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Service Manual Update Headlight Installation (TS 05 10124)

Publication date: 2004-10-11
Reference number: TS 05 10124

SERVICE MANUAL UPDATE HEADLIGHT INSTALLATION

SERVICE MANUAL UPDATE HEADLIGHT INSTALLATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 05 10124, Date of Issue:  October 12, 2004
SUZUKI: 2002-2004, AERIO (RH420/RH423)
SECTION: Body, Cab & Accessories

CONDITION

Service Manual update additional instructions for headlight installation

CAUSE

To aid in proper alignment and fit of headlight assembly

CORRECTION

Please update your Service Manual according to the attached sheet

AFFECTED SERVICE MANUAL(S)

Manual Name Part Number Corresponding Page
2002 Aerio (RH420) Service Manual 99500-54G00-33E Page 9-92
2003 Aerio (RH420) Service Manual 99500-54G10-33E Page 9-86
2004 Aerio (RH423) Service Manual 99500-54G20-33E Page 9B-8
NOTE: Replace the "Repair Instructions" section with one shown below.

REPAIR INSTRUCTIONS

HEADLIGHT ASSEMBLY REMOVAL AND INSTALLATION OR HEADLIGHT HOUSING REMOVAL AND INSTALLATION

Removal
  1. Disconnect negative cable at battery.
  2. Remove front bumper. Refer to "Front Bumper and Rear Bumper Components:".
  3. Remove headlight mounting bolts and clip.
  4. Detach headlight assembly (1) from vehicle.
  5. Disconnect couplers (2) from headlight assembly (1).
    Fig 1: Removing Headlight Assembly
    G02569070Courtesy of SUZUKI OF AMERICA CORP.
Installation

Reverse removal procedure for installation noting the following.

  • Install headlight mounting bolts and clip, and then tighten headlight mounting bolts ("1"-"4") according to numerical order as shown in Fig 2 .
    Fig 2: Installing Headlight Assembly
    G02569071Courtesy of SUZUKI OF AMERICA CORP.