Campaign NX - Long Brake Pedal Travel: Overview

Section Title: Brakes
TSB No. TS 03 02283

Division: Automotive
Category: Technical

SUBJECT:
CUSTOMER SATISFACTION CAMPAIGN: NX, Long Brake Pedal Travel

MODEL(S):
FORENZA (RQ420) Equipped with ABS brakes.

YEAR:
2008

PRODUCTION RANGE
KL5JD56Z18K862550 ~ KL5JD56Z58K865886

CONDITION:

Some customers may complain of long brake pedal travel and/or reduced brake performance.

CAUSE:
The change in brake pedal response is due to corrosion of the zinc plating on the ABS Hydraulic Modulator valve armature. This corrosion may lead to a gel build-up on the sides of the valve, which may affect the closing motion of the valve. There will be no loss of brake fluid no external leaking and no reduction in brake fluid level.

CORRECTION:
Suzuki dealers will test the ABS Hydraulic Modulator, and if it tests faulty, replace it. Also, Suzuki dealers are required to replace the brake system fluid with only Suzuki approved part number 990B0-99900-PKG brake fluid regardless of ABS Hydraulic Modulator condition.

NOTICE

Using brake fluid other than Suzuki approved brake fluid can cause damage and/or improper operation of this ABS Hydraulic Module.

Only use SUZUKI approved part number 990B0-99900-PKG brake fluid when completing this campaign.





PART(S) INFORMATION





WARRANTY INFORMATION

BULLETIN LAYOUT

This bulletin is comprised of four sections:

^ SECTION "A" - ABS Hydraulic Modulator Inspection

^ SECTION "B" - Brake Valve Cycling

^ SECTION "C" - ABS Hydraulic Modulator Replacement

^ SECTION "D" - Brake System Bleed Procedure

Section "A" - (ABS Hydraulic Modulator Inspection)
Will be your beginning point and will be completed for every vehicle. This section tests the condition of the ABS Hydraulic Modulator valves. Depending on the condition of the valves (pass or fail) sections "B" and "C" may or may not be necessary.

Section "B" - (Brake Valve Cycling)
Will be completed when all the ABS Hydraulic Modulator valves pass the inspection in section "A". In this case the ABS Hydraulic Modulator is not required to be replaced. However Brake Valve Cycling is necessary to cycle the old brake fluid from the existing modulator. Section "C" will not be necessary in this case.

Section "C" - (ABS Hydraulic Modulator Replacement)
Will be completed when any of the ABS Hydraulic Modulator valves fail the inspection in section "A". In this case the ABS Hydraulic Modulator will be replaced. The new modulator will come pre-filled with the required brake fluid, therefore the brake cycling procedure is not needed. Section "B" will not be necessary in this case.

Section "D" - (Brake System Bleed Procedure)
Section "D" contains the brake bleeding procedure for reference when called out in this bulletin.





Work Flow





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