicle is involved in “99-ST” recall campaign
Involved Not involved
Not yet* Done
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 4
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
1. Confirmation of Affected Vehicle
Check the vehicle identification number to see if the vehicle needs to replace / reposition the fuel filler hose.
Vehicle Identification Number (VIN) Location : On the cowl top panel in the engine compartment.
Affected Vehicle Refer to VIN list sent together with this instruction.
2. Preparation for Fuel Filler Hose Countermeasure
2-1. Necessary Tool and Material * : For reposition
No. Tool and Material
1 Offset box wrench (8 mm)
2 Spanner (8 mm)
3* Socket (8 and 10 mm, 9.5 sq)
4* Extension bar (100 mm, 9.5 sq)
5* Ratchet handle (9.5 sq)
6* Ruler (100 – 200 mm (3.94 – 7.87 in))
7* Hand-operated pump
8* Sealed and metal container (jerrycan, etc.)
9* White gasoline or Kerosene
10* White marker
Til toppen
VIN
青色シール
9
10
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 5
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange 2-2. Replacement Part: The part is needed only when you proceed to [Procedure A].
Part Name Part Number Quantity Comment
Fuel filler hose
89241-71L01-RX0
1
2WD model (Identification marks: Yellow)
89241-71L51-RX0 4WD model
(Identification marks: Green)
2-3. Preparation for Replacement / Reposition of Fuel Filler Hose
WARNING: Failure to observe the following points when servicing the fuel system will increase the risk of fire and personal injury.
Never perform service work near combustible / flammable materials. Put up a warning sign of “Fire Prohibited! Fuel System Under Work”.
Be sure to perform work in a well-ventilated area.
Never perform service work when engine and exhaust systems are hot.
Before performing any service work, touch an anti-static pad or unpainted metal part of the vehicle, etc. to discharge static electricity built up in your body.
Be sure to have a handy CO2 fire extinguisher.
Wear safety glasses.
[1] Confirmation of fuel remaining level
1) Set ignition “ON”.
2) Check fuel level by fuel meter.
3) Select work procedure, depending on fuel meter.
Fuel level Work procedure to select
1/2 or more Go to “[2] Fuel drainage”.
Less than 1/2 Go to “[3] Confirmation of VIN whether the vehicle is involved in “99-ST” recall campaign”
Fuel meter
2WD model 4WD model
Identification marks: Yellow
Identification mark: Nothing
Identification mark: Green
Identification marks: Green
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 6
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
[2] Fuel drainage
1) Remove fuel filler cap.
2) Insert hose of hand-operated pump into fuel tank from fuel filler neck. NOTICE:
The hose of the hand-operated pump could damage the fuel tank inlet valve if too much force is applied when inserting or removing it at the fuel tank. Do not apply too strong force when inserting or removing the hose of the hand-operated pump.
3) Drain fuel from fuel tank until fuel level becomes less than 1/2. WARNING:
There is a risk of fire or explosion if the drained fuel is stored in open container and/or plastic container. Store the fuel in a sealed metal container.
4) Pull out hose of hand-operated pump from fuel filler neck.
[3] Confirmation of VIN whether the vehicle is involved in “99-ST” recall campaign
1) Check VIN whether the vehicle is involved in “99-ST” recall campaign.
2) Go the next step according to the following table.
“99-ST” recall Next step
Involved Go to “[4] Check of the vehicle whether “99-ST” recall campaign has already been done or not”.
Not involved Go to “[Procedure B] Reposition of fuel filler hose”.
[4] Check of the vehicle whether “99-ST” recall campaign has already been done or not
1) Check the vehicle whether “99-ST” recall campaign has already been done or not”. 2) Go the next step according to the following table.
“99-ST” recall Next step
Done Go to “[Procedure B] Reposition of fuel filler hose”.
Not yet Go to “[Procedure A] Replacement of fuel filler hose”.
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 7
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
3. Repair procedure for Fuel Filler Hose Countermeasure
[Procedure A] Replacement of fuel filler hose
1) Set ignition “OFF”.
2) If procedure "[2] Fuel drainage" is skipped, remove fuel filler cap to release fuel vapor pressure in fuel tank.
3) Hoist vehicle.
4) Loosen clamps of fuel filler neck side and fuel tank side.
5) Disconnect fuel filler hose at fuel filler neck while temporarily put a fuel filler neck side clamp on fuel filler neck.
6) Disconnect fuel filler hose at fuel tank side and remove the hose with fuel tank side clamp.
7) Temporarily fit clamp at fuel tank side removed in step 6) to new fuel filler hose.
NOTE:
Clamp should be fitted temporarily with the head of the bolt facing as shown in the figure on the right.
Be sure to use genuine clamps specified by Suzuki if replacing.
8) Install fuel filler hose at fuel tank side first.
NOTE:
Install the fuel filler hose with identification marks approximately facing up.
9) Position fuel tank side clamp as specified.
Specified value:
“a” : 5 – 10 mm (0.2 – 0.39 in)
“b” : 45°
Fuel filler hose
Clamp of fuel filler neck side
Clamp of fuel tank side
Bolt head
Identification marks
Upper side
Lower side
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 8
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange 10) Straighten band part of fuel tank side clamp
with finger so that it becomes in parallel to bolt part.
11) Tighten clamp until dimension "c" becomes specified value.
Specified value:
“c”: 14 – 16 mm (0.55 – 0.63 in)
12) Push band part in arrow direction with finger and put it back.
13) Take off plastic clamp from hoses by rotating it.
Band part
Bolt part Band part
Rotate clamp
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 9
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange 14) Apply white gasoline or kerosene to all around on
the outer circumference of fuel filler pipe.
NOTICE:
Without applying the above mentioned agent, the hose contraction check in the following steps cannot be done. Apply agent without fail.
Use lint-free cloth to apply agent to avoid remaining lint, which may cause fuel leakage.
15) Insert fuel hose straight to the fuel filler pipe.
16) While pushing fuel filler hose by hand to fuel filler pipe, mark a line “A” at hose end on filler pipe.
17) Release hand and check that the hose contraction makes a “clearance” between line “A”. and hose end. Further, check the hose end is positioned over the bulge 2.
NOTICE:
If the “clearance” does not appear, erase line “A” and push the hose to insert furthermore. Then, recheck “clearance” repeating steps 16) and 17).
Do not loosen fuel tank side clamp trying hose position change.
Refer to the following illustration for hose positioning.
Clearance
A
Apply all around
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 10
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
1) Install clamp just between the two bulges, arrow portions.
2) Hold the clamp straight by hand at the center between two bulges and specified angle.
Specified angle:
“d” : 45°
3) Tighten clamp until dimension “e” becomes specified value.
Specified value:
“e” : 8 – 12 mm (0.3 – 0.47 in)
“e”
Filler pipe
Bulge 2 Bulge 1 Filler hose
Hose end positioned OK Hose end positioned NOT OK
Clamp
Hold the upper portion
Upper side
Lower side
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 11
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
18) Clamp hoses so that clamp line “F” becomes parallel to body member line “G” by turning the plastic clamp.
19) Lower vehicle.
20) If fuel is drained, return fuel to fuel tank.
21) Install fuel filler cap.
Til toppen
[Procedure B] Reposition of fuel filler hose
1) Set ignition “OFF”.
2) If procedure "[2] Fuel drainage" is skipped, remove fuel filler cap to release fuel vapor pressure in fuel tank.
3) Hoist vehicle.
4) Loosen clamp of fuel filler neck side.
NOTICE:
Do not loosen fuel tank side clamp.
5) Temporarily put a fuel filler neck side clamp on fuel filler neck.
F
G
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 12
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
6) Disconnect fuel filler hose at fuel filler neck and take off plastic clamp from hoses by rotating it.
7) Apply white gasoline or kerosene to all around on the outer circumference of fuel filler pipe.
NOTICE:
Without applying the above mentioned agent, the hose contraction check in the following steps cannot be done. Apply agent without fail.
Use lint-free cloth to apply agent to avoid remaining lint, which may cause fuel leakage.
8) Insert fuel hose straight to the fuel filler pipe.
9) While pushing fuel filler hose by hand to fuel filler pipe, mark a hose end line “A” on filler pipe.
A
Rotate clamp
Apply all around
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 13
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
10) Release hand and check that the hose contraction makes a “clearance” between line “A”. and hose end. Further, check the hose end is positioned over the bulge 2.
NOTICE:
If the “clearance” does not appear, erase line “A” and push the hose to insert furthermore. Then, recheck “clearance” repeating steps 9) and 10).
Do not loosen fuel tank side clamp trying hose position change.
Refer to the following illustration for hose positioning.
11) If the hose end does not position over the bulge 2, replace the hose with a new one according to [Procedure A].
12) Install clamp just between the two bulges, arrow portions.
Clearance
Clamp
Filler pipe
Bulge 2 Bulge 1 Filler hose
Hose end positioned OK Hose end positioned NOT OK
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 14
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
13) Hold the clamp straight by hand at the center between two bulges and specified angle.
Specified angle:
“a” : 45°
13) Tighten clamp until dimension “b” becomes specified value.
Specified value:
“b” : 8 – 12 mm (0.3 – 0.47 in)
14) Clamp hoses so that clamp line “F” becomes parallel to body member line “G” by turning the plastic clamp.
15) Lower vehicle.
16) If fuel is drained, return fuel to fuel tank.
17) Install fuel filler cap.
Til toppen
“b”
F
G
Hold the upper portion
Upper side
Lower side
“a”
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 15
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange
VIN liste kontroll (241 biler)
JSAFZD72S00130588
JSAFZD72S00130600
JSAFZD72S00130602
JSAFZD72S00130604
JSAFZD72S00130621
JSAFZD72S00130622
JSAFZD72S00130636
JSAFZD72S00130635
JSAFZD72S00130647
JSAFZD72S00130629
JSAFZD72S00130662
JSAFZD72S00130667
JSAFZD72S00130672
JSAFZD72S00130686
JSAFZD72S00130687
JSAFZD72S00130700
JSAFZD72S00130701
JSAFZD72S00130703
JSAFZD72S00130720
JSAFZD72S00130750
JSAFZD72S00130831
JSAFZD72S00130910
JSAFZD72S00130941
JSAFZD72S00130949
JSAFZD72S00130964
JSAFZD72S00131017
JSAFZD72S00131018
JSAFZD72S00130970
JSAFZD72S00130972
JSAFZD72S00130965
JSAFZD72S00131031
JSAFZD72S00131026
JSAFZD72S00130917
JSAFZD72S00131032
JSAFZD72S00131036
JSAFZD72S00131040
JSAFZD72S00130962
JSAFZD72S00131045
JSAFZD72S00130961
JSAFZD72S00131047
JSAFZD72S00131046
JSAFZD72S00131048
JSAFZD72S00131054
JSAFZD72S00131059
JSAFZD72S00131061
JSAFZD72S00130947
JSAFZD72S00130948
JSAFZD72S00131060
JSAFZD72S00131066
JSAFZD72S00130960
JSAFZD72S00131067
JSAFZD72S00131033
JSAFZD72S00131068
JSAFZD72S00131069
JSAFZD72S00130980
JSAFZD72S00131074
JSAFZD72S00130985
JSAFZD72S00130989
JSAFZD72S00130987
JSAFZD72S00130920
JSAFZD72S00131077
JSAFZD72S00131079
JSAFZD72S00131081
JSAFZD72S00131083
JSAFZD72S00131091
JSAFZD72S00130990
JSAFZD72S00131094
JSAFZD72S00130995
JSAFZD72S00130993
JSAFZD72S00131093
JSAFZD72S00131101
JSAFZD72S00130999
JSAFZD72S00131090
JSAFZD72S00131102
JSAFZD72S00131003
JSAFZD72S00131105
JSAFZD72S00131104
JSAFZD72S00131004
JSAFZD72S00131110
JSAFZD72S00131118
JSAFZD72S00131124
JSAFZD72S00131122
JSAFZD72S00130923
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JSAFZD72S00131128
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JSAFZD72S00131115
JSAFZD72S00131117
JSAFZD72S00130931
JSAFZD72S00131183
JSAFZD72S00131190
JSAFZD72S00131166
JSAFZD72S00131188
JSAFZD72S00131187
JSAFZD72S00130935
JSAFZD72S00131197
JSAFZD72S00131199
JSAFZD72S00131202
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JSAFZD72S00131216
JSAFZD72S00131215
JSAFZD72S00131208
JSAFZD72S00131213
JSAFZD72S00131204
JSAFZD72S00131232
JSAFZD72S00131237
JSAFZD72S00131218
Kampanje AZH-2 Dato: 31.10.2014 Revisjon , side 16
Kampanje AZH-2 (Revidert KAMPANJE 20120503 AZH): Kontroll / skifte av bensinslange JSAFZD72S00131231
JSAFZD72S00131222
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JSAFZD72S00131288
JSAFZD72S00131277
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