Rear Window Washer Does Not Spray (TS 12 02088)

REAR WINDOW WASHER DOES NOT SPRAY

TECHNICAL SERVICE BULLETIN

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 too hard. During cold weather the hose can crack when flexed. Also, if the washer fluid is pure water instead of washer solvent, the water could freeze and rupture the hose or cause the hose to disconnect.

CORRECTION

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

PART(S) INFORMATION

Part Numbers	Description	QTY	Notes
38491-85Z40	Washer Back Door Hose	1	Reno
38491-85Z80	A-T/Gate Hose	1	Forenza Wagon

WARRANTY CLAIM INFORMATION

Labor Operation	Description	Failed Part Number	Complaint Code	Defect Code	Labor Time
SH9999	Washer Back Door Hose	38491-85Z40 or 38491-85Z80	37	29	0.5 Hrs.

Forenza Wagon Washer Hose Replacement

1. Remove the back door upper trim to expose the washer hose connection to the washer nozzle.
   Fig 1: Removing Back Door Upper Trim

   Courtesy of SUZUKI OF AMERICA CORP.
2. Disconnect the hose from the nozzle.
   Fig 2: Disconnecting Hose From Nozzle

   Courtesy of SUZUKI OF AMERICA CORP.
3. Remove the tape and pull the hose out of the door frame.
   Fig 3: Pulling Hose Out Of Door Frame

   Courtesy of SUZUKI OF AMERICA CORP.
4. 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.
   Fig 4: Disconnecting Washer Hose

   Courtesy of SUZUKI OF AMERICA CORP.
5. Pull the grommet out of the door and the body to allow easy removal and installation of the washer hose.
6. Install the hose through the grommet and re-insert the hose into the body first and make the connection. (see step  4). This connection will gauge the hose length requirement through the back door.
7. Insert the hose into the door. It may require some movement to get the hose past the hinge mounting bolts inside the door. Connect the hose to the washer nozzle.
8. Re-tape the harness and hose to the tongue on the grommet at the door side and re-install the grommet.
   Fig 5: Identifying Tongue

   Courtesy of SUZUKI OF AMERICA CORP.
9. Re-install the back door upper trim.
   Fig 6: Installing Back Door Upper Trim

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove the right rear side panel trim to inspect the C403 and C404 connectors for water intrusion. Remove screw for the top of the trim panel near the seat belt.
    NOTE: The leaking fluid from the washer system could get into the these electrical connectors and cause various electrical system malfunctions. Once dried these malfunctions will cease.
    Fig 7: Identifying Top Of Trim Panel Screw

    Courtesy of SUZUKI OF AMERICA CORP.
11. Remove the screw at the rear of the trim panel at the end of the blind track and the bolt for the tie down.
    Fig 8: Identifying Screw At Rear Of Trim Panel

    Courtesy of SUZUKI OF AMERICA CORP.
12. Pull the trim panel away from the interior.
13. Disconnect and dry out any connectors that are wet. Dry out any other visible moisture in the area. Re-install the trim panel. Contact Suzuki Techline if corrosion or other damage to the connectors is observed.
    Fig 9: View Of Connectors

    Courtesy of SUZUKI OF AMERICA CORP.
14. Re-install the "D" pillar trim panel and reinstall the weather seal. Make sure the weather seal is seated properly around the entire opening.
    Fig 10: Identifying Correct Weather Seal Installation

    Courtesy of SUZUKI OF AMERICA CORP.

Reno Washer Hose Replacement

1. Remove the back door upper trim. Use a trim removal tool starting at the left or right side of the trim panel. Do not pry against the window.
   Fig 11: Locating Clips

   Courtesy of SUZUKI OF AMERICA CORP.
2. Remove the two screws supporting the center brake light.
Fig 12: Identifying Center Brake Light Supporting Screws
Courtesy of SUZUKI OF AMERICA CORP.
3. Disconnect the light connector and set the brake light assembly aside.
4. Disconnect the washer nozzle hose.
   Fig 13: Disconnecting Washer Nozzle Hose

   Courtesy of SUZUKI OF AMERICA CORP.
5. Remove grommet from frame and door as described in Forenza Wagon step  5. Slide the harness and hose assembly out of the door.
Fig 14: Sliding Harness And Hose Assembly Out Of Door
Courtesy of SUZUKI OF AMERICA CORP.
6. Unwrap the tape from the removed hose and harness.
7. Remove the left rear "C" pillar trim by removing the three screws
   Fig 15: Identifying Left Rear C Pillar Trim Screws

   Courtesy of SUZUKI OF AMERICA CORP.
8. Remove the weather seal the front side of the "C" pillar trim panel. Then remove the panel starting at the front of the panel.
   Fig 16: Removing Weather Seal From Front Side Of C Pillar Trim Panel

   Courtesy of SUZUKI OF AMERICA CORP.
9. Disconnect the hose and remove the tape from the hose and harness. Remove the hose from the vehicle.
   Fig 17: Disconnecting Hose And Tape From Hose And Harness

   Courtesy of SUZUKI OF AMERICA CORP.
10. 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 approximately the same dimensions shown.
    Fig 18: Identifying Wrapping Tape Dimensions

    Courtesy of SUZUKI OF AMERICA CORP.
11. Wrap the harness and hose up to the opening where the harness goes into the door. Then slide 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 some insertion angle changes of the harness to over come the hinge bolts.
    Fig 19: Wrapping Harness And Hose

    Courtesy of SUZUKI OF AMERICA CORP.
12. Connect the hose to the washer nozzle.
13. Attach the harness and hose to the grommet tongue with electrical tape.
Fig 20: Attaching Harness And Hose To Grommet Tongue
Courtesy of SUZUKI OF AMERICA CORP.
14. Insert both ends of the grommet into the body and door open.
15. Re-tape the hose to the harness inside the vehicle. It may be necessary to lower a section of the roof lining for access.
    Fig 21: Retaping Hose To Harness

    Courtesy of SUZUKI OF AMERICA CORP.
16. Re-connect the washer hose at the "C" pillar.
17. Inspect the C403 and C404 and dry out any connectors that are wet. Dry out any other visible moisture in the area. Contact Suzuki Techline if corrosion or other damage to the connectors is observed.
    NOTE: The leaking fluid from the washer system could get into the these electrical connectors and cause various electrical system malfunctions. Once dried out these malfunctions will cease.
    Fig 22: Identifying Connectors

    Courtesy of SUZUKI OF AMERICA CORP.
18. Re-assemble the "C" pillar cover and weather stripping. Note step  14 in the Forenza Wagon instructions for weather stripping installation tips.