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Section Title: Body, Cab & Accessories TSB No. TS 11 10177R2
Division: Automotive Category: Technical
SUBJECT:SAFETY RECALL CAMPAIGN "NB" LOW BEAM HEADLIGHT AND DAYTIME RUNNING LIGHT (DRL) SPLICE PACK REPAIR
MODEL(S):FORENZA SEDAN/WAGON, RENO (RQ420)
REVISION:THE VIN RANGE AND PARTS INFO HAS BEEN UPDATED
AFFECTED VIN(S): ALL 2004, 2005, AND CERTAIN 2006 MY UP TO 6K369480
NOTE :VIN numbers are not fully inclusive. Not all VIN's within the above range are included. If the vehicle owner does not present the Owner Notification Letter; with the printed VIN, check vehicle history in Suzuki Connect to verify if the VIN is affected and included or not.
CONDITION:Possible high resistance in the S201 splice pack may cause low beam headlights and DRL to not operate.
CAUSE:Affected vehicles were produced with splice packs which may have high resistance at the headlight lamp splice. It is possible for this high resistance to generate enough heat to melt the splice pack eventually causing the circuit for the low beam headlights and DRL to open. The low beam and DRL may not function if the circuit opens. A burning smell may also be present from the instrument cluster area.
CORRECTION:Please follow the instructions below to bypass the S201 splice pack on vehicles in the affected VIN range. The circuit for the headlights will be joined with a special crimp connector. This will join the circuit with mechanical force a solder welded joint and adhesion of the wire insulation. The same procedure is used for all listed models. Note that the cluster bezels may differ in appearance Forenza sedan is shown.
WARRANTY:Please refer to the Campaign Bulletin SC-41 for claim submission instructions and labor times.
Splice Pack Repair Procedure
If you want to return this to the dealer they will do the repair for free. If you want to pull the cluster and repair the splice pack yourself I will walk you through it if you solder.
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