Recall KY - Replacement of Front Seat Belt Buckles

FORENZA

Section Title: Restraint
TSB No. TS 04 08227R2

Division: Automotive
Category: Technical

SUBJECT:
SAFETY RECALL CAMPAIGN "KY" FRONT SEAT BELT BUCKLE ASSEMBLY REPLACEMENT

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

YEAR:
2006~2007

AFFECTED VIN(S):
CERTAIN 2006~2007 SUZUKI FORENZA SEDAN
KL5JD56Z_6K234758~KL5JD56Z_7K597150
KL5JJ56Z_6K234758~KL5JJ56Z_7K597150

CERTAIN 2006~2007 SUZUKI FORENZA WAGON
KL5JD86Z_6K234754~KL5JD56Z_7K573827
KL5JJ86Z_6K234754~KL5JJ56Z_7K573827

CERTAIN 2006~2007 RENO HATCHBACK
KL5JD66Z_6K234759~KL5JD66Z_7K597082
KL5JJ66Z_6K234759~KL5JJ66Z_7K597082

REVISION:
KY Bolt Kit part number was listed incorrectly, please view "Parts Information" for correct part number.

NOTE:
VINs are non-consecutive. If an affected vehicle is in dealer inventory or the customer 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 seat belt buckle tongue will not latch in the buckle or latches and can easily be pulled out.

CAUSE:
Affected vehicles were produced with improperly manufactured driver and front passenger seat belt buckles. It is possible that plastic pieces inside the seat belt buckle can break oft and remain inside the buckle. The buckle could fail to latch or could seem to have latched without latching completely. If the buckle does not latch completely the buckle could release without pressing the release button. These buckle malfunctions which could prevent a person from using the seat belt or could cause the seat belt to fail to function as designed can increase the risk of injury in a crash.

CORRECTION:
Please replace the front left and right side seat belt buckle assemblies on all vehicles in the affected VIN range. Please note the mounting hardware will require updating on certain vehicles. See note below. Use the attached instructions for replacement.





NOTE:
Certain vehicles produced before December; 2005 have buckles with a smaller mounting hole which use the bolt and a steel lock washer shown in figure 1. That bolt and steel lock washer MUST NOT be re-used for the new buckle installation.

The CORRECT hardware shown in figure 2 must be used.

WARRANTY:
Please refer to the Campaign Bulletin SC-39 for claim submission instructions and labor times.





PART(S) INFORMATION:

Replacement Procedure:





1. Park the vehicle in an area where all of the doors can be opened and set the parking brake. Slide both front seats all the way forward.





2. Remove the screws indicated on both side of the center console.





3. With the parking brake set lift the center console from the rear as high as it will go without excessive force.





4. Slide the driver seat back, about 5 notches, to give access to the seat belt buckle bolt.





5. Note the routing of the buckle switch wire. Remove the wire tie and disconnect the electrical connector for the driver seat belt buckle switch.





6. Use a 17 mm socket with the appropriate length extension to remove the bolt. The bolt and washer(s) will be re-used.

7. Remove the buckle and install the new buckle with the bolt and washers shown below. Do not re-use bolt and steel lock washer on vehicles produced prior to December, 2005. Torque the bolt to 42 Nm (31 lb-ft).





8. Route the buckle switch wire along the same route of the original wire. Allow a small amount of slack in the wire to allow the belt buckle to move for and aft.

9. Wrap the belt switch wire around the adjuster shaft the same as before it was removed. Position the airbag harness and the switch harness to allow plenty of slack for the seat to move all the way forward and aft without putting any tension on the harness. Then wire tie both harnesses into position.

10. Re-connect the buckle switch connector. re-use





11. Slide the passenger seat 5 notches back and replace the buckle with the same process. The passenger buckle does not have a wiring harness. Do not remove any wire ties. Torque the bolt to 42 Nm (31 lb- ft).





12. Re-install the center console by sliding the front section into place first.





13. Engage the tabs properly before securing the console. Secure the console with the two removed screws from step 2.





14. Write your dealer number on the green "KY sticker and affix the "KY sticker to the core support. Campaign is complete.





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