Suzuki Grand Vitara JB627. Manual - part 75

1B-6 Aux. Emission Control Devices: 

PCV Valve Removal and Installation

S6JB0B1206007

Removal

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

Installation

1) Apply sealant to thread part of PCV valve (1).

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

2) Install PCV valve (1) onto cylinder head cover.

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

3) Connect PCV hose (2) to PCV valve (1).

PCV Valve Inspection

S6JB0B1206008

NOTE
Be sure to check that there is no obstruction 
in PCV valve or its hoses before checking 
engine idle speed / IAC duty for obstructed 
PCV valve or hose hampers its accurate 
checking.

 

1) Remove PCV valve referring to “PCV Valve Removal 

and Installation”.

2) Connect PCV valve (1) to PCV hose and plug head 

cover hole.

3) Run engine at idle.
4) Place your finger on the hole of PCV valve (1) to 

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

5) After checking vacuum, stop engine and remove 

PCV valve (1). Shake valve and listen for the rattle of 
check needle inside the valve. If valve does not 
rattle, replace valve.

6) After inspection, remove plug from head cover hole. 

Then, install PCV valve to head cover hole referring 
to “PCV Valve Removal and Installation”, connect 
PCV valve, PCV hose and clamp securely.

EGR Valve Assembly Removal and Installation 
(If Equipped)

S6JB0B1206009

Removal

1) Remove intake collector from intake manifold 

referring to Step 1) to 11) of “Intake Collector and 
Intake Manifold Removal and Installation in Section 
1D”.

2) Remove EGR valve (1) and gasket from intake 

collector (2).

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

2

1, “A”, (a)

I4JA01121011-01

1

I5JA01121009-01

1

I4JA01121012-01

1

2

I6JB01120019-01

Aux. Emission Control Devices:  1B-7

EGR Valve Assembly Inspection (If Equipped)

S6JB0B1206010

1) Check resistance between the following terminals of 

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

EGR valve resistance
Terminal “A” and terminal “B”: 20 – 24 

Ω at 20 °C 

(68 

°F)

Terminal “C” and terminal “B”: 20 – 24 

Ω at 20 °C 

(68 

°F)

Terminal “F” and terminal “E”: 20 – 24 

Ω at 20 °C 

(68 

°F)

Terminal “D” and terminal “E”: 20 – 24 

Ω at 20 °C 

(68 

°F)

Terminal “B” and valve body: infinity (

∞)

Terminal “E” and valve body: infinity (

∞)

2) Remove carbon from EGR valve gas passage.

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

 

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

cracks bend or other damage.
If found faulty, replace EGR valve (1) assembly.

Specifications

Tightening Torque Specifications

S6JB0B1207001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

2. Connector

IYSQ01113035-01

IYSQ01120003-01

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

PCV valve

27

2.7 

19.5

)

1B-8 Aux. Emission Control Devices: 

Special Tools and Equipment

Recommended Service Material

S6JB0B1208001

Special Tool

S6JB0B1208002

Material

SUZUKI recommended product or Specification

Note

Water tight sealant

SUZUKI Bond No.1207F

P/No.: 99000–31250

)

09917–47011

SUZUKI scan tool

Vacuum pump gauge

—

)

 / )

This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12. ) / )

Engine Electrical Devices:  1C-1

Engine

Engine Electrical Devices

Repair Instructions

Engine Control Module (ECM) Removal and 
Installation

S6JB0B1306001

CAUTION

!

 

As ECM consists of precision parts, be 
careful not to expose it to excessive shock.

 

NOTE
If ECM is replaced with new one or with 
another one, make sure to register 
immobilizer transponder code to ECM 
correctly according to “Procedure after ECM 
Replacement in Section 10C”.

 

Removal

1) Disconnect negative cable from battery.
2) Remove ECM cover from bracket.
3) Disconnect connectors from ECM as follows.

a) Push lock (1) to release locking of lock lever (2).
b) Turn lock lever to arrow direction until it stops.

4) Remove ECM (1) from its bracket by removing its 

mounting bolts (2).

Installation
Reverse removal procedure noting the following:
• Connect connectors to ECM as follows.

a. Make sure that lock lever (1) of ECM connector is 

at unlock position.

b. In this state, insert connectors to ECM securely.
c.  Lock ECM connectors securely by turning its lock 

lever to left until it stops.

1

2

I6JB01130001-02

2

1

I6JB01130002-03

1

I6JB01130003-01