KAMPANJE AZH : Skifte av støvdeksel

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1 KAMPANJE AZH : Skifte av støvdeksel Berørte modeller: Swift AZH type (produsert i Japan) fra 00 til 03. Kampanjen omfatter totalt 334 biler med chassisnummer mellom JSAFZD7S og JSAFZD7S Eierne kontaktes pr. brev datert fra Teknisk avdeling. NB! Alle bilene har eiere, men erfaring viser at biler som går på leasingavtaler ikke alltid følges opp. Sjekk derfor på Forhandlerweb om bilen skal ha utført kampanje. Ved tvil tar dere kontakt med teknisk avdeling. Problem/symptomer: Materialet i støvdeksel montert over støtdempere foran er ikke godt nok. Dette kan over tid føre til sprekker i dekselet medfølgende skade på støtdemper. Tiltak: Skifte støvdeksel over begge støtdempere foran, ref. vedlagte arbeidsbeskrivelse. Et par viktige punkter: Sjekk støvdeksel for sprekker før jobben starter slik at støtdemper(e) er tilgjengelig om skifte av denne/disse er nødvendig. Les nøye gjennom arbeidsbeskrivelsen før jobben gjøres. Delebehov: Ved skifte av bare støvdeksel: RX0 stk. inneholder stk. støvdeksel og 4 stk. muttere. Ved sprukket støvdeksel kommer støtdemper(e) i tillegg: 460-7L30-RX0 stk. støtdemper høyre side 460-7L30-RX0 stk. støtdemper venstre side Tilleggsinformasjon: Det er opprettet kampanje på skifte av støvdeksel. Det er da mulig å kontrollere om deres biler skal ha utført kampanjen via Forhandlerweb. Kampanjen er lagt inn med 4 varianter; A Skifte støvdeksel (,6 timer) B Skifte støvdeksel og støtdemper høyre side (,6 timer) C Skifte støvdeksel og støtdemper venstre side (,6 timer) D Skifte støvdeksel og støtdempere begge sider (,6 timer) Velg "Kampanjesøk" på "Dashbord" (den siden du kommer til ved innlogging) og legg inn registreringsnummer eller VIN. Om bilen er omfattet av kampanjen vises dette på skjermen. Kampanjesøk kan også gjøres før innlogging på Forhandlerweb. Liste med chassisnummer over berørte biler legges IKKE ved dette skriv. Bruk Forhandlerweb! Kampanje AZH Dato: Revisjon B

2 KAMPANJE AZH : Skifte av støvdeksel Ved reklamasjon: Legg inn chassisnummer/registreringsnummer under "Teknisk" / "Opprett Reklamasjon" på Forhandlerweb og trykk på "Søk". Trykk på "Velg" når bil kommer opp under "Søkeresultat" Du får nå valget mellom å opprette en blank reklamasjon eller en forhåndssøknad eller en kampanje. Merk av for kampanje AZH-4 "Skifte støvdeksel", fyll ut datoer, arbeidsordrenummer og kilometerstand og lagre. Ved siden av kampanjekode "AZH-4" velges riktig variant (A, B, C eller D). Rapporten fylles automatisk ut med arbeid og deler. Trykk så på "Send reklamasjon" nederst på siden. Rapport ferdig. Se også eget skriv angående kampanjesøk og innlegging av kampanjer som finnes på samme sted som dette skriv på RSA Ekstranett. Kampanje AZH Dato: Revisjon B

3 KAMPANJE AZH : Skifte av støvdeksel Vedlegg ARBEIDSBESKRIVELSE: Kampanje AZH Dato: Revisjon B

4 SWIFT Replacement Procedure for Strut Dust Cover Workflow. Confirmation of Affected Vehicle Page. Replacement of Strut Dust Cover Page ~ Strut Dust Cover Removal Front Strut Inspection Defective Not defective Replacement Strut dust cover Front strut Replacement Strut dust cover Front Strut Assembly Reassembly / Installation

5 . Confirmation of Affected Vehicle Check the vehicle identification number to see if the vehicle needs replacement of strut dust cover. Vehicle Identification Number (VIN) SWIFT (AZG4 / AZH4 / AZH44) Location: On the cowl top panel in the engine compartment. VIN

6 . Replacement of Strut Dust Cover -. Necessary Tool Conventional Tool Number Tool Name Comment Torque wrench.7 sq, N m Torque wrench 9.5 sq, 0 00 N m 3 Spinner handle.7 sq 4 Ratchet handle.7 sq 5 Ring wrench 7 9 mm 6 Ring wrench 4 mm 7 Socket 9.5 sq, short mm 8 Socket.7 sq, short 7 mm 9 Socket.7 sq, short 9 mm 0 Hexagon bit socket 9.5 sq, 6 mm Socket adapter sq Crowfoot wrench 4 mm, 9.5 sq 3 Crowfoot wrench 9 mm, 9.5 sq 4 Hexagon wrench 5 mm 5 Pliers Special Tool Special Tool Number Tool Name Spring Compressor

7 -. Replacement Part Mandatory Replacement Parts Part Number Part Name Qty. Components Strut dust cover ( pcs) Material symbol [EPDM] RX0 Strut dust cover set set Strut bracket nut (4 pcs) Optional Replacement Parts Part Number Part Name Remarks 460-7L0-RX L30-RX P00-RX L0-RX L30-RX P00-RX0 Front strut (right) Front strut (left) WD, Non-ENG A-STOP model 4WD WD, ENG A-STOP model WD, Non-ENG A-STOP model 4WD WD, ENG A-STOP model *If defect is found at inspection, replace only defective parts. 3

8 -3. Replacement procedure (Right and Left) [] Front Strut Assembly Components 0 9. Front strut 0. Strut rod cap Coil spring. Strut bracket bolt : Insert from vehicle front side. 3. Bump stopper. Stabilizer joint Strut dust cover : Set strut dust cover over the damper cap 3. Steering knuckle 5. Coil spring upper seat 4. Damper cap 6. Strut bearing :50 N m (5. kgf-m, 37.0 lbf-ft) 7. Strut bearing plate :90 N m (9. kgf-m, 66.5 lbf-ft) 8. Strut support : Do not reuse. 9. Rebound stopper [f] : Forward 3 [] Strut Dust Cover Removal NOTE Pulling steering knuckle outward with drive shaft fixed to steering knuckle could cause drive shaft to be removed from transaxle or intermediate shaft. Do not pull steering knuckle outward. If drive shaft is removed, replace drive shaft circlip with new one. ) Remove strut rod cap. NOTE When servicing strut assembly components, loosen strut support upper nut a little before removing strut assembly. This will facilitate service work. Note that the nut must not be removed at this point. ) Hoist vehicle, allowing front suspension to be free of vehicle weight and then remove front wheel. 4

9 3) Remove stabilizer joint nut (4) while holding stud using hexagon wrench () and then disconnect stabilizer upper joint () from strut (3) ) Remove brake hose mounting bolt () to detach brake hose (), front wheel speed sensor harness (3) and clip (7) from front strut (4) as shown in figure. 5) Remove strut bracket nuts (5) and bolts (6) ) Remove strut support upper nut () and rebound stopper (), and then remove front strut assembly from vehicle. NOTE Hold strut assembly by hand so that it will not fall off. 5

10 7) Attach special tool (A) to coil spring as shown. Screw in special tool bolts () alternately until coil spring tension is released from strut. Rotate strut to check that it is free of coil spring tension. Write down total length of compressed coil spring. Special Tool (A) : a (A) WARNING Failure to take proper precautions when compressing the coil spring can result in severe personal injury. Attach the spring compressors to the positions that allow an even spring compression. Do not use an impact wrench when compressing the coil spring. When using commercially available spring compressors, follow the manufacturer s instructions described in the manual attached to the spring compressors. 8) While keeping coil spring compressed using special tool, remove strut support lower nut () while holding strut rod (3) using hexagon bit socket () as shown in figure. 3 9) Remove strut support (), strut bearing plate (), strut bearing (3) and coil spring upper seat (4) in this order

11 0) Remove strut dust cover (), bump stopper () and coil spring (3). 3 7

12 [3] Front Strut Inspection Check right and left side front struts referring to a) and b) below. If any defect is found at a) or b), replace defective front strut. a) Check if any strut dust cover shard () is stuck in front strut sliding area. NOTE Using a light, check if any strut dust cover shard () remains stuck in sliding area. b) Shrink strut rod by hand to the bottom and then release it. Measure stroke a : how far strut rod has extended after 0 seconds. Stroke a How far strut rod has extended after 0 seconds. : 00 mm or more a 8

13 [4] Front Strut Assembly Reassembly / Installation ) Compress coil spring using special tool (A) until total length a becomes the same as that written down at step 7) in []. [u] [l] (A) [u] [l] Upper side (large diameter) Lower side (small diameter) a ) Install compressed coil spring to front strut by fitting coil spring end () to spring lower seat stepped end () as shown in figure 3) Install bump stopper (). 4) Set new strut dust cover () over three claws () of damper cap (3). 3 9

14 5) Pull strut rod (5) as far up as possible and then install coil spring upper seat (4), strut bearing (3), strut bearing plate () and strut support () in this order not to allow strut rod to retract into strut ) Tighten strut support lower nut () to specified torque while holding strut rod (3) using hexagon bit socket (). Tightening torque Strut support lower nut (a): 50 N m (5. kgf-m, 37.0 lbf-ft) 3, (a) NOTE When tightening strut support lower nut using crowfoot wrench on torque wrench, actual torque is bigger than torque wrench reading. For tightening using crowfoot wrench, calculate the torque wrench reading to which nut should be tightened according to the following formula. a Formula M = T x L / (L + a ) L M:Torque wrench reading (N m) T:Specified torque (N m) L:Torque wrench length (mm) a :Crowfoot wrench length(mm) e.g.) When tightening strut support lower nut using the following tools, tighten it to 46 N m according to the formula. Torque wrench length L = 30 mm Crowfoot wrench length a = 0 mm Specified torque of strut support lower nut T = 50 N m M = T x L / (L + a ) = 50 N m x 30 mm / (30 mm + 0 mm) = 46 N m 7) Remove special tool (spring compressor) from coil spring. Then, check that coil spring end does not ride on protrusion of spring lower seat. 0

15 8) Install front strut assembly to vehicle and then fix it using rebound stopper () and strut upper nut (). At this step, tighten strut upper nut temporarily by hand. 9) Insert strut bracket bolts () from vehicle front side and tighten new strut bracket nuts () to specified torque. Tightening torque Strut bracket nut (a) : 90 N m (9. kgf-m, 66.5 lbf-ft) NOTICE The strut bracket nut is pre-coated with friction stabilizer. If the nut is reused, it may work loose. Never reuse the strut bracket nut. 0) Install brake hose (3), front wheel speed sensor harness (5) and clip (6) to front strut (7) not to twist them. ) Tighten brake hose mounting bolt (4) to specified torque. Tightening torque Brake hose mounting bolt (b): 6 N m (.7 kgf-m, 9.5 lbf-ft) [f] 5 7 [f] Forward , (b), (a)

16 ) Install stabilizer upper joint () to front strut (3). Tighten stabilizer joint nut (4) to specified torque while holding stud using hexagon wrench (). Tightening torque Stabilizer joint nut (c): 50 N m (5. kgf-m, 37.0 lbf-ft) NOTE When tightening stabilizer joint nut using crowfoot wrench on torque wrench, calculate the torque wrench reading referring to NOTE at step 6) in [4]. 3 4,(a) 3) Install front wheel and tighten wheel nuts () to specified torque in sequence. Tightening order : Tightening torque Wheel nut (a): 85 N m (8.7 kgf-m, 63.0 lbf-ft), (a) 4) Lower hoist with vehicle in unloaded condition, and then tighten strut support upper nut () to specified torque. Tightening torque Strut support upper nut (a): 50 N m (5. kgf-m, 37.0 lbf-ft), (a) 5) Install strut rod cap. 6) Check front wheel alignment referring to the corresponding SWIFT service manual and adjust front wheel alignment if necessary.