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Old 12-16-2009, 06:02 PM   #1 (permalink)
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Default Low beam h/l problem with a twist

OK guys and gals. Noob to the Suzuki forums, but I am trying to help out a friend with her 04 Forenza.

Low beams do not work. Highs and marker lights work as they should. I immediately checked all fuses and the h/l relay. No problems there. Bulbs are good. I found the TSB pertaining to splicing the headlights and performed it (cutting and splicing the three purple wires behind the cluster), but still no change. I am able to power the yellow wire going to the underhood fuse box and the low beams work.

Any other ideas before I bite the bullet and replace the combination switch?

Thanks in advance!
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Old 12-17-2009, 10:33 AM   #2 (permalink)
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I don't know why you would fix something that they would address for free as the repair was a recall, not a TSB (see below). Go to the dealership and they should fix it for nothing - although now you have done it yourself, they may not.


Make: SUZUKI Model: FORENZA
Model Year: 2004
Manufacturer: AMERICAN SUZUKI MOTOR CORP. Mfr's Report Date: SEP 25, 2007
NHTSA CAMPAIGN ID Number: 07V452000 PE07039
NHTSA Action Number: PE07039
Component: EXTERIOR LIGHTING
Potential Number of Units Affected: 93963
Summary:
ON CERTAIN PASSENGER VEHICLES, HEADLAMP LOW BEAM OR DAYTIME RUNNING LIGHT (DRL) FUNCTION MAY BE INOPERATIVE DUE TO A MELTED SPLICE PACK ON THE WIRING HARNESS.
Consequence:
INAPPROPRIATE LIGHTING COULD REDUCE VISIBILITY OF VEHICLES AND INCREASE THE POTENTIAL FOR A CRASH.
Remedy:
DEALERS WILL SPLICE THE POWER CIRCUIT WIRES FOR THE LOW-BEAM HEADLAMPS AND DRL FREE OF CHARGE. THE RECALL WILL BE MAILED IN THREE PHASES, STARTING AT THE END OF OCTOBER 2007 AND CONCLUDING BY THE END OF JANUARY 2008;. OWNERS MAY CONTACT SUZUKI AT 1-800-934-0934.
Notes:
SUZUKI RECALL NO. NB. CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.
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Old 12-17-2009, 11:03 AM   #3 (permalink)
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I am repairing it for her because there is not a Suzuki dealer close to us, but that 's beside the point. I figured out the problem and repaired it this morning.

As it turns out, there are two of the harnesses behind the cluster that have the same problem. I didn't see the one to the left of the column on initial inspection and it turned out to be the problem. :doh:
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Old 01-29-2010, 04:34 PM   #4 (permalink)
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i have an 05 forenza.....there is not a dealership for 100 miles....

the low beams will not work.. high beams/fog lights do........replaced switch...not bad fuse or relay.....must be burned wires.

...i am an electrician....but know nothing about cars. where is this cluster of wires found and is it possible for me to find them?

any help would be appreciated

g
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Old 01-29-2010, 05:19 PM   #5 (permalink)
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It is a really simple repair. Should take no more than an hour to complete.

Remove the instrument cluster and look back and to the left of the steering wheel (drivers side of wheel).
There will be a bundle of six or so wires that terminate in a flat plastic(white-ish colored)connector. The connector should be clipped to the metal bar that reinforces the dash.
Usually the wires get hot enough to melt the connector and that's what causes the problem.
Cut the wires from the connector and solder them together and heat shrink them. (That is the way Suzuki says to repair it. I actually just used a wire nut).


As a precautionary measure, there is also an identical connector on the right side of the steering column. I'm not sure what those wires go to, but I did the same thing to them since I was already in there.

Feel free to email me at terryjmatthew(at)yahoo dot com if you have any questions.
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Old 01-29-2010, 05:39 PM   #6 (permalink)
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ok before i ask this........ just dont give up on me

what/where is the instrument cluster?

please just give me points for trying...i am female....lol
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Old 01-29-2010, 05:41 PM   #7 (permalink)
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haha. It's the speedometer housing in laymans terms
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Old 01-29-2010, 05:44 PM   #8 (permalink)
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thank you

i looked under the dash and saw about 50 connectors and did not see any burned ones....really didnt want to take anything apart until i had to.....i am sure i will be back for more advise...thank you !! thank you!!!
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