Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 108

1B-2 Aux. Emission Control Devices: For Petrol Engine Model

EVAP Canister Purge Valve and Its Circuit 
Inspection

S6JB0A1216002

WARNING

!

 

Do not apply vacuum by mouth; otherwise 
harmful fuel vapor can be breathed in.

 

CAUTION

!

 

Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge 
valve could be damaged.

 

1) Prepare to operate EVAP canister purge valve as 

follows.
a) When using SUZUKI scan tool:

i)

Connect SUZUKI scan tool to DLC (1) with 
ignition switch turned OFF and disconnect 
purge valve vacuum hoses from intake 
manifold and purge pipe.

ii) Turn ON ignition switch, clear DTC and 

select “MISC TEST” mode on SUZUKI scan 
tool.

Special tool
(A):  SUZUKI scan tool

b) When not using SUZUKI scan tool:

NOTE
Before performed this check, be sure to read 
the “Precautions of ECM Circuit Inspection: 
For Petrol Engine Model in Section 1A”.

 

i)

Disconnect purge valve vacuum hoses from 
intake manifold and purge pipe.

ii) Remove ECM cover.
iii) Connect special tool between ECM and ECM 

connector referring to “Inspection of ECM 
and Its Circuits: For Petrol Engine Model in 
Section 1A”.

iv) Turn ON ignition switch.

Using service wire, ground “C37-13” terminal 
circuit of special tool (valve ON: “B”) and 
unground it (valve OFF: “A”).

2) Check purge valve (2) for operation and vacuum 

passage for clog when valve is switched ON and 
OFF by using SUZUKI scan tool or service wire.
If check result is not satisfactory, check vacuum 
hoses, EVAP canister purge valve, wire harness and 
connections.

EVAP canister purge valve specification
[C] Valve OFF: When vacuum (–60 kPa (–8.7 psi)) 
is applied to hose (1), vacuum can be applied.
[D] Valve ON: When vacuum is applied to hose 
(1), vacuum can not be applied.

Special tool
(A):  09917–47011

(A)

1

I5JB0A120003-01

[A]: For J20 engine
[B]: For M16 engine

“C37-13”

“A”

“B”

I5JB0A120004-01

[B]

[A]

[D]

[C]

(A)

1

1

2

2

(A)

I5JB0A120005-01

Aux. Emission Control Devices: For Petrol Engine Model 1B-3

Vacuum Passage Inspection

S6JB0A1216003

Start engine and run it at idle speed. Disconnect vacuum 
hose (1) from EVAP canister purge valve (2). With finger 
placed against disconnected hose, check that vacuum is 
applied.
If it is not applied, clean vacuum passage by blowing 
compressed air.

Vacuum Hose and Purge Valve Chamber 
Inspection

S6JB0A1216004

Check hoses and purge valve chamber for connection, 
leakage, clog and deterioration.
Replace as necessary.

EVAP Canister Purge Valve Inspection

S6JB0A1216005

WARNING

!

 

Do not apply vacuum by mouth; otherwise 
harmful fuel vapor can be breathed in.

 

CAUTION

!

 

Do not apply vacuum more than –86 kPa (–
12.47 psi); otherwise EVAP canister purge 
valve could be damaged.

 

1) With ignition switch turned OFF, disconnect coupler 

and vacuum hoses from canister purge valve.

2) Remove EVAP canister purge valve from intake 

manifold.

3) Check resistance between two terminals of EVAP 

canister purge valve.
If resistance is not as specified, replace EVAP 
canister purge valve.

EVAP canister purge valve resistance
30 – 34 

Ω at 20 °C (68 °F)

[A]: For J20 engine
[B]: For M16 engine

[B]

[A]

2

2

1

2

I5JB0A120006-01

I5JB0A120007-01

I3RM0A120008-01

1B-4 Aux. Emission Control Devices: For Petrol Engine Model

4) With coupler disconnected, apply vacuum (–60 kPa 

(–8.7 psi)) to pipe (1). If vacuum can be applied, go 
to next step. If vacuum can not be applied, replace 
EVAP canister purge valve.

5) In this state, connect 12 V-battery to EVAP canister 

purge valve terminals. If vacuum can not be applied, 
EVAP canister purge valve is in good condition.
If applied, replace EVAP canister purge valve.

WARNING

!

 

Do not suck the air through valve. Fuel vapor 
inside valve is harmful.

 

Special tool
(A):  09917–47011

6) Install EVAP canister purge valve to intake manifold.

EVAP Canister Inspection

S6JB0A1216006

WARNING

!

 

Do not suck nozzles on EVAP canister. Fuel 
vapor inside EVAP canister is harmful.

 

1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.

3) Check that there is no restriction of flow through 

purge pipe (1) and air pipe (2) when air is blown (4) 
into tank pipe (3).
If any faulty condition is found in this inspection, 
replace EVAP canister.

EGR Valve Removal and Installation

S6JB0A1216007

Removal

1) Disconnect negative cable at battery.
2) Remove EGR pipe.
3) Disconnect EGR valve connector.
4) Remove EGR valve and gasket from cylinder head.

Installation
Reverse removal procedure noting the following.
• Clean mating surface of valve and cylinder head.
• Use new gaskets.

EGR Valve Inspection

S6JB0A1216008

1) Check resistance between following terminals of 

EGR valve (1) in each pair.
If found faulty, replace EGR valve assembly.

EGR valve resistance (A – B, C – B, F – E, D – E 
terminal)
20 – 24 

Ω

1

1

(A)

(A)

I3RB0A120007-01

I2RH0B120001-01

I2RH0B120005-01

Aux. Emission Control Devices: For Petrol Engine Model 1B-5

2) Remove carbon from EGR valve gas passage.

CAUTION

!

 

Do not use any sharp-edged tool to remove 
carbon.
Be careful not to damage or bend EGR valve 
(1), valve seat (3) and rod.

 

3) Inspect valve (2), valve seat and rod for fault, cracks, 

bend or other damage.
If found faulty, replace EGR valve assembly.

PCV Hose Inspection

S6JB0A1216009

NOTE
Be sure to check that there is no obstruction 
in PCV valve or its hoses before checking 
IAC throttle opening, for obstructed PCV 
valve or hose hampers its accurate 
adjustment.

 

Check hoses for connection, leakage, clog and 
deterioration.
Replace as necessary.

PCV Valve Removal and Installation

S6JB0A1216010

Removal

1) Disconnect PCV hose from PCV valve.
2) Remove PCV valve from cylinder head cover.

Installation
Reverse removal procedure noting the following.
• For J20 engine, apply sealant to thread part of PCV 

valve (1).

“A”:  Water tight sealant 99000–31250 (SUZUKI 
Bond No.1207F)

• For J20 engine, tighten PCV valve to specified torque.

Tightening torque
PCV valve (a):  27 N·m (2.7 kgf-m, 19.5 lb-ft)

• Connect PCV hose to PCV valve securely.

PCV Valve Inspection

S6JB0A1216011

NOTE
Be sure to check that there is no obstruction 
in PCV valve or its hoses before checking 
IAC throttle opening, for obstructed PCV 
valve or hose hampers its accurate 
adjustment.

 

1) Remove PCV valve referring to “PCV Valve Removal 

and Installation: For Petrol Engine Model”

2) Connect PCV valve to hose and install plug to 

cylinder head cover hole.

3) Run engine at idle.
4) Place your finger over end of PCV valve (1) to check 

for vacuum.
If there is no vacuum, check for clogged valve. 
Replace as necessary.

I2RH0B120006-01

[A]: For J20 engine
[B]: For M16 engine

1, (a), A

I5JB0A120008-01

I5JB0A120009-04