38410-94550 Suzuki TRIM RELAY, UP

This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4244" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
November 30, 1998Problem
The fuel air ratio control group with air-actuated override system may fail to operate correctly under certain field conditions.
Affected Product
Model & Identification Number
3208 (03Z13826, 03Z14546, 03Z14621, 03Z14765, 03Z14875, 03Z14877, 03Z14974, 03Z14976-14989 , 03Z14991-14993, 03Z15139, 03Z15142, 03Z15144, 03Z15146 , 03Z15149, 03Z15151-15154, 03Z15164, 03Z15166, 03Z15173, 03Z15176 , 03Z15178, 03Z15180, 03Z15189, 03Z15191, 03Z15192, 03Z15201, 03Z15209 , 03Z15211, 03Z15213, 03Z15215, 03Z15216, 03Z15219, 03Z15285, 03Z15292 , 03Z15293, 03Z15306, 03Z15307, 03Z15325, 03Z15359, 03Z15361, 03Z15365 , 03Z15368, 03Z15370, 03Z15371, 03Z15373, 03Z15375, 03Z15377, 03Z15379 , 03Z15381, 03Z15382, 03Z15384, 03Z15397, 03Z15412)
Parts Needed
2 - 3E4352 Washer1 - 6L5766 Gasket1 - 5M2894 Washer3 - 6N7523 Washer1 - 5P3456 Seal-O-Ring1 - 5P8245 Washer1 - 2R1913 Strap1 - 0S0509 Bolt3 - 0S1588 Bolt2 - 0S1616 Bolt2 - 0S1617 Bolt1 - 0S1620 Bolt1 - 9U2277 Clip Assembly1 - 2W5447 Gasket3 - 9X6458 Washer1 - 1287793 Bolt1 - 1318201 Clip1 - 1318202 Clip1 - 1413270 Harness Assembly1 - 1413271 Bracket Assembly1 - 1413276 Mount1 - 1413277 Cover1 - 1439368 Solenoid AssemblyAction Required
Replace the air-actuated fuel air ratio control override system with an electric solenoid override system. See the attached rework procedure.
Service Claim Allowances
In most cases, this Program can and should be completed at the customer site.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
1. Remove the hood assembly from the machine for access to the engine and Fuel Air Ratio Control (FARC) system components. Bleed the machine air system pressure down to zero by loosening appropriate fitting(s) at the firewall-mounted regulator, connections to the OEM air supply for the FARC override, etc..2. Loosen the alternator belt tension and alternator pivot bolt. Disconnect the tensioning rod assembly from the 4N9319 Support Bracket (attached to the top of front housing), and swing the alternator outboard.3. Remove all parts of the air-actuated fuel ratio control override group (1431310) except for the 9L5125 Elbow (45-degree) on the air intake manifold. Reinstall the short (13.5 inch long) hose 3N4579 at the port in the FARC and connect to the 9L5125 Elbow. All other parts removed from the 1431310 group should be discarded. Reconnect the customer (OEM) air line(s) where the 0520572 Tee was removed to provide correct charging and operation of the OEM air system. See Illustration 1.4. Remove the Fuel Shutoff Solenoid and save for reinstallation later in this procedure.5. Remove only the top adjustment cover and gasket from the fuel air ratio control. Discard the cover and bolts.6. Install the new gasket (6L5766), adjustment cover (1413277), seal-o-ring (5P3456), and mount (1413276) to the top of the FARC using (3) 6N7523 Washers, (2) 0s1616 Bolts, and (1) 1287793 Tamperproof Bolt (reference 1471662 Protection Group). See Illustration 2.7. Re-install the fuel shutoff solenoid using the new 2W5447 Gasket. The shutoff solenoid must be oriented as shown in Illustration 3. 8. Install the electric (12V) override solenoid (1439368) into mount on the top of the FARC. A spanner wrench is being developed to fit this solenoid, but is not yet available. A strap-type wrench, such as 2P8250, may be used. Tighten the solenoid to a torque of 20 N m (15 lb ft). Install the 1413271 Bracket Assembly, clips, etc., for securing the solenoid as shown in Illustration 4. It is very important to follow the bolt tightening procedure shown to assure proper alignment:(a) Finger tighten bolts "A" (solenoid and alternator tensioning brackets to front housing).(b) Tighten bolts "B" to 25 6 N m (18 4.5 lb ft).(c) Tighten bolts "A" to 47 9 N m (35 7 lb ft).(d) Tighten bolts "C" to 47 9 N m (35 7 lb ft).Install the 1413270 Wiring Harness Assembly, clips, etc., as shown in Illustration 4.
9. Attach the alternator tensioner rod. Adjust belts to proper tension and secure alternator, etc..10. Test FARC override system for proper operation. The solenoid should be activated whenever the starter is cranking (key in "start" position). Start the engine and allow the OEM air system to fully charge. Check for air leaks.11. Re-install the hood, etc., to complete the repair.
Illustration 1.
Illustration 2.
Illustration 3.
Illustration 4.