Safety Recall Campaign 4013 2012-2013 SX4 Power Steering Pump (SC-83)

Publication date: 2019-10-18
Reference number: SC-83

SAFETY RECALL CAMPAIGN 4013 2012-2013 SX4 POWER STEERING PUMP

SERVICE CAMPAIGN BULLETIN

Reference Number(s): SC-83, Date of Issue: October 18, 2019

SUZUKI:	2012 - 2013 SX4
GROUP:	Automotive

AFFECTED MODELS

Certain 2012 - 2013 SX4 Vehicles (RX420)

AFFECTED DEPARTMENTS

Management, Service, Warranty, Parts

REFERENCE

Safety Recall Campaign "VS"

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2012 - 2013 model-year SX4 vehicles.

SERVICE PROVIDER CAMPAIGN RESPONSIBILITY

Suzuki Service Providers will complete this important safety recall campaign on all affected vehicles, including branded title vehicles. This repair must be performed regardless of vehicle age or mileage, and at no charge to the customer. When contacted by the customer, Suzuki Service Providers need to schedule an appointment to perform the campaign service and order required parts.

If you have questions, please contact your Suzuki District Service and Parts Manager (DSPM) or the Warranty Assistance Help-Line at (714) 996-7042.

What is the problem?

In 2015, Suzuki Motor of America, Inc. (Suzuki) initiated a safety recall (Recall 15V-587) for certain 2012 - 2013 model-year SX4 vehicles, which involved replacing the power steering pump assembly. The reason for the safety recall was that under certain operating conditions, insufficient clearance between the power steering pump body and the fluid control valve may cause improper movement of the valve, which can lead to seizure of the power steering pump. If the power steering pump seizes, the pump system cannot provide steering assist, which could increase the risk of a crash.

Suzuki Motor Corporation has now determined that, even with the Recall 15V-587 countermeasure power steering pump, during cold-weather starting conditions, the internal hydraulic pressure inside the power steering pump may rise, resulting in steering operation becoming heavy, and the pump potentially seizing. As with the safety recall noted above, if the power steering pump seizes, it will require the driver to use increased steering effort, increasing the risk of a crash.

Campaign 4013 replaces the VS campaign. However, if the VS campaign repair was performed prior to the publication date of this Technical Service Bulletin (TSB), SMAI will continue to accept VS claims for a limited time with prior authorization.

In addition, the Campaign 4013 repair must be performed on all affected vehicles, even if previously repaired under the VS safety recall as noted above.

AFFECTED MODELS

2012 MODEL-YEAR SX4 (RW420) VIN RANGE	2013 MODEL-YEAR SX4 (RW420) VIN RANGE
JS2YA5A1#C6300001 to JS2YA5A1#C6300280	JS2YA5A1#D6100020 to JS2YA5A1#D6100242
JS2YA5A3#C6300022 to JS2YA5A3#C6300357	JS2YA5A3#D6100001 to JS2YA5A3#D6100128
JS2YA5A5#C6300204 to JS2YA5A5#C6300899	JS2YA5A5#D6100002 to JS2YA5A5#D6100291
JS2YA5A7#C6300096 to JS2YA5A7#C6300229	JS2YA5A7#D6100001 to JS2YA5A7#D6100209
JS2YB5A3#C6301674 to JS2YB5A3#C6308840	JS2YB5A3#D6100002 to JS2YB5A3#D6102811
JS2YB5A7#C6300012 to JS2YB5A7#C6300334	JS2YB5A4#D6100001 to JS2YB5A4#D6100748
JS2YC5A1#C6300001 to JS2YC5A1#C6300008	JS2YB5A7#D6100004 to JS2YB5A7#D6100221
JS2YC5A3#C6301505 to JS2YC5A3#C6305832	JS2YC5A1#D6100011 to JS2YC5A1#D6100012
JS2YC5A5#C6300181 to JS2YC5A5#C6300410	JS2YC5A3#D6100001 to JS2YC5A3#D6103180
JS2YC5A9#C6300274 to JS2YC5A9#C6300650	JS2YC5A5#D6100002 to JS2YC5A5#D6100042
	JS2YC5A9#D6100001 to JS2YC5A9#D6100647

Verify if the vehicle is affected by the campaign:

Confirm the recall campaign status by checking the VIN on the driver's side dashboard against the Vehicle Master Inquiry in Suzuki Connect to see if the power steering pump needs to be replaced. If you have a question regarding vehicle eligibility, contact the Suzuki Motor of America, Inc. (Suzuki) Warranty Department.

What you will do as a Suzuki Service Provider:

Replace the power steering pump assembly and power steering fluid.
Submit a warranty claim.

What Suzuki Motor of America, Inc. (Suzuki) will do:

During the week of October 21, 2019, Suzuki will mail notification letters to owners of affected vehicles for whom we have information. The letter instructs the customer to contact a Suzuki Service Provider to schedule an appointment.

PARTS ORDERING

Parts for this campaign are available now.
Use the normal parts ordering procedure to order the parts needed for vehicles in your inventory or for customer vehicles in your shop.
If you have any questions related to parts ordering, contact Suzuki National Parts Coordination at (714) 854-2165.

NOTE:

To simplify the ordering process, Suzuki has created a part number specifically for a parts kit that includes the countermeasure parts needed for this repair (power steering pump and power steering fluid).
This part number listed below is only to be used for ordering the parts kits for this repair.
If you attempt to use the parts kit part number to submit a warranty claim to suzuki, the warranty claim will be rejected.

PARTS ORDERING INFORMATION

Parts Kit Name	Parts Kit Number	Qty. Required
Power Steering Pump Set	99963-PPKIT-SX4 Includes: Power Steering Pump Assembly & Pressure (1) Pipe Gasket (1) Power Steering Fluid (2)	1

CONTENTS FOR PARTS KIT 99963-PPKIT-SX4:

Power Steering Pump Assembly with identification mark

Power steering Fluid

Presure Pipe Gasket

WARRANTY CLAIM PROCESSING

Submit a warranty claim for each safety recall campaign service immediately upon completion of the repair. This campaign requires you to file a warranty claim using ONE of the methods described below:

SUZUKI CONNECT SHORT CAMPAIGN CLAIM

A Short Campaign Claim will reimburse you for replacement of the power steering pump assembly, the required power steering fluid, and the replacement labor time of 1.1 hours.

CAMPAIGN 4013 SX4 POWER STEERING SUZUKI CONNECT SHORT FORM INSTRUCTIONS

CLAIM INFORMATION
CLAIM NUMBER:	XXXXX, X (Service Providers enters number)
ENTRY TYPE:	Vehicle Identification Number (VIN)
VIN:	XXXXXXXXXXXXXXXXX
REPAIR DATE:	Enter date of repair
MILEAGE:	Enter mileage at repair date
CAMPAIGN NUMBER:	4013
VARIATION CODE:	JB

SUZUKI CONNECT LONG CAMPAIGN CLAIM

The Long Campaign Claim entry should be used only if additional parts or labor are required to complete the Recall Campaign service. A Long Campaign Claim requires prior DSPM authorization.

CAMPAIGN 4013 SX4 POWER STEERING SUZUKI CONNECT LONG FORM INSTRUCTIONS

CLAIM INFORMATION
CLAIM NUMBER:	XXXXX, X (Service Provider enters number)
ENTRY TYPE:	Vehicle Identification Number (VIN)
VIN	XXXXXXXXXXXXXXXXX
REPAIR DATE:	Enter date of repair
MILEAGE:	Enter mileage at repair date
CAMPAIGN NUMBER:	4013
VARIATION CODE:	JK
LABOR OPERATION:	LJ9999
LABOR HOURS:	As authorized by your DSPM

PARTS INFORMATION
FAILED PART NUMBER:	49100-54812-RX0 (1) 99000-22BA0-RX0 (2)
REPLACEMENT PARTS AND QUANTITIES:	As authorized by your DSPM
AUTHORIZATION NUMBER:	Issued by DSPM
FAILURE DESCRIPTION
DEFECT DESCRIPTION:	Performed recall repair
REPAIR DESCRIPTION:	Performed recall repair
SUBLET INFORMATION:	Sublet Expenses (only as authorized by your DSPM)

REPAIR PROCEDURE

NOTE: Record the clock and audio settings before disconnecting the battery so you can restore them after the repair is complete.

Disconnect the negative (-) battery cable from the battery.
Remove the power steering fluid from the reservoir using a dropper or other such tool (1).

NOTE: If care is not used when removing the engine cover, it can hit the cowling front panel, and damage the cover.
Remove the engine cover carefully so that it does not hit other components.
Remove the engine cover:
Disconnect the engine cover hose (1) from the air cleaner assembly. Then disconnect the front (2) and rear (3) side hooks from the engine cover pins.
Disconnect the IMT valve actuator connector (1) and harness clamp (2).
Disconnect the suction hose clamp (3).
Clean the high pressure pipe (1) joints and suction hose (2) before removing them.
Remove the high pressure pipe and the suction hose from the power steering pump assembly (3).
NOTE: The power steering system can be damaged if foreign material or debris gets in the suction hose.
Be sure to immediately plug the suction hose after disconnecting it.
Disconnect the lead wire (1) of the power steering pump pressure switch at the switch terminal (2).
Remove the accessory drive belt:
1. Hoist the vehicle.
2. Remove the right engine undercover (1) by removing the bolts (2), screws (3) and clips.
3. Loosen the belt tension by turning the tensioner (1) clockwise.
4. While keeping the tensioner loose, remove the accessory drive belt (2).
Remove the power steering pump mounting bolts (1), then remove the power steering pump assembly (2) from the brackets (3).

Install the new power steering pump assembly (1) and tighten the mounting bolts (2) to the specified torque.

Tightening Torque: Power Steering Pump Mounting Bolts (a) 25 N.m (92.5 kgf-m, 18.5 lbf-ft)

NOTE:

Use a torque adapter, which is attached to a torque wrench, when tightening "A".

When using a torque adapter on a torque wrench, calculate the torque wrench reading to the bolt being tightened using the following formula:

M = T x L (L + "x")

M: Torque wrench reading (N.m)

T: Specified torque (N.m)

L: Torque wrench length (mm) "x": Torque adapter length (mm)

For example:

When tightening the power steering pump mounting bolt using the following tools, tighten it to 20 N.m according to the formula.

Torque wrench length L = 200mm
Torque adapter length "x" = 50mm
Specified torque of the power steering pump mounting bolt T = 25 N.m

M = T x L/(L + "a") = 25 N.m x 200mm (200mm + 50mm) = 20 N.m

Install the accessory drive belt:
1. Hoist the vehicle.
2. Loosen the belt tension by turning the tensioner (1) clockwise with a torque wrench.
  NOTE: Over-tightening the tensioner may damage it.
  Be careful not to turn the tensioner pulley more than 59 N.m (6.0 kgf-m, 43.5 lbf-ft) using a torque wrench.
3. While keeping the tensioner loose, install the accessory drive belt (2).
Connect the lead wire (1) of the power steering pump pressure switch to the switch terminal (2).
Connect the suction hose (1) to the power steering pump assembly (2) and secure it with a clamp (6).
Install a high pressure pipe (3) with a new pressure pipe gasket (4), then tighten the high pressure pipe union bolt (5) to the specified torque.
Torque Specification: High Pressure Pipe Union Bolt (a) 65 N.m (6.6 kgf-m, 48.0 lbf-ft)
Connect the suction hose clamp (3).
Connect the IMT valve actuator connector (1) and harness clamp (2).
Install the engine cover.
Connect the negative (-) battery cable to the battery.
Bleed the power steering system:
NOTE: The power steering system will be damaged if the power steering fluid is contaminated by foreign material.
Use a clean container of power steering fluid that is not contaminated when adding fluid to the system.
1. Hoist the front end of the vehicle and place safety stands under it.
2. Fill the power steering fluid reservoir with fluid up to the specified level.
  You are required to use the power steering fluid provided in the Suzuki parts kit.
  
  99000-22BA0-RX0 (Qty 2)
3. Shift the gear shift lever into neutral (M/T) or into the P range (CVT model), and apply the parking brake.
4. Start the engine.
5. Let the engine idle for 3 - 5 seconds, then turn it OFF and check the power steering fluid level. If necessary, add more fluid to the specified level.
6. With the engine OFF, turn the steering wheel to the right until it stops, then turn it to the left until it stops.
  Repeat this 3 times, then check the power steering fluid level and add more fluid if necessary.
7. Start the engine and let it idle, then turn the steering wheel both right and left from stop to stop until all the foam in the power steering fluid reservoir is gone.
8. Check that the power steering fluid level is between the UPPER and LOWER marks on the reservoir.
  NOTE: If air remains in the power steering fluid, the power steering pump may make a humming noise or the steering may feel heavy while turning the vehicle.
  Be sure the air is completely bled out of the power steering system.
Replace the power steering fluid using the fluid provided in the parts kit as follows:
1. Using a dropper or other such tool, remove as much of the power steering fluid from the reservoir as possible.
2. Fill the reservoir with the new power steering fluid noted above to the UPPER mark.
3. Start the engine.
4. With the engine running at idling speed, turn the steering wheel to the right and to the left 5 or 6 times each until it cannot be turned any farther.
5. Stop the engine.
6. Repeat steps A - E until you've used all the new power steering fluid provided in the parts kit.
7. Adjust the fluid level in the reservoir so it is between the UPPER and LOWER marks.
Install the right engine undercover.
Lower the vehicle on the lift.
Perform the electronic throttle control system calibration by doing the following:
1. Turn the engine OFF.
2. Turn the ignition switch ON without starting the engine for 5 seconds.
3. Check that a diagnostic trouble code (DTC) is not set.
For ESP® models, perform the sensor calibration:
NOTE: If any DTC other than C1075 is detected, the sensor calibration cannot be completed. Repair the other detected DTC first.

METHOD USING THE SUZUKI SCAN TOOL:
1. Set the steering wheel in the straight ahead position.
2. Connect the Suzuki Scan tool (Suzuki SDT or Suzuki SDT-II) to the DLC with the ignition OFF.
3. Turn the ignition ON and confirm that only DTC C1075 is detected. If any other DTCs are detected, repair them before completing the rest of this procedure.
4. Park the vehicle on a level surface with the parking brake applied, stop the engine, but leave the ignition switch turned to the ON position. Then set the steering wheel in straight ahead position without pressing down on the brake pedal, and wait for the sensor calibration to finish.
5. Under the Utility mode of the Scan tool, select Sensor Calibration.
  After completing the calibration, turn the ignition OFF and disconnect the Scan tool from the DLC.
METHOD NOT USING THE SUZUKI SCAN TOOL:
1. Set the steering wheel in the straight ahead position.
2. Confirm the battery terminals and related fuses are securely installed (if they were removed previously).
3. Start the engine.
  NOTE: If power to the steering angle sensor is removed, DTC C1075 will be detected and the ESP OFF indicator (1) will turn on. If any other indicator turns on, a DTC other than C1075 may have been detected - diagnose the other DTC before C1075.
4. Drive straight at approximately 22 mph or more for 10 seconds or more.
Restore the customer's clock and audio presets.

OWNER NOTIFICATION LETTER

SUZUKI MOTOR OF AMERICA, INC.

IMPORTANT SAFETY RECALL

This Notice Applies to Your Suzuki Vehicle Identification Number (VIN)

XXXXXXXXXXXXXXXXX

October 25, 2019

Dear Suzuki Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2012 - 2013 model-year Suzuki SX4 vehicles. According to our records, you own one of the vehicles affected by this recall.

What is the problem?

This new recall repair must be performed on all affected vehicles, even if previously repaired under the safety recall as noted above.

What is Suzuki Motor of America, Inc. (Suzuki) doing to solve the problem?

Your Suzuki Service Provider will replace the power steering pump assembly and the power steering fluid. This procedure will take approximately two hours to complete. Parts are available now, and there will be no charge to you for any recall campaign service-related parts or labor.

What you should do:

Make sure you are prepared for the service by taking the following steps:

Before taking your vehicle to your Suzuki Service Provider, contact them as soon as possible to set up an appointment for the service.
We suggest that you bring this letter to your Suzuki Service Provider to help them process your vehicle for repair.

3251 E. Imperial Highway, P.O. Box 1100, Brea, CA 92822-1100

Phone (714) 996-7040

What to do if you receive this letter in error:

This notice was mailed to you according to the most current information we have available. If you no longer own the Suzuki vehicle described in this letter, please forward this campaign information to the current owner (if known), or contact the Suzuki Automotive Customer Relations Department at (714) 572-1490.

Federal regulations require that any vehicle lessor receiving this campaign notice must forward a copy of this notice to the lessee within ten days.

Customer reimbursement for repairs prior to this Safety Recall Notification:

If your vehicle is included in this recall and you have paid for repairs to address the defect that led to this recall, you may be eligible for full or partial reimbursement. Please note the following conditions for reimbursement:

Only repairs made to address the defect that led to this recall are reimbursable. Additional expenses such as towing, car rental, accommodations, damage repairs, etc., will not be reimbursed. Reimbursement will not be provided for routine scheduled maintenance.
Reimbursement may be limited to the suggested list price for parts, the Suzuki published flat-rate time allowance for the repair, and the labor rate that an authorized Suzuki Service Provider in the same area would charge for the same repair.
Reimbursement claims may also be excluded when adequate documentation is not submitted by the claimant. This includes a proof of ownership, a repair order, and proof of payment for the repair.

To apply for reimbursement, contact Suzuki's Customer Service Department at (714) 572-1490.

Who to contact if you experience problems:

Your Suzuki Service Provider can provide you the fastest response to your questions or concerns about this safety recall campaign. If you have any difficulty with this recall campaign, you may contact Suzuki's Customer Service Department for assistance at (714) 572-1490 during the hours of 7:00 AM to 4:30 PM Pacific Time. Please have your vehicle identification number (VIN) ready when calling. The VIN for your vehicle is listed at the top of this notice.

If you need to locate your nearest Suzuki Service Provider, please visit www.suzuki.com , click on Automotive , followed by the Service Provider tab at the top of the web page.

If you believe that Suzuki has failed to provide the safety recall campaign service without charge or is unable to do so within a reasonable time, you may submit a complaint to the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington D.C., 20590 or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-888-424-9153) or go to www.safercar.gov.

We apologize for any inconvenience this recall campaign causes you. We hope you understand that your safety and satisfaction are important priorities for us.

We sincerely regret any inconvenience this Important Safety Recall may cause, but we are certain you understand our interest in your safety and your continued satisfaction with your Suzuki vehicle.

Sincerely,

Suzuki Motor of America, Inc.