Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 92

1A-315 Engine General Information and Diagnosis: For Diesel Engine Model

Troubleshooting

DTC P0340: CMP Sensor Circuit

S6JB0A1124110

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.A drop in engine
speed followed by nominal behavior from the vehicle is possible.

• If this fault is present:

– It is impossible to start the vehicle.
– The Injection warning light (gravity 1 warning light) is lit.

• Use service wire for all operations on the ECM connectors.

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

Check the CKP sensor connections.
Repair if necessary.
Check that the sensor is correctly mounted and that the flywheel target is not damaged.
Check that the gap between the CKP sensor and the engine flywheel is 0.5 – 1.8 mm (0.020 – 0.071 in.).
Measure the resistance of the CKP sensor between “C20-1” and “C20-2” terminals of CKP sensor connector.
If the coil resistance is not 720 – 880

Ω at an engine temperature of 20 °C, 68 °F, replace the CKP sensor.

Check the ECM connections.
Repair if necessary.
Check the following connections for continuity and the absence of interference resistance:
• Between “C20-1” wire of CKP sensor connector and “C86-17” terminal of ECM connector
• Between “C20-2” wire of CKP sensor connector and “C86-16” terminal of ECM connector
Repair if necessary.
If the fault is still present, substitute a known-good ECM and recheck.

Displaying on SUZUKI scan tool

Detecting condition

D1

No signal

D2

Inconsistency of signal

Check the CMP sensor connections.
Check the ECM connections.
Check the CMP sensor mounting and positioning.
Also check its general condition, (damaged housing, heating up, etc.)
Carry out the necessary repairs.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “C08-2” wire of CMP sensor connector and “C86-15” terminal of ECM connector
• Between “C08-1” wire of CMP sensor connector and “C86-18” terminal of ECM connector
With ignition switch ON and the CMP sensor connected:
• Use a voltmeter to measure the voltage across “C08-1” and “C08-3” wires of the CMP sensor connector:

The voltage displayed should be equal to the battery voltage 0.08 V)
– If the voltage is outside permitted tolerance values, take the measurement again on the connector, with the

CMP sensor disconnected.

– If the voltage is still outside permitted tolerance values with the sensor disconnected.

• Check the following connection for continuity and the absence of interference resistance:

– Between “C08-3” wire of the CMP sensor connector and “E33-6” wire of main relay mounting connector

If the measured voltage is correct with the sensor disconnected.

Measure the CMP sensor resistance between “C08-2” and “C08-3” terminals.
Replace the sensor if the resistance is not 9750 – 10750

Ω at 20 °C, 68 °F.

If the fault is still present, substitute a known-good ECM and recheck.

Engine General Information and Diagnosis: For Diesel Engine Model 1A-316

DTC P0380: Glow Plug Control Module Circuit

S6JB0A1124111

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after output test “Pre/Post Heater Relay Control” on SUZUKI scan tool,
or after an attempted engine start.

• If the fault is present, it is difficult or even impossible to start the vehicle when cold.
• If the fault is present, the Injection warning light (gravity 1 warning light) is lit.
• Use service wire for all operations on the ECM connectors.

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 CC1: Short circuit to +12 V

Troubleshooting for CC0: Open circuit or short circuit to vehicle body ground and CO: Open circuit

NOTE

• If the glow plug control module has a short circuit to vehicle body ground there is a risk that the

glow plugs will be operated continuously.

• The glow plugs and the engine may be damaged.

Displaying on SUZUKI scan tool

Detecting condition

CC1

Short circuit to +12 V

CC0

Open circuit or short circuit to vehicle body ground

CO

Open circuit

D1

Internal electronic fault

Check the glow plug control module connections and the glow plug supply cables.
Check the ECM connections.
Repair if necessary.
Check the condition of the 80A fuse on the battery fuse box.
Check for continuity and insulation against the +12 V feed on the following connections:
• Between “C74-3” wire of glow plug control module connector and “C85-1” terminal of ECM connector
• Between “C74-1” wire of glow plug control module connector and “C85-17” terminal of ECM connector
Repair if necessary.
If the fault is still present, replace the glow plug control module.

Check the glow plug control module connections and the glow plug supply cables.
Check the ECM connections.
Repair if necessary.
Check the condition of the 80A fuse on the battery fuse box.
Check the continuity and insulation against vehicle body ground of the following connection:
• Between “C74-3” wire of glow plug control module connector and “C85-1” terminal of ECM connector
• Between “C74-1” wire of glow plug control module connector and “C85-17” terminal of ECM connector
Repair if necessary.
If the fault is still present, replace the glow plug control module.

1A-317 Engine General Information and Diagnosis: For Diesel Engine Model

Troubleshooting for D1: Internal electronic fault

DTC P0403: EGR Control Circuit

S6JB0A1124112

NOTE

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

The fault is declared present after a road test.

• The EGR function is deactivated if several faults with “DTC P0638: Inlet Throttle Valve Control

Range / Performance: For Diesel Engine Model” are present.

• If D1 is present,

– The Injection warning light (gravity 1 warning light) is lit.
– The vehicle performances are reduced.
– There is smoke at the exhaust.

• Use service wire for all operations on the ECM connectors.

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

CAUTION

!

EGR valve data initialization procedure is required when the EGR valve is replaced.
The “EGR valve initial offset” and “EGR valve last offset” parameters must be reinitialised.
Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C” to carry out this
programming.

Check the glow plug control module connections and the glow plug supply cables.
Check the ECM connections.
Repair if necessary.
Check the condition of the 80A fuse on the battery fuse box.
Check the continuity and insulation against vehicle body ground of the following connection:
• Between “C74-3” wire of glow plug control module connector and “C85-1” terminal of ECM connector
• Between “C74-1” wire of glow plug control module connector and “C85-17” terminal of ECM connector
Repair if necessary.
If the fault is still present, replace the glow plug control module.

Displaying on SUZUKI scan tool

Detecting condition

D1

Valve stuck open

D2

Valve stuck closed

Check the EGR valve connections.
Check the ECM connections.
Repair if necessary.
Measure the resistance of the EGR valve motor between “C10-4” and “C10-6” terminals.
If the resistance displayed is not approximately 2.66 – 3.26

Ω at 20 °C, 68 °F, replace the EGR valve.

Check the following connections for continuity and make sure there is no interference resistance:
• Between “C10-4” wire of EGR valve connector and “C86-26” terminal of ECM connector
• Between “C10-6” wire of EGR valve connector and “C86-25” terminal of ECM connector
Check there are no leaks on the EGR circuit: pipe pierced or damaged and that clamps are properly tightened.
Check the operation of the EGR valve:
Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and
launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine
Model in Section 1C”).
If the valve is jammed or irrevocably seized, replace the EGR valve.

Engine General Information and Diagnosis: For Diesel Engine Model 1A-318

DTC P0409: EGR Motor Malfunction

S6JB0A1124113

CAUTION

!

This fault can result in a rapid and significant fouling of the diesel particulate filter. If the EGR needs to
be replaced to deal with the fault, it must be cleared.

NOTE

• Conditions for applying fault finding procedures to stored faults: The fault is declared present after:

– Engine start.
– A road test.

• If the fault is present the EGR function is deactivated.
• If D2 is present,

– The Injection warning light (gravity 1 warning light) is lit.
– There is smoke at the exhaust.

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

Apply the procedure for dealing with fault “DTC P0403: EGR Control Circuit: For Diesel Engine
Model” 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

CAUTION

!

EGR valve data initialization procedure is required when the EGR valve is replaced.
The “EGR valve initial offset” and “EGR valve last offset” parameters must be reinitialised.
Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C” to carry out this
programming.

Displaying on SUZUKI scan tool

Detecting condition

D1

Insufficient EGR valve flow

D2

Excessive EGR valve flow

Check the EGR valve connections.
Check the ECM connections.
Repair if necessary.
Measure the resistance of the EGR valve motor between “C10-4” and “C10-6” terminals.
If the resistance displayed is not approximately 2.66 – 3.26

Ω at 20 °C, 68 °F, replace the EGR valve.

Check the following connections for continuity and make sure there is no interference resistance:
• Between “C10-4” wire of EGR valve connector and “C86-26” terminal of ECM connector
• Between “C10-6” wire of EGR valve connector and “C86-25” terminal of ECM connector
Check there are no leaks on the EGR circuit: pipe pierced or damaged and that clamps are properly tightened.
Check the operation of the EGR valve:
Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and
launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine
Model in Section 1C”).
If the valve is jammed or irrevocably seized, replace the EGR valve.