Suzuki Grand Vitara JB419. Service manual — part 33

Engine General Information and Diagnosis: 1A-109

Test 7: Exhaust gas recirculation valve

S5JB0B1104172

3

Manually check the axial play of the wheels. ([A]: Axial play,
[B]: Radial play)

The significant axial play is approximately 2 mm (0.080 in.).
Does the turbo have too much play in the shaft?

Replace the
turbocharger. If the
rotating part is broken:
change the engine oil
and the oil filter.
clean the intercooler
and the air circuit ducts.

The rotating part is in
order.

Step

Action

Yes

No

I5JB0B110015-01

Step

Action

Yes

No

1

VALVE POSITION FAULT FINDING:
Or detection of a leak in the exhaust gas recirculation valve
Clear the faults.
Use “Initialize EGR valve data” on SUZUKI scan tool
command to try to reinitialise the operating values of the
EGR valve.
Switch OFF the ignition and wait 40 seconds.
Switch the ignition back on and check for faults.
If the fault is still present:
• Switch OFF the vehicle ignition.
• Disconnect the connector of the EGR valve.
• Remove the EGR valve referring to “EGR Valve Removal

and Installation in Section 1D” and reconnect it after
having removed it.

• Check that no particles are blocking the movement of the

EGR valve flap.

• Check that the EGR valve is not stuck or jammed in one

position.

• Switch ON the ignition again.
• Check the movement of the valve with displaying “EGR

position sensor” on Data List of SUZUKI scan tool (0 to
2.5 mm travel for an opening cyclic ratio of 40% and when
fully open, ~ 5 mm, for an opening cyclic ratio of 95%).

• Check that the EGR valve flap closes completely.

Is there in good condition?

Go to Step 2.

Replace the EGR valve
referring to “EGR Valve
Removal and
Installation in Section
1D”.

2

EGR VALVE BUSHING FAULT FINDING:
Remove the EGR valve referring to “EGR Valve Removal
and Installation in Section 1D” the EGR valve should not
contain a cluster of soot between the base and the valve.
Clean the EGR valve sleeve if necessary.

Is there in good condition?

Go to Step 3.

Replace the EGR valve
referring to “EGR Valve
Removal and
Installation in Section
1D”.

1A-110 Engine General Information and Diagnosis:

Test 8: Injector malfunction

S5JB0B1104173

WARNING

!

When servicing fuel system, be sure to observe WARNING in “Precautions on Fuel System Service in
Section 1G” to reduce the risk of fire and personal injury.

3

1) Use “Initialize EGR valve data” on SUZUKI scan tool

command to try to reinitialise the operating values of the
EGR valve.

2) Check the air circuit referring to “Test 3: Checking the

turbocharged air inlet circuit”.

3) Check the MAF sensor referring to “Test 4: MAF sensor”.

Is there in good condition?

Go to Step 4.

Repair as necessary.

4

Confirmation of the fault finding:
• Start the vehicle.
• Leave the engine at idling speed for 1 min.
• Accelerate very slowly up to 1500 rpm for 2 mins until the

exhaust gas recirculation function becomes active.

• Carry out a vehicle test at low speed, without accelerating

heavily, then normally.

• Check for faults using SUZUKI scan tool.

Does customer complaint or the faults recur?

Substitute a known-
good ECM and recheck.

Exhaust gas
recirculation valve
correct.

Step

Action

Yes

No

Step

Action

Yes

No

1

CHECK THE FUEL REGULATION BALANCE, INJECTOR
BY INJECTOR
• With the engine at idle speed, coolant temperature > 80

°C, 176 °F, display the each injector fuel flow correction
values “Cyl # FF Correction” on Data List of SUZUKI scan
tool.

The normal value for fuel flow correction for an injector is

±

1.0 mm

3

/stroke.

This tolerance may increase with time, but indicates an
injector/cylinder fault if it exceeds

± 5.0 mm

3

/ stroke.

Do one of these values exceed

±

5.0 mm

3

/stroke?

Go to Step 2.

Go to Step 4.

Engine General Information and Diagnosis: 1A-111

2

CHECK THE FUEL REGULATION BALANCE, INJECTOR
BY INJECTOR:
1) If at least one of these values is > +5.0 mm

3

/stroke

• Check the valve clearance.
• Check the engine compression referring to

“Compression Check in Section 1D”.
– If the compression test reveals a cylinder fault,

carry out the necessary repairs.

– If the compression is in order, check the conformity

of the assembly of the injector referring to “Fuel
Injector Removal and Installation in Section 1G”,
then check the fuel regulation again, injector by
injector. If the customer complaint is still present,
replace the injector

2) If at least one of these values is < –5.0 mm

3

/stroke

• Check the valve clearance.
• Check the level and condition of the engine oil.
• Remove the injector with the largest adjustment.
• If there is pollution via the diesel, check the condition

of the cylinder concerned (cylinder, piston, valves).

• Replace the injector.

NOTE
Before replacing an injector, check for the
presence and conformity of its sealing washer
(refer to “Table 5: Poor Performance with
Smoke”).

After replacing an injector, enter the code into an fuel
injector that has not been programmed referring to
“Registration Procedure for the Fuel Injector Calibration
Code in Section 1C”.

Is there in good condition?

Go to Step 3.

Repair as necessary.

3

CONFIRMATION OF THE FAULT FINDING FOR THE
CORRECTION OF THE FLOW, INJECTOR BY INJECTOR:
Clear the fault(s) and carry out a test with the engine at idle
speed, coolant temperature > 80

°C, 176 °F and check that

no faults appear on the diagnostic tool and the fuel flow
correction values do not reach

± 5.0 mm

3

/stroke to confirm

the repair.
• If any other cylinders have injector fuel flow correction

values >

± 5.0 mm

3

/stroke, follow the fault finding

procedure in Step 2 of this test.

• If the repairs carried out have not repaired the engine,

substitute a known-good ECM and recheck.

Is there in good condition?

Go to step 4.

Repair as necessary.

Step

Action

Yes

No

1A-112 Engine General Information and Diagnosis:

4

INJECTOR RETURN FLOW BALANCE CHECK:
• Allow the engine to heat up to a coolant temperature of >

80

°C, 176 °F.

• Switch OFF the ignition.
• Protect the upper engine edges with rags (mainly around

the injectors).

• Disconnect the injector return pipes.
• Connect special tool (09912 – 96540) to injector.
• Start the engine and let it idle.
• Disconnect the fuel pressure regulator.
• Start the ignition and perform a starting sequence

(activate the starter motor for 5 seconds),

• The flow of fuel on the return is normally very weak.
Otherwise, replace the injector.
• Clear the fault caused by the disconnection of the fuel

flow actuator.

• Refit the injector fuel return pipes after checking that the

seals and pipes are in good condition.

• If this is not the case, replace the injector fuel return

pipes.

• Confirm the repairs by means of a road test.

Special tool
(A): 09912–96540

Is there in good condition?

Go to Step 5.

Repair as necessary.

5

INJECTOR NOZZLE SEALING TEST:
• Check the level and condition of the engine oil:
• If there is pollution via the diesel fuel, the injector nozzle

which is leaking will be “greasy”.

• Disconnect the preheating relay.
Check that this is not caused by rising engine oil by checking
the engine compression values.
Check the condition of the heater plug: this must not be
humid. If this is the case, change the defective injector.
If the compression values are in order, locate the faulty
injector by examining the condition of the cylinders and the
pistons via the heater plug wells (greasy cylinder,
overheating, starting to disintegrate, etc.).
If the cylinder-piston examination is not conclusive, remove
the injectors and change the one with the “greasy” nozzle.

NOTE
Before replacing an injector, check for the
presence and conformity of its sealing washer
(refer to “Table 5: Poor Performance with
Smoke”).

Is there in good condition?

Fuel injector correct.

Repair as necessary.

Step

Action

Yes

No