CALIFORNIA Models EGR System Modification (TS 4-10 11080)

WARNING: This page is about the Sidekick JLX, which is a different variant/trim than selected.

Publication date: 1970-01-01
Reference number: TS 4-10 11080

CALIFORNIA MODELS EGR SYSTEM MODIFICATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 4-10 11080, Date of Issue:

EGR SYSTEM MODIFICATION (CALIFORNIA SPECIFICATION)

Model(s); 1989 & Later Suzuki Sidekick

Bulletin No.: TS 4-10 11080

Group: Engine Performance

SERVICE INFORMATION

This bulletin is to inform you that as of October 1988 production there has been a modification to the EGR control system for California specification Sidekicks. The early California specification features two EGR system circuits; one through a main EGR valve and the other through a sub EGR valve. This system was modified to an EGR control system that is virtually the same as that used in Federal specification vehicles. To determine whether you have an early or late type vehicle late EGR system, visually check the intake manifold. As shown in figures 1 and 2 the early one is equipped with the Bimetallic Vacuum Switching Valve (BVSV) and the late is not. For Illustrations of related parts, refer to Fig 3 through Fig 5 .

AFFECTED VINs

BEGINNING VINS: JS4TA01V()K4104870 - JS4TA01C()K4107317

Fig 1: Early Design Emission Control System w/ BVSV Valve

Fig 2: Late Design Emission Control System w/o BVSV Valve

The difference between Federal and Late California are referenced in the chart below.

CALIFORNIA/FEDERAL COMPARISON CHART

DESCRIPTION ITEM	CALIFORNIA SPECIFICATION	FEDERAL SPECIFICATION
5th (Over top) switch assy,(M/T)	Not equipped	Equipped
Input signal at A/T lock up with (A/T)	Not equipped	Equipped
Recirculated exhaust gas temp sensor	Equipped	Not Equipped

PARTS APPLICATION

REF NO.	PART NAME	EARLY P/N	LATE P/N
1	EGR valve	18111-61A10	18111-61A10
2-1	Intake manifold (for MT)	13110-61A21	13110-61A02
2-2	Intake manifold (for AT)	13400-61A20	13110-61A13
3-1	Throttle body assy (For MT)	13400-61A20	13400-61A00
3-2	Throttle body assy (For AT)	13400-61A30	13400-61A10
4-1	Throttle valve body Assy (For MT)	13402-61A20	13402-61A00
4-2	Throttle valve body Assy (For AT)	13402-61A30	13402-61A10
5	BVS valve	18550-73031	---
6	Vacuum hose (L=470mm) (EGR modulator to BVS valve)	09343-03501	---
7	Vacuum hose (L=525mm) (EGR modulator to VSV)	---	09358-35754 -525
8	Vacuum hose (L=130mm) (BVS valve to 3 way union)	09343-03093	---
9	Vacuum hose (L=240mm) (VSV to 3 way union)	---	09343-03101
10	Vacuum hose (L=350mm) (VSV to throttle body)	09343-03104	---
11	Vacuum hose (L=240mm) (VSV to throttle body)	09343-03101	---
12	Emission control label	11955-61A32	11955-61A33
13	Transmission Case Assy	24700-60A11	24700-60A01
14	5th (Over top) switch Assy	37610-60A00	---
15-1	Main wiring harness (For MT)	36610-61A50	36610-61A52
15-2	Main wiring harness (for AT Non power window)	36610-61A70	36610-61A71
15-3	Main wiring harness (For AT with power window)	36610-61A90	36610-61A91
16-1	EFI controller Assy (For MT)	33920-60130	33926-60A32
16-2	EFI controller Assy (For AT)	33920-60A40	33920-60A42

SUPPLY OF SPARE PARTS

REF NO.	PART NAME	QTY	SUPPLY OF SPARE PARTS
1	EGR valve	1	Both early and late
2-1	Intake manifold (for MT)	1	Both early and late
2-2	Intake manifold (for AT)	1	Both early and late
3-1	Throttle body assy (For MT)	1	Both early and late
3-2	Throttle body assy (For AT)	1	Both early and late
4-1	Throttle valve body Assy (For MT)	1	Both early and late
4-2	Throttle valve body Assy (For AT)	1	Both early and late
5	BVS valve	1	Early only
6	Vacuum hose (L=470mm) (EGR modulator to BVS valve)	1	Early only
7	Vacuum hose (L=525mm) (EGR modulator to VSV)	1	Late only
8	Vacuum hose (L=130mm) (BVS valve to 3 way union)	1	Early only
9	Vacuum hose (L=240mm) (VSV to 3 way union)	1	Late only
10	Vacuum hose (L=350mm) (VSV to throttle body)	1	Early only
11	Vacuum hose (L=240mm) (VSV to throttle body)	1	Early only
12	Emission control label	1	Both early and late
13	Transmission Case Assy	1	Both early and late
14	5th (Over top) switch Assy	1	Early only
15-1	Main wiring harness (For MT)	1	Both early and late
15-2	Main wiring harness (for AT Non power window)	1	Both early and late
15-3	Main wiring harness (For AT with power window)	1	Both early and late
16-1	EFI controller Assy (For MT)	1	Late only after early stock depleted.
16-2	EFI controller Assy (For AT)	1	Late only after early stock depleted.

INTERCHANGEABILITY CHART

REF NO.	PART NAME	Interchangeability X = No O = Ok
1	EGR valve	EARLY <----X----> Late
2-1	Intake manifold (for MT)	EARLY <----X----> Late
2-2	Intake manifold (for AT)	EARLY <----X----> Late
3-1	Throttle body assy (For MT)	EARLY <----X----> Late
3-2	Throttle body assy (For AT)	EARLY <----X----> Late
4-1	Throttle valve body Assy (For MT)	EARLY <----X----> Late
4-2	Throttle valve body Assy (For AT)	EARLY <----X----> Late
5	BVS valve	---
6	Vacuum hose (L=470mm) (EGR modulator to BVS valve)	---
7	Vacuum hose (L=525mm) (EGR modulator to VSV)	---
8	Vacuum hose (L=130mm) (BVS valve to 3 way union)	---
9	Vacuum hose (L=240mm) (VSV to 3 way union)	---
10	Vacuum hose (L=350mm) (VSV to throttle body)	---
11	Vacuum hose (L=240mm) (VSV to throttle body)	---
12	Emission control label	Early <----X----> Late
13	Transmission Case Assy	Early <----X----> Late
14	5th (Over top) switch Assy	---
15-1	Main wiring harness (For MT)	Early <----X----> Late
15-2	Main wiring harness (for AT Non power window)	Early <----X----> Late
15-3	Main wiring harness (For AT with power window)	Early <----X----> Late
16-1	EFI controller Assy (For MT)	Late to early
16-2	EFI controller Assy (For AT)	Late to early

NOTE: The callout numbers in Fig 3 - Fig 5 correspond to the PARTS APPLICATION TABLE.

Fig 3: Early Design Related Vacuum Line Parts - Vacuum Diagram

Fig 4: Late Design Related Vacuum Line Parts - Vacuum Diagram

Fig 5: Related Parts