ARTICLE BEGINNING AFFECTED VIN(S)

REAR WINDOW WASHER DOES NOT SPRAY

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 12 02088, Date of Issue: February 08, 2008SUZUKI: 2005-2008 FORENZA WAGON, RENO (RQ420)SECTION:Body, Cab and AccessoriesRelated Ref Number(s): TS 12 02088

ARTICLE BEGINNING

AFFECTED VIN(S)

-KL5JJ86Z06K263629 (AUG. 16, 2005)

CONDITION

Rear window washer does not spray even when fluid tank is full.

CAUSE

The back door washer hose may be detached or split due to the material of the hose being toohard. During cold weather the hose can crack when flexed. Also, if the washer fluid is purewater instead of washer solvent, the water could freeze and rupture the hose or cause the hoseto disconnect.

CORRECTION

There is an updated back door washer hose available which is more flexible and resistant tocold temperatures. Follow attached instructions for installation. The attached instructions arespecific to each body style; Forenza Wagon and Reno.

NOTE: 1: Always use windshield washer fluid designed for cold weather32°F or below. This will prevent any damage of components in thewasher system from expansion of untreated water.

NOTE: 2: The leaking fluid from the washer system could get into theelectrical connectors and cause various electrical systemmalfunctions. Once dried these malfunctions will cease.

PART(S) INFORMATION

PART(S) INFORMATION CHART

Part Numbers Description QTY Notes

38491-85Z40 Washer Back DoorHose

1 Reno

38491-85Z80 A-T/Gate Hose 1 Forenza Wagon

WARRANTY CLAIM INFORMATION

WARRANTY CLAIM INFORMATION

Page 1 of 23REAR WINDOW WASHER DOES NOT SPRAY -2007 Suzuki Reno

11/6/2011http://www.ondemand5.com/mric/common/asp/printart.aspx

LaborOperation

Description Failed PartNumber

ComplaintCode

DefectCode

LaborTime

SH9999 Washer BackDoor Hose

38491-85Z40 or38491-85Z80

37 29 0.5 Hrs.

FORENZA WAGON WASHER HOSE REPLACEMENT

Remove the back door upper trim to expose the washer hose connection to the washernozzle.

1.

Fig. 1: Removing Back Door Upper TrimCourtesy of SUZUKI OF AMERICA CORP.

Disconnect the hose from the nozzle.2.



Fig. 2: Disconnecting Hose From NozzleCourtesy of SUZUKI OF AMERICA CORP.

Remove the tape and pull the hose out of the door frame.3.



Fig. 3: Pulling Hose Out Of Door FrameCourtesy of SUZUKI OF AMERICA CORP.

Pull a section of the door seal away from the body just enough to uncover the edge of the"D" pillar trim panel. Remove the "D" pillar trim panel by pulling it away from the "D"pillar. Remove the tape and disconnect the washer hose.

4.



Fig. 4: Disconnecting Washer HoseCourtesy of SUZUKI OF AMERICA CORP.

Pull the grommet out of the door and the body to allow easy removal and installation ofthe washer hose.

5.

Install the hose through the grommet and re-insert the hose into the body first and makethe connection. (see step 4). This connection will gauge the hose length requirementthrough the back door.

6.

Insert the hose into the door. It may require some movement to get the hose past thehinge mounting bolts inside the door. Connect the hose to the washer nozzle.

7.

Re-tape the harness and hose to the tongue on the grommet at the door side and re-installthe grommet.

8.



Fig. 5: Identifying TongueCourtesy of SUZUKI OF AMERICA CORP.

Re-install the back door upper trim.9.



Fig. 6: Installing Back Door Upper TrimCourtesy of SUZUKI OF AMERICA CORP.

Remove the right rear side panel trim to inspect the C403 and C404 connectors for waterintrusion. Remove screw for the top of the trim panel near the seat belt.

10.

NOTE: The leaking fluid from the washer system could get into thethese electrical connectors and cause various electricalsystem malfunctions. Once dried these malfunctions willcease.



Fig. 7: Identifying Top Of Trim Panel ScrewCourtesy of SUZUKI OF AMERICA CORP.

Remove the screw at the rear of the trim panel at the end of the blind track and the boltfor the tie down.

11.



Fig. 8: Identifying Screw At Rear Of Trim PanelCourtesy of SUZUKI OF AMERICA CORP.

Pull the trim panel away from the interior.12.

Disconnect and dry out any connectors that are wet. Dry out any other visible moisture inthe area. Re-install the trim panel. Contact Suzuki Techline if corrosion or other damageto the connectors is observed.

13.



Fig. 9: View Of ConnectorsCourtesy of SUZUKI OF AMERICA CORP.

Re-install the "D" pillar trim panel and reinstall the weather seal. Make sure the weatherseal is seated properly around the entire opening.

14.



Fig. 10: Identifying Correct Weather Seal InstallationCourtesy of SUZUKI OF AMERICA CORP.

RENO WASHER HOSE REPLACEMENT

Remove the back door upper trim. Use a trim removal tool starting at the left or rightside of the trim panel. Do not pry against the window.

1.



Fig. 11: Locating ClipsCourtesy of SUZUKI OF AMERICA CORP.

Remove the two screws supporting the center brake light.2.



Fig. 12: Identifying Center Brake Light Supporting ScrewsCourtesy of SUZUKI OF AMERICA CORP.

Disconnect the light connector and set the brake light assembly aside.3.

Disconnect the washer nozzle hose.4.



Fig. 13: Disconnecting Washer Nozzle HoseCourtesy of SUZUKI OF AMERICA CORP.

Remove grommet from frame and door as described in Forenza Wagon step 5. Slide theharness and hose assembly out of the door.

5.



Fig. 14: Sliding Harness And Hose Assembly Out Of DoorCourtesy of SUZUKI OF AMERICA CORP.

Unwrap the tape from the removed hose and harness.6.

Remove the left rear "C" pillar trim by removing the three screws7.



Fig. 15: Identifying Left Rear C Pillar Trim ScrewsCourtesy of SUZUKI OF AMERICA CORP.

Remove the weather seal the front side of the "C" pillar trim panel. Then remove thepanel starting at the front of the panel.

8.



Fig. 16: Removing Weather Seal From Front Side Of C Pillar Trim PanelCourtesy of SUZUKI OF AMERICA CORP.

Disconnect the hose and remove the tape from the hose and harness. Remove the hosefrom the vehicle.

9.



Fig. 17: Disconnecting Hose And Tape From Hose And HarnessCourtesy of SUZUKI OF AMERICA CORP.

Insert the new hose through the body and grommet. (The nipple end goes to the door).Wrap the hose and brake light harness side by side with electrical tape at approximatelythe same dimensions shown.

10.



Fig. 18: Identifying Wrapping Tape DimensionsCourtesy of SUZUKI OF AMERICA CORP.

Wrap the harness and hose up to the opening where the harness goes into the door. Thenslide the hose and harness through the opening from which the harness was removed.The harness may get caught on the hinge bolts inside the door. It may take someinsertion angle changes of the harness to over come the hinge bolts.

11.



Fig. 19: Wrapping Harness And HoseCourtesy of SUZUKI OF AMERICA CORP.

Connect the hose to the washer nozzle.12.

Attach the harness and hose to the grommet tongue with electrical tape.13.



Fig. 20: Attaching Harness And Hose To Grommet TongueCourtesy of SUZUKI OF AMERICA CORP.

Insert both ends of the grommet into the body and door open.14.

Re-tape the hose to the harness inside the vehicle. It may be necessary to lower a sectionof the roof lining for access.

15.



Fig. 21: Retaping Hose To HarnessCourtesy of SUZUKI OF AMERICA CORP.

Re-connect the washer hose at the "C" pillar.16.

Inspect the C403 and C404 and dry out any connectors that are wet. Dry out any othervisible moisture in the area. Contact Suzuki Techline if corrosion or other damage to theconnectors is observed.

17.

NOTE: The leaking fluid from the washer system could get into thethese electrical connectors and cause various electricalsystem malfunctions. Once dried out these malfunctions willcease.



Fig. 22: Identifying ConnectorsCourtesy of SUZUKI OF AMERICA CORP.

Re-assemble the "C" pillar cover and weather stripping. Note step 14 in the ForenzaWagon instructions for weather stripping installation tips.

18.

© 2008 Mitchell Repair Information Co., LLC.



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ARTICLE BEGINNING AFFECTED VIN(S)