Emissions - Refuel Vapor Control Valve Damaged/MIL ON Section Title: Engine TSB No. TS R

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1 1999 Suzuki Esteem GL Sedan L4-1.8L Page 1 Technical Service Bulletin # TS02R Date: Emissions - Refuel Vapor Control Valve Damaged/MIL ON Section Title: Engine TSB No. TS R Division: Automotive Category: Esteem SUBJECT: REFUEL VAPOR CONTROL VALVE MODEL(S): ESTEEM YEAR: AFFECTED VIN(S): ALL L SEDANS & WAGONS ALL L SEDANS CONDITION: These vehicles may have damage to the refuel vapor control valve due to interference with the body panel. If the refuel vapor control valve is damaged the Malfunction Indicator Lamp (MIL) will illuminate. CAUSE: In certain cases the refuel vapor control valve may come into contact with the underside of floor panel just above the fuel tank. This may cause damage to the refuel vapor control valve. A damaged refuel vapor control valve will allow fuel vapors to enter the atmosphere. CORRECTION: Inspect the gap between the fuel tank and the underside of the floor panel. Install a pad to the refuel vapor control valve and if necessary replace the refuel vapor control valve. PART(S) INFORMATION: Disclaimer A. Vehicle Inspection Procedure

2 1999 Suzuki Esteem GL Sedan L4-1.8L Page 2 Using the vehicle VIN perform a CLAIM HISTORY INQUIRY and inspect for a DG STICKER on the vehicle (Figure 1). - If the CLAIM HISTORY INQUIRY states DG NOT YET PERFORMED and a DG STICKER is not present proceed to B. REPAIR PROCEDURE." - If the CLAIM HISTORY INQUIRY states DG NOT YET PERFORMED and a DG STICKER is present, contact ASMC Warranty Department (800) They will update vehicle claim history. - If the CLAIM HISTORY INQUIRY states DG ALREADY PERFORMED and a DG STICKER is present, return the vehicle to the customer or dealer inventory. No further action is needed. - If the CLAIM HISTORY INQUIRY states DG ALREADY PERFORMED and a DG STICKER is NOT present, proceed to D. CAMPAIGN STICKER INSTALLATION PROCEDURE." B. Fuel Tank Measurement Procedure 1. Hoist vehicle. 2. Locate the measuring gauge enclosed with this bulletin and identify the end of the measuring gauge stamped 99, 00MY". This end of the gauge is 18 mm high (Figure 2). NOTE: Additional gauges are available via ASMC's Parts Department.

3 1999 Suzuki Esteem GL Sedan L4-1.8L Page 3 3. Refer to Figure 3 for the measuring location under the vehicle. Using the 18 mm end of the gauge measure and note the clearance between the fuel tank flange and the underside of the floor panel as shown in Figure 4. If the clearance is more than 18 mm the vehicle's fuel tank needs to be removed refuel vapor control valve inspected for damage the valve's hose clamp tabs adjusted a valve pad installed and the fuel tank reinstalled with more than 18 mm of fuel tank flange clearance. NOTE: In reference to the above, it is not necessary to replace the refuel vapor control valve unless it is damaged. ^ If the clearance is less than 18 mm the vehicle's fuel tank needs to be removed the refuel vapor control valve replaced the valve's hose clamp tabs adjusted a valve pad installed and the fuel tank reinstalled with more than 18 mm of fuel tank flange clearance. 4. Proceed to C. REPAIR PROCEDURE." C. Repair Procedure 1. Release vehicle fuel pressure using the following procedure: CAUTION: Make sure that the engine is cold before releasing the fuel pressure. Damage to the catalyst may occur if this procedure is done when the engine is hot. A. Place the transmission gear shift in Neutral (M/T) or Park (A/T), set the parking brake and block the drive wheels. B. Remove the fuel filler cap to release fuel vapor pressure in the fuel tank. Reinstall the fuel filler cap.

4 1999 Suzuki Esteem GL Sedan L4-1.8L Page 4 C. Remove the relay box cover and remove the fuel pump relay (Figure 5). D. Start the engine and run it until it stops for lack of fuel. Repeat cranking 2 or 3 times for about 3 seconds each time to dissipate fuel pressure in the lines. Fuel connections are now safe for servicing.. Disconnect negative cable from battery.. Remove rear seat cushion, rear seat back, right side sill scuff, right front partition trim and right rear door opening trim. 4. Disconnect connectors from fuel tank wire harness (Figure 6). 5. Remove parking brake cover and console box (1.6L). Remove the HO2S-2 coupler (Figure 7). 6. Hoist vehicle.

5 1999 Suzuki Esteem GL Sedan L4-1.8L Page 5 7. Remove muffler (Figure 8). WARNING: To avoid danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system has cooled down. 8. Disconnect connectors from EVAP canister air valve. Be sure to remove all debris around the quick connectors with compressed air before disconnecting. To disconnect the quick connectors push both sides of joint in while pulling hose joint out (Figure 9). 9. Disconnect fuel filler hose and breather hose from filler neck (Figure 10). 10. Use a hand operated pump to pump fuel out through the fuel tank filler. WARNING: Never drain or store fuel into an open container to avoid the possibility of fire or explosion. CAUTION: Do not force hose from hand operated pump into or out of fuel tank. Doing so may damage inlet valve.

6 1999 Suzuki Esteem GL Sedan L4-1.8L Page Remove all debris around the quick connectors with compressed air. Disconnect fuel pipe joints from pipes. To disconnect the quick connectors locate the special tool enclosed with this bulletin and insert it between joint and pipe (Figure 11). SPECIAL TOOL: NOTE: Additional Special Tools are available via ASMC's Parts Department. WARNING: A small amount of fuel may be released after the fuel hose is disconnected. To reduce the chance of personal injury, cover hose and pipe to be disconnected with a shop cloth. Be sure to place the cloth in an approved container when the disconnection has been completed. 2. Support the fuel tank with a jack and remove the fuel tank from the vehicle. 3. Using the clearance measurement from Step B. FUEL TANK MEASUREMENT PROCEDURE", perform one of the following: ^ If the clearance was less than 18 mm or if the vapor control valve nipple is found to be broken, replace the vapor control valve (Figure 12). ^ If the clearance was more than 18 mm and the nipple is not broken, reposition the hose clamp tab to face downward, then go to Step 18.

7 1999 Suzuki Esteem GL Sedan L4-1.8L Page 7 CAUTION: Make sure hose clamp tabs face downward (Figure 13). 4. Remove all debris around the refuel vapor control valve quick connectors with compressed air. Disconnect the hoses from the refuel vapor control valve. To disconnect the quick connectors push both sides of joint in while pulling hose joint out. 5. Remove the refuel vapor control valve screws with a hand impact driver and remove the refuel vapor control valve from the fuel tank. 6. Clean the mating surfaces of the refuel vapor control valve and fuel tank. Install the new refuel vapor control valve ( G00) to the fuel tank. 7. Connect the hoses to the refuel vapor control valve and clamp the hoses with the hose clamp tabs facing downward (Figure 13). AUTION: ^ Be sure hose clamp tabs face downward. ^ Align screw holes in fuel tank gasket and plate accurately or vapor may leak (Figure 14). 18. Clean the top surface of the refuel vapor control valve. Install the pad ( G00) to the top of the refuel vapor control valve using the adhesive (Figure 15).

8 1999 Suzuki Esteem GL Sedan L4-1.8L Page Install the fuel tank to the vehicle. Tighten the fuel tank fixer belt bolts (Figure 16). Tightening torque: 50 N.m (5.0 kg-m, 36.5 lb-ft) CAUTION: Make sure that the fuel tank flange is not positioned between the body and fuel tank fixer belt (Figure 16). 20. Measure the clearance between the fuel tank flange and the underside of the floor panel using the end of the measuring gauge stamped 99, 00MY". The end of the gauge stamped 99, 00MY" is 18 mm high (Figure 17). ^ If the clearance is less than 18 mm re-adjust the tank by loosing the fuel tank fixer belt bolts push the tank rearward while first tightening the rear fuel tank fixer belt bolts and then tightening the front bolts. 21. Connect the fuel filler hose and the breather hose to the filler (Figure 18). Tighten clamps. Tightening torque: 3.5 N.m (0.35 kg-m, 2.5 lb-ft)

9 1999 Suzuki Esteem GL Sedan L4-1.8L Page Connect the pipe joints to each pipe (Figure 19). CAUTION: When connecting joint, clean outside surfaces of pipe, push joint into pipe until joint lock clicks and check to ensure that pipes are connected securely, or a fuel leak may occur. 23. Connect the EVAP canister air valve connectors. Connect vapor control valve hose and purge hose to EVAP canister. For the quick connector push joint into pipe until joint lock clicks (Figure 20). 24. Install the muffler and tighten the muffler nuts (Figure 21).

10 1999 Suzuki Esteem GL Sedan L4-1.8L Page Install the HO2S-2 coupler. Install the parking brake cover and console box (SY416) (Figure 22). 26. Connect connectors from fuel tank wire harness Figure 23). 27. Install rear seat cushion rear seat back right side sill scuff right front partition trim and right rear door opening trim. 28. Refuel fuel tank with fuel removed during STEP Re-install the fuel pump relay into the relay box. Reinstall the relay box cover (Figure 24). 30. Connect the negative battery cable. 31. With engine OFF and ignition switch ON check for fuel leaks. 32. Start the engine and check each joint of the exhaust system for leakage. 33. Road test the vehicle and confirm that there are no service related defects. D. Campaign Sticker Installation Procedure

11 1999 Suzuki Esteem GL Sedan L4-1.8L Page 11 Enter your dealer number on the DG Recall Campaign sticker and install it to the flat surface on the upper radiator support just above the left head lamp (Figure 1). This will identify that the campaign has been completed. IMPORTANT NOTICE FOR CALIFORNIA DEALERS: The California Air Resources Board requires that all applicable emission recall campaigns to be completed prior to California registration renewal. If the owner does not have this recall performed, they will not be able to renew their California vehicle registration. After completing the recall service, your Service Department must give each owner a "Proof of Correction Certificate." If required, the owner must present this certificate to the Department of Motor Vehicles when renewing their California registration. Refer to ATTACHMENT B of the Campaign Service Bulletin SC-18. ASMC will be supplying a quantity of these certificates to each California Suzuki Dealer. Be sure to complete this certificate after repairs have been completed and attach it to the customer's copy of the completed repair order.