CALIFORNIA Models EGR System Modification (TS 4-10 11080)
Publication date: 1970-01-01Reference 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
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 |