Suzuki Grand Vitara JB419. Manual - part 19

Engine General Information and Diagnosis:  1A-53

DTC P0409: Exhaust Gas Recirculation Sensor “A” Circuit Malfunction

S5JB0B1104113

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 2.DEF 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: Exhaust Gas Recirculation Control Circuit 
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

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 in Section 1C” to carry out this programming.

 

Displaying on SUZUKI scan tool

Detecting condition

1.DEF

Insufficient EGR valve flow

2.DEF

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 in Section 1C”).
If the valve is jammed or irrevocably seized, replace the EGR valve.

1A-54 Engine General Information and Diagnosis: 

DTC P0470: Exhaust Pressure Sensor Malfunction

S5JB0B1104114

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:

– The Injection warning light (gravity 1 warning light) is lit.
– The diagnostic of the diesel particulate filter is inhibited.
– Diesel particulate filter regenerations are inhibited.

 

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: Open circuit and CC.1: Short circuit to +12 V

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

Troubleshooting for 1.DEF: Inconsistency of signal and 2.DEF: Signal outside lower limit

Displaying on SUZUKI scan tool

Detecting condition

CO

Open circuit

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

Signal outside lower limit

Check the condition of the connectors on the differential pressure sensor and the ECM.
Repair if necessary.
Check the following connections for insulation, continuity and make sure there is no interference resistance:
• Between “C89-2” wire of differential pressure sensor connector and “C85-12” terminal of ECM connector
• Between “C89-3” wire of differential pressure sensor connector and “C85-14” terminal of ECM connector
• Between “C89-1” wire of differential pressure sensor connector and “C86-42” terminal of ECM connector
Repair if necessary.
Check for the presence of ground on “C89-2” of the differential pressure sensor connector.
Repair if necessary.
If the fault is still present, substitute a known-good ECM and recheck.

Check the continuity, the absence of interference resistance and the insulation from vehicle body ground of the 
following connections:
• Between “C89-3” wire of differential pressure sensor connector and “C85-14” terminal of ECM connector
• Between “C89-1” wire of differential pressure sensor connector and “C86-42” terminal of ECM connector
Repair if necessary.
If the fault is still present, substitute a known-good ECM and recheck.

Check the condition of the pressure pipes on the differential pressure sensor.
Verify that they are sealed and check their position.
Replace if necessary.
Check the condition of the connectors on the differential pressure sensor and the ECM.
Repair if necessary.
Check the continuity and for the absence of interference resistance on the following connections:
• Between “C89-3” wire of differential pressure sensor connector and “C85-14” terminal of ECM connector
• Between “C89-1” wire of differential pressure sensor connector and “C86-42” terminal of ECM connector
Repair if necessary.
If the fault is still present, change the differential pressure sensor.

Engine General Information and Diagnosis:  1A-55

DTC P0480: Fan 1 Control Circuit

S5JB0B1104150

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine is started.

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

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

Displaying on SUZUKI scan tool

Detecting condition

CO.0

Open circuit or short circuit to vehicle body ground

CO.1

Short circuit to +12 V

Check the condition of the radiator fan relay No.1 (Low).
Check the ECM connections.
Repair if necessary.
Check the radiator fan relay No.1 (Low) mounting connections.
If these checks are correct,
Check the continuity and insulation from vehicle body ground of the following connections:
• Between “E29-5” wire of radiator fan relay No.1 (Low) mounting connector and “C85-20” terminal of ECM 

connector

• Between “E29-3” wire of radiator fan relay No.1 (Low) mounting connector and “E33-6” wire of main relay 

connector

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

Check the condition of the radiator fan relay No.1 (Low).
Check the ECM connections.
Repair if necessary.
Check the radiator fan relay No.1 (Low) mounting connections.
Check the continuity and insulation from +12 V of the following connection:
• Between “E29-5” wire of radiator fan relay No.1 (Low) mounting connector and “C85-20” terminal of ECM 

connector

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

1A-56 Engine General Information and Diagnosis: 

DTC P0481: Fan 2 Control Circuit

S5JB0B1104151

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine is started.

• “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 CO.0: Open circuit or short circuit to vehicle body ground

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

Displaying on SUZUKI scan tool

Detecting condition

CO.0

Open circuit or short circuit to vehicle body ground

CO.1

Short circuit to +12 V

Check the condition of the radiator fan relay No.2 (High) and radiator fan relay No.3 (High).
Check the ECM connections.
Repair if necessary.
Check the radiator fan relay No.2 (High) and radiator fan relay No.3 (High) mounting connections.
If these checks are correct,
Check the continuity and insulation from vehicle body ground of the following connections:
• Between “E30-5” wire of radiator fan relay No.2 (High) mounting connector and “C85-18” terminal of ECM 

connector

• Between “E30-3” wire of radiator fan relay No.2 (High) mounting connector and “E33-6” wire of main relay 

connector

• Between “E31-5” wire of radiator fan relay No.3 (High) mounting connector and “C85-18” terminal of ECM 

connector

• Between “E31-3” wire of radiator fan relay No.3 (High) mounting connector and “E33-6” wire of main relay 

connector

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

Check the condition of the radiator fan relay No.2 (High) and radiator fan relay No.3 (High).
Check the ECM connections.
Repair if necessary.
Check the radiator fan relay No.2 (High) and radiator fan relay No.3 (High) mounting connections.
Check the continuity and insulation from +12 V of the following connection:
• Between “E30-5” wire of radiator fan relay No.2 (High) mounting connector and “C85-18” terminal of ECM 

connector

• Between “E31-5” wire of radiator fan relay No.3 (High) mounting connector and “C85-18” terminal of ECM 

connector

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