Suzuki Grand Vitara JB419. Manual - part 30

Engine General Information and Diagnosis:  1A-97

Table 4: Injection Noise

S5JB0B1104157

Troubleshooting

Step

Action

Yes

No

1

If injection noise occurs after starting from cold:
Check the priming of the low pressure fuel circuit.
Check the fuel heater supply.
Check the operation of the preheating system.
Check that fuel and engine temperatures are consistent.

Is there in good condition?

Go to Step 2.

Carry out the required 
repairs.

2

If the injection noises occur at idling speed:
Check the condition of the injector connector and pressure 
regulator terminals.
Check the conformity of the air flow signal “MAF” on Data 
List of SUZUKI scan tool or perform test 3 referring to “Test 
3: Checking the turbocharged air inlet circuit”.

Is there in good condition?

Go to Step 3.

Carry out the required 
repairs.

3

If the injection noise occur at all engine speeds:
Perform fault finding on the injectors referring to “Test 8: 
Injector malfunction”.
Check the condition of the injector connector and pressure 
regulator terminals.
Ensure that the correct fuel is being used:
Smell and compare the fuel with unpolluted diesel fuel:
To detect petrol, solvent, thinner, sulphuric acid (fuel with a 
white colour), water or fuel oil.
If the diesel fuel is not correct:
• Replace the diesel fuel.
• Change the fuel filter.
• Bleed the low and high pressure diesel circuit.
Check the conformity of the air flow signal “MAF” on Data 
List of SUZUKI scan tool.

Is there in good condition?

End of fault finding.

Carry out the required 
repairs.

1A-98 Engine General Information and Diagnosis: 

Table 5: Poor Performance with Smoke

S5JB0B1104158

NOTE
In the case of engine overheating to more than 119 

°C, 246°F the computer deliberately limits the fuel 

flow (overheating warning light illuminates from 115 

°C, 239 °F).

 

Troubleshooting

Step

Action

Yes

No

1

Is the poor performance accompanied by smoke?

Go to Step 2.

Go to Table 6 referring 
to “Table 6: Poor 
Performance without 
Smoke”.

2

Check the following:
Ensure that the correct fuel is being used:
Smell and compare the fuel with unpolluted diesel fuel:
To detect petrol, solvent, thinner, sulphuric acid (fuel with a 
white colour), water or fuel oil.
If the diesel fuel is not correct:
• Replace the diesel fuel.
• Change the diesel filter.
Bleed the low and high pressure diesel circuit.

Is there in good condition?

Go to Step 3.

Carry out the required 
repairs.

3

The conformity of the assembly of the injectors (presence 
and conformity of the sealing washer).
Checking procedure:
• Take a straightedge approximately 40 cm (15.7 in.) long 

and place it on the 4 injectors. The straightedge should 
rest on the 4 injectors.

• If 1 injector protrudes, remove the injector and check that 

the sealing washer is correct.

• If one injector does not touch the straightedge (clearance 

of more than 1 mm (0.040 in.)), remove the injector and 
check that there is a sealing washer.

• Clean the injector wells and the injector, refit the injector 

with the correct sealing washer.

Is there in good condition?

Go to Step 4.

Carry out the required 
repairs.

4

Check the following:
The sealing and condition of the inlet circuit referring to “Test 
3: Checking the turbocharged air inlet circuit”.
The condition of the MAF sensor referring to “Test 4: MAF 
sensor”.
The turbocharger referring to “Test 5: Variable geometry 
turbocharger control” and “Test 6: Rotating part of a 
turbocharger”.
Check that the boost pressure follows the rise in the engine 
speed and that the loop difference with the boost pressure is 
low.

Is there in good condition?

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

Replace turbocharger.

Engine General Information and Diagnosis:  1A-99

Table 6: Poor Performance without Smoke

S5JB0B1104159

NOTE
In the case of engine overheating to more than 119 

°C, 246 °F the computer deliberately limits the fuel 

flow (overheating warning light illuminates from 115 

°C, 239 °F).

 

Troubleshooting

Step

Action

Yes

No

1

Is the engine running on all cylinders?

Go to Step 2.

Check the injector 
operation referring to 
“Test 8: Injector 
malfunction”.

2

Check the conformity of the accelerator pedal position 
sensor, the brake lamp switch, the boost pressure sensor, 
the EGR valve and the inlet throttle valve.

Is there in good condition?

Go to Step 3.

Carry out the required 
repairs.

3

Check the consistency of the signal: of the MAF sensor, of 
the ECT sensor and of the engine speed.
Check the connections, the continuity and absence of 
interference resistance of the MAF sensor (refer to “DTC 
P0100: Mass or Volume Air Flow Circuit Malfunction” of 
troubleshooting for 2.DEF: Offset at minimum threshold.), of 
the ECT sensor (refer to “DTC P0115: Engine Coolant 
Temperature Circuit Malfunction”), and the engine speed 
(refer to “DTC P0016: Crankshaft Position-Camshaft 
Position Correlation Malfunction”).

Is there in good condition?

Go to Step 4.

Carry out the required 
repairs.

4

Check the following:
• Diesel filter not clogged (for the test, refer to “DTC P0089: 

Fuel Pressure Regulator 1 Performance Malfunction” of 
troubleshooting for 2.DEF: Measured pressure too low.).

• There are no leaks on the low and high pressure air 

circuits referring to “Test 3: Checking the turbocharged air 
inlet circuit”.

• The oil vapour rebreathing system is connected.
• The fuel flow actuator (blocked/seized, perform output 

test “IMV/Flow actuator” on SUZUKI scan tool.).

• The engine timing (and the position of the high pressure 

pump sprocket).

Is there in good condition?

Go to Step 5.

Carry out the required 
repairs.

5

Are the compressions correct?

End of fault finding.

Carry out the required 
repairs.

1A-100 Engine General Information and Diagnosis: 

Table 7: Irregular Engine Operation

S5JB0B1104160

Troubleshooting

Step

Action

Yes

No

1

If the engine races during gear changes, check, if there is a 
floor carpet, that this is not blocking the accelerator pedal, 
the brake pedal and the clutch pedal, then check the 
conformity of the clutch switch and the conformity of the 
accelerator pedal sensor when the pedal is released.

Is there in good condition?

Go to Step 2.

Carry out the required 
repairs.

2

Check the following:
• CKP sensor and its circuit (refer to “DTC P0335: 

Crankshaft Position Sensor “A” Circuit Malfunction”.).

• Check that the engine earthing is in order (oxidation, 

tightness, etc.).

• Check the mounting, the air gap and the condition of the 

sensor (overheating).

Is there in good condition?

Go to Step 3.

Carry out the required 
repairs.

3

Low pressure circuit check.
Check the fuel flow actuator by applying Step 12 of the 
“Table 9: Rough idle” finding table.
The sealing and condition of the inlet circuit referring to “Test 
3: Checking the turbocharged air inlet circuit”.
The condition of the air flow sensor referring to “Test 4: MAF 
sensor”.
The turbocharger referring to “Test 5: Variable geometry 
turbocharger control” and “Test 6: Rotating part of a 
turbocharger”.

Is there in good condition?

Go to Step 4.

Carry out the required 
repairs.

4

Are the compressions correct?

End of fault finding.

Carry out the required 
repairs.