Suzuki Grand Vitara JB419. Manual - part 15

Engine General Information and Diagnosis:  1A-37

Troubleshooting for 1.DEF: Offset at minimum threshold

DTC P0201: Fuel Injector Circuit / Open Malfunction-Cylinder 1

S5JB0B1104097

CAUTION

!

 

• This fault can result in a rapid and significant fouling of the diesel particulate filter.
• 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 test enables the condition and the conformity of the engine wiring harness to be checked.

 

NOTE

• Cylinder number is counted from flywheel side.
• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine has been started.

• If CC.1, CC, or 1.DEF is present, the Red stop warning light (gravity 2 warning light) is lit.
• If CO is present the Injection warning light (gravity 1 warning light) is lit.
• If CO is still present, the Malfunction indicator light (MIL) will come on after three consecutive 

driving cycles (starting +5 seconds + turn OFF ignition switch and wait 40 seconds.).

• If the fault is present, the injection on cylinder 1 is disabled.
• 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

Check the fuel pressure sensor connectors.
Check the ECM connections.
Repair if necessary.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “C84-2” wire of fuel pressure sensor connector and “C86-32” terminal of ECM connector
• Between “C84-3” wire of fuel pressure sensor connector and “C86-48” terminal of ECM connector
• Between “C84-1” wire of fuel pressure sensor connector and “C86-46” terminal of ECM connector
Repair if necessary.
With ignition switch ON and the engine stationary for more than one minute:
• Check for fuel pressure sensor output voltage between “C84-2” and “C84-1” wire of fuel pressure sensor 

connector.
– If the voltage is above 0.5V, the sensor is in order.

• In this case, substitute a known-good ECM and recheck.

– If the voltage is below 0.5V, replace the fuel pressure sensor with common rail referring to “Common Rail 

(High Pressure Fuel Injection Rail) Removal and Installation in Section 1G”.

Displaying on SUZUKI scan tool

Detecting condition

CC.1

Short circuit to +12 V

CO

Open circuit

CC

Short circuit

1.DEF

Fuel injector control

1A-38 Engine General Information and Diagnosis: 

Troubleshooting

DTC P0202: Fuel Injector Circuit / Open Malfunction-Cylinder 2

S5JB0B1104098

CAUTION

!

 

• Cylinder number is counted from flywheel side.
• This fault can result in a rapid and significant fouling of the diesel particulate filter.
• 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 test enables the condition and the conformity of the engine wiring harness to be checked.

 

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine has been started.

• If CC.1, CC, or 1.DEF is present, the Red stop warning light (gravity 2 warning light) is lit.
• If CO is present the Injection warning light (gravity 1 warning light) is lit.
• If CO is still present, the Malfunction indicator light (MIL) will come on after three consecutive 

driving cycles (starting +5 seconds + turn OFF ignition switch and wait 40 seconds.).

• If the fault is present, the injection on cylinder 2 is disabled.
• 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

Check the connections on fuel injector No.1.
Check the ECM connections.
Repair if necessary.
Disconnect fuel injector No.1.
Measure the resistance of fuel injector No.1 between “C04-1” and “C04-2” 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 “C04-2” wire of fuel injector No.1 connector and “C85-27” terminal of ECM connector
• Between “C04-1” wire of fuel injector No.1 connector and “C85-32” 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

CC.1

Short circuit to +12 V

CO

Open circuit

CC

Short circuit

1.DEF

Fuel injector control

Engine General Information and Diagnosis:  1A-39

Troubleshooting

DTC P0203: Fuel Injector Circuit / Open Malfunction-Cylinder 3

S5JB0B1104099

CAUTION

!

 

• Cylinder number is counted from flywheel side.
• This fault can result in a rapid and significant fouling of the diesel particulate filter.
• 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 test enables the condition and the conformity of the engine wiring harness to be checked.

 

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine has been started.

• If CC.1, CC, or 1.DEF is present, the Red stop warning light (gravity 2 warning light) is lit.
• If CO is present the Injection warning light (gravity 1 warning light) is lit.
• If CO is still present, the Malfunction indicator light (MIL) will come on after three consecutive 

driving cycles (starting +5 seconds + turn OFF ignition switch and wait 40 seconds.).

• If the fault is present, the injection on cylinder 3 is disabled.
• 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

Check the connections on fuel injector No.2.
Check the ECM connections.
Repair if necessary.
Disconnect fuel injector No.2.
Measure the resistance of fuel injector No.2 between “C05-1” and “C05-2” 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.2.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “C05-2” wire of fuel injector No.2 connector and “C85-25” terminal of ECM connector
• Between “C05-1” wire of fuel injector No.2 connector and “C85-29” 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

CC.1

Short circuit to +12 V

CO

Open circuit

CC

Short circuit

1.DEF

Fuel injector control

1A-40 Engine General Information and Diagnosis: 

Troubleshooting

DTC P0204: Fuel Injector Circuit / Open Malfunction-Cylinder 4

S5JB0B1104100

CAUTION

!

 

• Cylinder number is counted from flywheel side.
• This fault can result in a rapid and significant fouling of the diesel particulate filter.
• 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 test enables the condition and the conformity of the engine wiring harness to be checked.

 

NOTE

• Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine has been started.

• If CC.1, CC, or 1.DEF is present, the Red stop warning light (gravity 2 warning light) is lit.
• If CO is present the Injection warning light (gravity 1 warning light) is lit.
• If CO is still present, the Malfunction indicator light (MIL) will come on after three consecutive 

driving cycles (starting +5 seconds + turn OFF ignition switch and wait 40 seconds.).

• If the fault is present, the injection on cylinder 4 is disabled.
• 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

Check the connections on fuel injector No.3.
Check the ECM connections.
Repair if necessary.
Disconnect fuel injector No.3.
Measure the resistance of fuel injector No.3 between “C06-1” and “C06-2” 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.3.
Check the following connections for continuity and make sure there is no interference resistance:
• Between “C06-2” wire of fuel injector No.3 connector and “C85-26” terminal of ECM connector
• Between “C06-1” wire of fuel injector No.3 connector and “C85-30” 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

CC.1

Short circuit to +12 V

CO

Open circuit

CC

Short circuit

1.DEF

Fuel injector control