Suzuki Grand Vitara JB419. Manual - part 27

Engine General Information and Diagnosis:  1A-85

DTC P2120: Throttle/Pedal Position Sensor/Switch “D” Circuit Malfunction

S5JB0B1104137

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 the fault 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” wire 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:

Apply the procedure for dealing with fault “DTC P0651: Sensor Reference Voltage “B” 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

NOTE
Priorities when dealing with a number of faults:
If fault “DTC P0225: Accelerator Pedal Position (APP) Sensor Assembly / Switch “C” Circuit 
Malfunction” is present at the same time, check that the sensor is connected correctly.

 

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 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 “E68-6” 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

Repair if necessary.
Measure the resistance on the accelerator pedal position (APP) sensor (sub) on accelerator pedal position 
(APP) sensor assembly between “E68-1” and “E68-5” terminals.
Replace the accelerator pedal position (APP) sensor assembly if the resistance is not 0.8 – 4.9 k

Ω.

1A-86 Engine General Information and Diagnosis: 

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

NOTE
Priorities when dealing with a number of faults:
If fault “DTC P0225: Accelerator Pedal Position (APP) Sensor Assembly / Switch “C” Circuit 
Malfunction” is present at the same time, check that the sensor is connected correctly.

 

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 in relation to +12 V of the following connections:
• 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

Repair if necessary.
Measure the resistance on the accelerator pedal position (APP) sensor (sub) on accelerator pedal position 
(APP) sensor assembly between “E68-1” and “E68-5” terminals.
Replace the accelerator pedal position (APP) sensor assembly if its resistance is not approximately: 0.8 – 4.9 
k

Ω.

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 “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

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

Engine General Information and Diagnosis:  1A-87

DTC P2141: Exhaust Gas Recirculation Throttle Control Circuit Low Malfunction

S5JB0B1104138

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.

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

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 a road test.

• If the fault is present:

– The EGR function is inhibited.
– Diesel particulate filter regenerations are inhibited.
– Turbocharging is disabled,
– The Injection warning light (gravity 1 warning light) is lit.

• Use service wire for any operation on the ECM connectors.

 

Troubleshooting

Check the connections of the EGR valve
Check the ECM connections.
Repair if necessary.
• Check the operation of the EGR valve:

Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve”.

• If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reintialise 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-88 Engine General Information and Diagnosis: 

DTC P2142: Exhaust Gas Recirculation Throttle Control Circuit High Malfunction

S5JB0B1104139

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.

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

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 a road test.

• If the fault is present:

– The EGR and turbocharging functions are inhibited.
– The Injection warning light (gravity 1 warning light) is lit.

• Use service wire for any operation on the ECM connectors.

 

Troubleshooting

Check the connections of the EGR valve
Check the ECM connections.
Repair if necessary.
• Check the operation of the EGR valve:

Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve”.

• If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reinitialize 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.