Suzuki Grand Vitara JB419. Service manual — part 16

Engine General Information and Diagnosis: 1A-41

Troubleshooting

DTC P0225: Accelerator Pedal Position (APP) Sensor Assembly / Switch “C” Circuit Malfunction

S5JB0B1104101

CAUTION

!

• This fault may appear if the wiring harness has been damaged.Follow the procedure described in

“Electrical Circuit Inspection Procedure in Section 00 in related manual”.

• This check enables the condition and the conformity of the engine wiring harness to be checked.

NOTE

• Conditions for applying the fault finding procedure to stored faults:

– The fault is declared present after a series of full load/no load actions on the accelerator pedal.

• Turbocharging, passenger compartment heating resistor activation and cruise control/ speed limiter

are not authorised.
If CO.0, CC.1, 1.DEF is present the Injection warning light (gravity 1 warning light) is lit.

• The engine speed is fixed at 1400 rpm if there is a fault on main and sub of the accelerator pedal

position (APP) sensor and the engine torque is limited.

• Use service wire for all operations on the controller connectors.
• Priorities when dealing with a number of faults:

– Deal with fault “DTC P0641: Sensor Reference Voltage “A” Circuit / Open Malfunction” first if it is

present or stored.

Wiring Diagram
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in
Section 9A”.

Detecting Condition

Check the connections on fuel injector No.4.
Check the ECM connections.
Repair if necessary.
Disconnect fuel injector No.4.
Measure the resistance of fuel injector No.4 between “C07-1” and “C07-2” terminals.
Replace the fuel injector if there is a short circuit (R = 0

Ω) or an open circuit (resistance = infinity).

Otherwise reconnect fuel injector No.1.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “C07-2” wire of fuel injector No.4 connector and “C85-28” terminal of ECM connector
• Between “C07-1” wire of fuel injector No.4 connector and “C85-31” terminal of ECM connector
If the fault is still present: apply Test 8 of Fault Finding-Tests referring to “Test 8: Injector malfunction”.
If the fault is still present, substitute a known-good ECM and recheck.

Displaying on SUZUKI scan tool

Detecting condition

CO.0

Open circuit or short circuit to vehicle body ground

CC.1

Short circuit to +12 V

1.DEF

Inconsistency of signal

2.DEF

Accelerator pedal position (APP) sensor locked

1A-42 Engine General Information and Diagnosis:

Troubleshooting for CO.0: Open circuit or short circuit to vehicle body ground

NOTE
Priorities when dealing with a number of faults:
• If fault “DTC P2120: Throttle/Pedal Position Sensor/Switch “D” Circuit Malfunction” is present at the

same time, check that the accelerator pedal position (APP) sensor assembly connector is
connected correctly.

Troubleshooting for CC.1: Short circuit to +12 V

Troubleshooting for 1.DEF: Inconsistency of signal

Check the connections of the accelerator pedal position (APP) sensor.
Check the ECM connections.
Repair if necessary.
Check the continuity and insulation from vehicle body ground of the following connections:
• Between “E68-3” wire of accelerator pedal position (APP) sensor connector and “E66-3” terminal of ECM

connector

• Between “E68-2” wire of accelerator pedal position (APP) sensor connector and “E66-4” terminal of ECM

connector

Repair if necessary.
Measure the resistance on the accelerator pedal position (APP) sensor (main) on accelerator pedal position
(APP) sensor assembly between “E68-4” and “E68-2”.
Replace the accelerator pedal position (APP) sensor assembly if the resistance is not approximately 0.8 – 2.6
k

Ω.

Check the connections of the accelerator pedal position (APP) sensor.
Check the ECM connections.
Repair if necessary.
Check for continuity and insulation from the +12 V feed on the following connections:
• Between “E68-3” wire of accelerator pedal position (APP) sensor connector and “E66-3” terminal of ECM

connector

• Between “E68-2” wire of accelerator pedal position (APP) sensor connector and “E66-4” terminal of ECM

connector

• Between “E68-4” wire of accelerator pedal position (APP) sensor connector and “E66-5” terminal of ECM

connector

Repair if necessary.
Measure the resistance on the accelerator pedal position (APP) sensor (main) on accelerator pedal position
(APP) sensor assembly between “E68-4” and “E68-2”.
Replace the accelerator pedal position (APP) sensor assembly if the resistance is not approximately 0.8 – 2.6
k

Ω.

Check the connections of the accelerator pedal position (APP) sensor.
Check the ECM connections.
Repair if necessary.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “E68-3” wire of accelerator pedal position (APP) sensor connector and “E66-3” terminal of ECM

connector

• Between “E68-2” wire of accelerator pedal position (APP) sensor connector and “E66-4” terminal of ECM

connector

• Between “E68-4” wire of accelerator pedal position (APP) sensor connector and “E66-5” terminal of ECM

connector

• Between “E68-6” wire of accelerator pedal position (APP) sensor connector and “E66-21” terminal of ECM

connector

• Between “E68-1” wire of accelerator pedal position (APP) sensor connector and “E66-15” terminal of ECM

connector

• Between “E68-5” wire of accelerator pedal position (APP) sensor connector and “E66-27” terminal of ECM

connector

If the fault is still present, replace the accelerator pedal position (APP) sensor assembly.

Engine General Information and Diagnosis: 1A-43

Troubleshooting for 2.DEF: Accelerator pedal position (APP) sensor locked

DTC P0235: Turbo / Super Charger Boost Sensor “A” Circuit Malfunction

S5JB0B1104102

CAUTION

!

This fault can result in a rapid and significant fouling of the diesel particulate filter.

NOTE

• Conditions for applying the fault finding procedure to stored faults:

The fault is declared present:
– When an attempt is made to start the engine
– With the engine running

• Use service wire for all operations on the ECM connectors.
• If the fault is present:

– The EGR function is inhibited.
– The turbocharging pressure value changes to safe mode: “Turbo Pressure” on Data List of

SUZUKI scan tool = 1000 hPa.

– The Injection warning light (gravity 1 warning light) is lit.

• Order of priority in the event of more than one fault:

Deal with fault “DTC P0641: Sensor Reference Voltage “A” Circuit / Open Malfunction” first if it is
present or stored.

Wiring Diagram
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in
Section 9A”.

Detecting Condition

Troubleshooting for CO.0: Open circuit or short circuit to vehicle body ground

Check the mechanical status of the accelerator pedal:
• Locked in full load position.
• Pedal blocked by an external component.

Repair if necessary.
Vary the position of the pedal and display the parameter “Pedal position” on Data List of SUZUKI scan tool.
If the values displayed are inconsistent, replace the accelerator pedal position (APP) sensor assembly.

Displaying on SUZUKI scan tool

Detecting condition

CO.0

Open circuit or short circuit to vehicle body ground

CC.1

Short circuit to +12 V

1.DEF

Inconsistency of signal

Check the boost pressure sensor connections.
Check the ECM connections.
Repair if necessary.
Check the continuity and insulation from vehicle body ground of the following connections:
• Between “C76-3” wire of boost pressure sensor connector and “C86-42” terminal of ECM connector
• Between “C76-74” wire of boost pressure sensor connector and “C86-19” terminal of ECM connector
Repair if necessary.
If the fault is still present, replace the boost pressure sensor.

1A-44 Engine General Information and Diagnosis:

Troubleshooting for CC.1: Short circuit to +12 V

Troubleshooting for 1.DEF: Inconsistency of signal

DTC P0243: Turbo / Super Charger Wastegate Solenoid “A” Malfunction

S5JB0B1104103

CAUTION

!

This fault can result in a rapid and significant fouling of the diesel particulate filter.

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine is started or following a road test.

• If the fault is present:

– Turbocharging is no longer authorised.
– The EGR function is inhibited.
– The Injection warning light (gravity 1 warning light) is lit.

• Use service wire for all operations on the ECM connectors.
• Order of priority in the event of more than one fault:

– Firstly, deal with fault “DTC P1431: Clogged Particulate Filter Failures Malfunction” if it is present

or stored.

Detecting Condition

Check the boost pressure sensor connections.
Check the ECM connections.
Repair if necessary.
Check the continuity and insulation against +12 volts of the following connections:
• Between “C76-3” wire of boost pressure sensor connector and “C86-42” terminal of ECM connector
• Between “C76-14” wire of boost pressure sensor connector and “C86-45” terminal of ECM connector
• Between “C76-4” wire of boost pressure sensor connector and “C86-19” terminal of ECM connector
Repair if necessary.
If the fault is still present, replace the boost pressure sensor.

In the event of a number of faults with “DTC P0105: Manifold Absolute Pressure / Barometric Pressure Circuit
Malfunction”, display parameter “Turbo Pressure” on Data List of SUZUKI scan tool.
If this value is locked at 1000 hPa and “Barometric Pres” on Data List of SUZUKI scan tool is displaying a
different value, replace the boost pressure sensor.
Check the boost pressure sensor connections.
Check the ECM connections.
Repair if necessary.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “C76-3” wire of boost pressure sensor connector and “C86-42” terminal of ECM connector
• Between “C76-1” wire of boost pressure sensor connector and “C86-45” terminal of ECM connector
• Between “C76-4” wire of boost pressure sensor connector and “C86-19” terminal of ECM connector
Repair if necessary.
If the fault is still present, replace the boost pressure sensor.

Displaying on SUZUKI scan tool

Detecting condition

1.DEF

Pressure too low

2.DEF

Pressure too high