Revised ANNEX5 Replacement Procedure For Vacuum Pump Check Valve 20221007

Replacement Procedure for Check
Valve Body on Vacuum Pump
©Suzuki Motor Corporation, 2022. All rights reserved.

Workflow
1. Confirmation of Affected Vehicle ……………………………… Page2
2. Check Valve Body Replacement Procedure …… Page 3

2-1. Necessary Tools ………………………………………… Page 3
2-2. Replacement Parts ……………………………………… Page 6
2-3. Vacuum Pump Identification ……………………………… Page 6
Not Countermeasure Part Countermeasure Part
2-4. Check Valve Body Replacement …………… Page 8
2-4-1. Vacuum Pump Removal ………………… Page 8

2-4-2. Check Valve Body Removal ……………… Page 11
2-4-3. Check Valve Body Installation …………… Page 17
2-4-4. Airtightness Check ………………………… Page 19
2-4-5. Vacuum Pump Installation ………………… Page 21
2-4-6. Vacuum Pump Inspection ………………… Page 27
2-4-7. Initial Setting ………………………………… Page 28
End
1
1. Confirmation of Affected Vehicle
Check Vehicle Identification Number (VIN) to see if vehicle is affected on or not.
Affected Vehicle VIN Range
Name / Model VIN Range*
TSMLYD01S00600029 to TSMLYD01S00724470
TSMLYDA1S00115721 to TSMLYDA1S00B11178
TSMLYDD1S00656041 to TSMLYDD1S00B20281
TSMLYE01S00600028 to TSMLYE01S00724466
VITARA (APK310, APK414) TSMLYEA1S00115719 to TSMLYEA1S00B11149
TSMLYED1S00656033 to TSMLYED1S00B20300
TSMYDA1S2JM423445
TSMYDA1S6HM317722
TSMYDA1S6LM756377
TSMJYA02S00500247 to TSMJYA02S00702387
TSMJYAA2S00500249 to TSMJYAA2S00A24947
TSMJYAD2S00751004 to TSMJYAD2S00A29663
TSMJYB02S00500324 to TSMJYB02S00702384
SX-4 S-CROSS (AKK310, AKK415)
TSMJYBA2S00500248 to TSMJYBA2S00A24763
TSMJYBD2S00750971 to TSMJYBD2S00A29791
TSMYAA2S2JM567746
TSMYAA2S8LM751480
JSAAZC13S00100044 to JSAAZC13S00400882
SWIFT (A2L310)
SWIFT Sport (A2L414)
JSAAZCC3S00400003 to JSAAZCC3S00504328
MA3EWB42S00142314 to MA3EWB42S00655192
BALENO (A1K310)
MBHEWB42S00285339 to MBHEWB42S00823660
*Even if the vehicle is in VIN range, it may not be affected vehicle.
Check VIN list to confirm the eligibility.
Vehicle Identification Number (VIN)
model VIN Location
VIN
The number is
punched on the cowl
VITARA upper panel in engine
SX-4 S- compartment and it is
CROSS VIN also attached on the
Figure shows VITARA left side of instrument
panel depending on the
vehicle specification.
The number is
VIN punched on the right
VIN side dash side front
panel in engine
SWIFT compartment and it is
SWIFT Sport also attached on the
BALENO Figure shows BALENO left side of cowl top
panel and the rear floor
panel depending on the
vehicle specification.
2
2. Check Valve Body Replacement Procedure
2-1. Necessary Tools
General tools
Tool name Remark
Ratchet wrench －
Socket 7-14 mm
Torque wrench 1.0-25 N·m
Box-end wrench 8-10 mm

Waste cloth －
Special tools
Number Tool name Q’ty
09915-67311 Vacuum gauge 1
Set number Set name Q’ty Remark

Oceanian Country (who sold only KC
18110-68800-RX0 JIG SET, VP 1
engine)
For Except Oceanian Country (who sold
18110-538A0-RX0 JIG SET, VP 1
KC and KD engine)
JIG SET, VP is needed to replace the check valve body. It is not necessary when
replacing the vacuum pump Assy.
3
Components of JIG SET, VP
4 5 6
2 3
9 10 12
8 13
11
19
15
14
18
16
17
*For the SYRINGE 17, either separate syringe and

nozzle type or integrated syringe type is included.
4
Special Tool Parts
No. Part name Q’ty Remark

1 JIG, VP No.1 1 ―
2 JIG, VP No.2 1 For K14C, K10C Engine
3 JIG, VP No.2 1 For K14D Engine *Not included in 18110-68800-RX0
4 NIPPLE 1 ―
5 BOLT, STUD 1 ―
6 BOLT 2 M8, Lower neck length:30mm
7 NUT 1 ―
8 JIG, VP No.3 1 Length: 160mm
9 JIG, VP No.4 1 ―
10 JIG, VP No.5 1 ―
11 JIG, VP No.6 1 Length: 227mm
12 JIG, VP No.7 2 ―
13 JIG, VP No.8 1 ―
17 SYRINGE 1 ―
18 HOSE 1 ―
19 WASHER 1 ―
5
2-2. Replacement Parts
For K14C, K10C Engine
Part number Part name Q’ty Remark

18100-68803-RX0 BODY SET, CHECK VALVE 1 Include vacuum pump O-ring
For K14D Engine
Revised on September 19, 2022
Part number Part name Q’ty Remark

18100-538A3-RX0 BODY SET, CHECK VALVE 1 Include vacuum pump O-ring
2-3. Vacuum Pump Identification
Check if the countermeasure is installed. Revised on September 19, 2022
Whether it is a countermeasure part or not can be judged by chamfering shape of the check valve body.
Valve Body
Figure shows SWIFT Sport
6
Chamfering shape of the check valve body
Chamfering shape of the check valve body Judgment
R 0.5
OK:
Countermeasure part
*There are types with
and without machined
lines.
Machining line
No Good:
Not Countermeasure
part
R2
To perform “2-4.
Check Valve
Replacement”
*Non-machining line
No Good:
Not Countermeasure
part
C2
To perform “2-4.
Check Valve
Replacement”
*Non-machining line
Judgment Next Step

OK: Countermeasure part installed End
No Good: Not countermeasure part To perform “2-4. Check Valve Replacement”
For distributor which the countermeasure check valve body is supplied, Go to“2-4. Check Valve
Replacement” to replace the check valve body. For distributor which the countermeasure check
valve body is NOT supplied, or in case of related parts of vacuum pump Assy are damaged during
“check valve body” replacement, replace vacuum pump Assy according to service manual.
7
2-4. Check Valve Body Replacement
2-4-1. Vacuum Pump Removal
NOTE;
Disconnection of battery cable will reset audio setting etc.
Before disconnecting the battery cable, record the necessary items to restore the
setting at completion of the countermeasure.
VITARA, SX4 S-CROSS (K14C model)

1) Disconnect negative (–) cable at battery.
2) Remove engine cover.
3) Remove air cleaner suction hose referring to “1D Air Cleaner Components” of service manual.
4) Remove WGV-VSV referring to “1C WGV-VSV Removal and Installation” of service manual.
5) Disconnect boost pressure sensor with IAT 1 3

sensor-2 connector (1).
6) Disconnect intercooler outlet hose No.1 (2) and
intercooler outlet hose No.2 (3).
7) Remove intercooler outlet pipe (4).
8) Disconnect brake vacuum pump hose (1) and

waste gate control hose No.2 (2).
2
9) Remove vacuum pump (3) with O-ring.
8
SWIFT Sport (K14C model)
3) Drain coolant referring to “1F Cooling System Draining” of service manual.
4) Remove air cleaner suction hose No.2 (1).
5) Disconnect connector from boost pressure

sensor with IAT sensor-2 (1).
6) Remove intercooler outlet pipe No.2 (2).
1
7) Disconnect vacuum hose (1) and waste gate

control hose No.2 (2) from vacuum pump. 1
8) Remove thermostat cap bolt (3) and nut (4), 2
and intercooler outlet pipe No.2 bracket (5).
5
4
9
9) Tighten thermostat cap bolt (1) and nut (2) securely, and cover thermostat cap with waste cloth (3).
NOTICE;
If leaking oil from camshaft end adheres to thermostat, thermostat rubber ring
could be damaged and cause coolant leakage.
To prevent oil from adhering to thermostat, tighten thermostat cap bolt and nut and
cover thermostat cap with waste cloth. 4
2
3
VITARA, SX4 S-CROSS, SWIFT Sport (K14D model)

2) Disconnect vacuum hose (1) and waste gate
2
control hose No.4 (2) from vacuum pump.
3) Remove vacuum pump (3) with O-ring. 1
VITARA, SX4 S-CROSS, SWIFT, BALENO (K10C model)

3) Remove air cleaner suction hose No.2 referring to “1D Air Cleaner Components” of service manual.
4) Disconnect brake vacuum pump hose (1) and 2
waste gate control hose No.3 (2).

1
10
Added on September 19, 2022
2-4-2. Check Valve Removal
NOTICE;
Removing or inserting the check valve body without using a special tool will cause
damage of the vacuum pump. Do not pull out the check valve by plier and/or hit the
check valve into vacuum pump by hammer. Be sure to use special tools.
1) Tighten stud bolt (1) to JIG No.1 (2) until

incomplete thread is seated. (Place the side
with the punch hole on the side of the vacuum
pump.)
JIG Side
1
1
Vacuum Pump Punch Hole

Mounting Side
2
Punch Hole
2) Wrap seal tape (commercially available) 1

2
around the JIG No.1 side of nipple (1) and
attach to JIG No.1 (2).
Seal tape wrap position
3) Turn the coupling to drain the engine oil from

vacuum pump.
4) Clean the vacuum pump body, especially Added on September 17, 2022
around check valve body mounting area .
4, (b)
5) Set the pump (1) with used O-ring in the JIG
No.1 (2) and tighten the bolts (3) (M8, Lower
1
neck length:30mm) and nuts (4) to the
specified torque.
Tightening torque
Bolts (a) and Nut (b): 25 N·m (2.5 kgf-m, 18.5
lbf-ft)
2 3, (a)
11
6) Set JIG, VP No. 4 (1) and JIG, VP No. 5 (2) on the check valve body (3) attached to the vacuum
pump and tighten temporarily with bolts (4) (M6, Lower neck length:35mm) alternately so that both
side gap (1) and (2) is even on the left and right.
Revised on October 10, 2022
K14C model, K10C model K14D model
4 1
4
2
3
Front View Front View
1 1
3 2
2
gap (right side)
gap (left side)
Add on October 10, 2022
Back View Back View
12
7) Assemble JIG, VP No. 7 (1) and JIG, VP No. 8 (2) to JIG, VP No. 1 (3) with bolts (4) (M10, Lower
neck length:90mm).
4 4
1
1
2
2
3
3
Front View Front View
1 1
1
3
3
Back View Back View
1
8) The bolt (1) (M10, Lower neck length:40mm)
is passed through the washer (2), center hole
3
of the JIG, VP No. 8 (3) and tightened into the
JIG, VP No. 4 (4) for seating. (The purpose of
2
the seating is to make the posture of JIG, VP
No. 4 (4) vertical).
4
Figure shows K14C JIG type.
13
9) Tighten the bolts (1) (M6, Lower neck
length:35mm) alternately to the specified
torque with the following order to confirm that
the gap between JIG, VP No. 4 and JIG, VP
No. 5 is even on the left and right. 1, (a)
Tightening torque
Bolts (a):
Step 1: 2 N·m (0.2 kgf-m, 1.5 lbf-ft)
If the bolt is tighten with wrong procedure, it

might be bended and no more usage as JIG. Figure shows K14C JIG
Then change to a new bolt as following parts type.
number.
Part number Part name
01550-0635A Bolt Revised on October 10, 2022
10) Loosen the bolts (1) (M10, Lower neck length:90mm), 1

and the bolt (2) (M10, Lower neck length:40mm).
Figure shows K14C JIG

type.
14
11) Insert JIG, VP No. 6 (1) (Length:227mm) into the hole of JIG, VP No. 1 (2).
12) Tighten bolts (3) (M10, Lower neck length:90mm) with specified torque.
Tightening torque
Bolts (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
13) Apply lubricant to the seat of bolt (4) (M10, Lower neck length:40mm) and washer (5).
14) Reseat bolt (4) (M10, Lower neck length:40mm) with washer (5)
3, (a) 3, (a)
4
4
5
2 2
15) Fix JIG, VP No. 1 (1) in a vise in a position with

the vacuum pump on top.
1
NOTE;
Fix the JIG so that the check valve

pulling direction is horizontal so
that contamination does not fall
when the check valve body is
pulled out.
Figure shows K14C JIG

type.
15
16) Tighten the bolt (1) (M10, Lower neck
length:40mm) and pull out the check valve 2
body (2) completely.
17) Remove JIG, VP No.8 (1) with check valve

body, JIG, VP No.7(2), JIG, VP No.6 (3) 3
from JIG, VP No.1(4).
1
2
18) Check the hole side where the check valve

was installed of the vacuum pump for
contamination, and if so, remove the vacuum
pump for contamination and clean any
contamination.
NOTICE;
To remove contamination, wipe

with a clean cloth. Do not use a
parts cleaner because it may
push in contamination.
16
2-4-3. Check Valve Body Installation
1) Set the new check valve body (1) in the hole of the vacuum pump.
2) Set JIG, VP No.3 (2) (Length:160mm) to JIG, VP No.1(3).
3) Set JIG, VP No. 2 (4) along the check valve body and adjust its position.
1
4
2
2
3 3
1 1
17
4) Press the check valve body into the end face position of JIG, VP No. 2 (1) with a press fitting
machine (2) at about 2.5kN to 15kN.
NOTICE;
Inappropriate press position
For K14D model, press head and
JIG must not interfere.
5) After visually press-fitting the check valve

body (3) to the end face of JIG, VP No. 2
2
1
(1), stop press-fitting when the load of the
press-fitting machine (2) increases.
6) Check that the jig and check valve are flat
(Round part shown).
NOTICE;
Overload can lead to product and

jig failure.
Stop press-fitting when the load
3
of the press-fitting machine
increases.
18
2-4-4. Airtightness Check
NOTICE;
Use a syringe to push in air during leak checks.
Air compressors and air guns can cause high pressure and lead to vacuum pump
damage.
1) Insert hose (1) into nipple (2).
2) Position the plunger so that the syringe has a volume of 100 ml.
100 ml
3) If the syringe (1) and nozzle (2) are separate, attach the nozzle to the syringe.
4) Insert the tip of the nozzle into the hose (3).
5) Check the hose system (Between nipple (4), hose and syringe) for leaks.
3 2 1
19
6) Apply leak check spray or soapy water to the
press-fit part of the check valve body (1).
NOTE;
1
Leak check spray and soapy water can be
substituted with dishwashing detergent.
7) Push the plunger until it hits and hold it for 10 seconds.

8) Check that no air bubbles come out from the press-fit part when holding the plunger.
9) If air leakage is confirmed by bubbles, replace the vacuum pump assy refer to service manual.
NOTE;
・It can be confirmed that there is no problem with airtightness by the fact that the
syringe has reaction force.
・If not pushed back, check for leaks from connections.
10) Remove all JIGs.
20
2-4-5. Vacuum Pump Installation
VITARA, SX4 S-CROSS (K14C model)
1) Clean mating surfaces of thermostat case and
3
vacuum pump.
2) Install new O-ring (1) to vacuum pump.
1 2
3) Install vacuum pump (2) to thermostat case (3)
aligning vacuum pump coupling (4) with slit (5)
of camshaft.
5
4
4) Tighten vacuum pump bolts (1) to specified

3
torque.
2
Tightening torque
Vacuum pump bolt (a): 25 N·m (2.5 kgf-m, 1, (a)
18.5 lbf-ft)
5) Connect waste gate control hose No.2 (2) and

1, (a) 1, (a)
brake vacuum pump hose (3).
6) Install intercooler outlet pipe (1). 2

7) Connect boost pressure sensor with IAT
sensor-2 connector (2).
8) Tighten intercooler outlet hose No.1 clamp and
intercooler outlet hose No.2 clamp to specified
torque.
Tightening torque 1
Intercooler Outlet Hose No.1 clamp:
4.5 N·m (0.46 kgf-m, 3.5 lbf-ft)
Intercooler Outlet Hose No.2 clamp:
4.5 N·m (0.46 kgf-m, 3.5 lbf-ft)
21
9) Install WGV-VSV referring to “1C WGV-VSV Removal and Installation” of service manual.
10) Install air cleaner suction hose referring to “1D Air Cleaner Components” of service manual.
11) Connect negative (–) cable at battery.
SWIFT Sport (K14C model)

1) Clean mating surfaces of thermostat case and 3
vacuum pump.
2) Install new O-ring (1) to vacuum pump. 2
1
of camshaft.
5
4

1, (a)
torque.
Tightening torque 1, (a)

Vacuum pump bolt (a): 25 N·m (2.5 kgf-m,
18.5 lbf-ft) 3
5) Remove thermostat cap bolt (2) and nut (3). 2 1, (a)
6) Install intercooler outlet pipe No.2 bracket (3)

and tighten thermostat cap bolt (1) and nut (2)
2, (b)
to specified torque.
3
Tightening torque
Thermostat cap bolt (a): 11 N·m (1.1 kgf-m,
8.5 lbf-ft)
Thermostat cap nut (b): 11 N·m (1.1 kgf-m, 1, (a)
8.5 lbf-ft)
22
7) Connect waste gate control hose No.2 (1) and
1
vacuum hose (2).
8) Install intercooler outlet pipe No.2 (1), and fix

radiator inlet hose (2) and outlet hose (3) with
clamps on intercooler outlet pipe No.2. 1
9) Tighten intercooler outlet pipe No.2 clamps to

specified torque referring to “1D Intercooler 2
Components” of service manual.
3
Tightening torque
Intercooler Outlet Pipe No.2 clamp:
8.5 N·m (0.87 kgf-m, 6.5 lbf-ft) 1
3
10) Connect boost pressure sensor with IAT

sensor-2 (1) connector.
23
11) Install air cleaner suction hose No.2 (1).
1
NOTE;
・Clamp the fuel and purge hoses

securely to the air cleaner
suction hose No. 2.
・Position the protector so that it
is in the clamp position.
Fuel and purge hoses fastened to the air Fuel and purge hoses fastened to the air
cleaner suction hose No. 2: OK cleaner suction hose No. 2: Imperfect
12) Refill cooling system with coolant referring to “1F Cooling System Refilling” of service manual.
13) Check cooling system for leakage referring to “1F Engine Cooling System Inspection” of service
manual.
24
VITARA, SX4 S-CROSS, SWIFT Sport (K14D model)
vacuum pump. 3 2
of camshaft.
5
4 1

torque. 2
1, (a) 3
Tightening torque
18.5 lbf-ft)
5) Connect waste gate control hose No.4 (2) and 1, (a)

vacuum hose (3). 1, (a)
VITARA, SX4 S-CROSS, SWIFT, BALENO (K10C model)

vacuum pump. 3
2
3) Install vacuum pump (2) to thermostat case (3) 1
of camshaft.
5
4
25
4) Tighten vacuum pump bolts (1) to specified 2
torque. 1, (a) 3
Tightening torque
18.5 lbf-ft)
5) Connect waste gate control hose No.3 (2) and 1, (a)

brake vacuum pump hose (3).
1, (a)
NOTE;
・Clamp the fuel and purge hoses securely to the air cleaner suction hose No. 2.
・Position the protector on fuel hose so that it is in the clamp position.
Fuel and purge hoses fastened to the air Fuel and purge hoses fastened to the air
cleaner suction hose No. 2: OK cleaner suction hose No. 2: Imperfect
6) Install air cleaner suction hose No.2 referring to “1D Intercooler Components” of service manual.
Tightening torque
Air Cleaner Suction Hose No.2 Clamp
VITARA, SX4 S-CROSS, SWIFT: 1.0 N·m (0.10 kgf-m, 1.0 lbf-ft)
BALENO: 1.3 N·m (0.13 kgf-m, 1.0 lbf-ft)
26
2-4-6. Vacuum Pump Inspection
1) Warm up engine to normal operating temperature.
2) Stop engine after warming up.
3) Disconnect vacuum hose (1) from brake booster.
4) Connect special tool to vacuum hose.
Special Tool
(A): 09915-67311
5) Close brake booster using tape or the like.
6) Check negative pressure with engine idling. If negative pressure is not as specified, replace vacuum
pump refer to service manual.
Negative pressure Inspection time

–50 kPa (–0.5 kgf/cm2, –7.25 psi, –0.5 bar) Within 7 seconds
–85 kPa (–0.87 kgf/cm2, –12.3 psi, –0.85 bar) Within 28 seconds
7) Pull off tape from brake booster.
8) Disconnect special tool and connect vacuum hose to brake booster.
9) Install engine cover.
27
2-4-7. Initial Setting
CAUTION;
・Without initialization of power window system, auto operation and anti-pinching function (If
equipped) will not work correctly.
・Do not pinch any object during the initialization. Doing so may spoil original performance in
the power window system.
1) Set ignition “ON” and lower driver side front

door glass fully.
1
2) Pull up and hold driver side power window
main switch in auto-up position (1) until door
glass is fully raised and continue holding it up 2
for about 2 sec.
3
3) Perform auto-down and auto-up operating 1. Auto UP 3. OFF

power window main switch to check that door
2. Manual UP
glass is lowered and raised fully. Repeat
4) procedure from Step 1) if auto-down or auto-up
function does not work.
5) Check anti-pinching function.

a) Lower door glass fully.
b) Place wood handle of hammer as shown in
figure.
c) Activate auto-up function of power window.
d) Check that window glass automatically
reverses at the position the hammer handle
is lightly pinched to prevent the hammer
handle from being pinched hard (to a point
about 220 mm (8.66 in.) below outside top
end (1) of glass run).
6) Recover original audio setting.
28

Revised ANNEX5 Replacement Procedure For Vacuum Pump Check Valve 20221007

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Revised ANNEX5 Replacement Procedure For Vacuum Pump Check Valve 20221007

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Replacement Procedure for Check

Valve Body on Vacuum Pump

©Suzuki Motor Corporation, 2022. All rights reserved.

1. Confirmation of Affected Vehicle ……………………………… Page2

2. Check Valve Body Replacement Procedure …… Page 3

Not Countermeasure Part Countermeasure Part

2-4. Check Valve Body Replacement …………… Page 8

2-4-1. Vacuum Pump Removal ………………… Page 8

Vehicle Identification Number (VIN)

model VIN Location

Torque wrench 1.0-25 N·m

Box-end wrench 8-10 mm

Set number Set name Q’ty Remark

*For the SYRINGE 17, either separate syringe and

No. Part name Q’ty Remark

For K14C, K10C Engine

Part number Part name Q’ty Remark

Part number Part name Q’ty Remark

Figure shows SWIFT Sport

Judgment Next Step

VITARA, SX4 S-CROSS (K14C model)

5) Disconnect boost pressure sensor with IAT 1 3

8) Disconnect brake vacuum pump hose (1) and

5) Disconnect connector from boost pressure

7) Disconnect vacuum hose (1) and waste gate

VITARA, SX4 S-CROSS, SWIFT Sport (K14D model)

VITARA, SX4 S-CROSS, SWIFT, BALENO (K10C model)

4) Disconnect brake vacuum pump hose (1) and 2

waste gate control hose No.3 (2).

1) Tighten stud bolt (1) to JIG No.1 (2) until

Vacuum Pump Punch Hole

2) Wrap seal tape (commercially available) 1

Seal tape wrap position

3) Turn the coupling to drain the engine oil from

K14C model, K10C model K14D model

Front View Front View

gap (right side)

gap (left side)

Add on October 10, 2022

Back View Back View

K14C model, K10C model K14D model

Front View Front View

Back View Back View

Figure shows K14C JIG type.

If the bolt is tighten with wrong procedure, it

10) Loosen the bolts (1) (M10, Lower neck length:90mm), 1

Figure shows K14C JIG

K14C model, K10C model K14D model

15) Fix JIG, VP No. 1 (1) in a vise in a position with

Fix the JIG so that the check valve

Figure shows K14C JIG

17) Remove JIG, VP No.8 (1) with check valve

18) Check the hole side where the check valve

To remove contamination, wipe

K14C model, K10C model K14D model

5) After visually press-fitting the check valve

Overload can lead to product and

1) Insert hose (1) into nipple (2).

7) Push the plunger until it hits and hold it for 10 seconds.

10) Remove all JIGs.

4) Tighten vacuum pump bolts (1) to specified

5) Connect waste gate control hose No.2 (2) and

6) Install intercooler outlet pipe (1). 2