Suzuki Grand Vitara JB419. Manual - part 33

Engine General Information and Diagnosis:  1A-109

Test 7: Exhaust gas recirculation valve

S5JB0B1104172

3

Manually check the axial play of the wheels. ([A]: Axial play, 
[B]: Radial play)

The significant axial play is approximately 2 mm (0.080 in.). 
Does the turbo have too much play in the shaft?

Replace the 
turbocharger. If the 
rotating part is broken:
change the engine oil 
and the oil filter.
clean the intercooler 
and the air circuit ducts.

The rotating part is in 
order.

Step

Action

Yes

No

I5JB0B110015-01

Step

Action

Yes

No

1

VALVE POSITION FAULT FINDING:
Or detection of a leak in the exhaust gas recirculation valve
Clear the faults.
Use “Initialize EGR valve data” on SUZUKI scan tool 
command to try to reinitialise the operating values of the 
EGR valve.
Switch OFF the ignition and wait 40 seconds.
Switch the ignition back on and check for faults.
If the fault is still present:
• Switch OFF the vehicle ignition.
• Disconnect the connector of the EGR valve.
• Remove the EGR valve referring to “EGR Valve Removal 

and Installation in Section 1D” and reconnect it after 
having removed it.

• Check that no particles are blocking the movement of the 

EGR valve flap.

• Check that the EGR valve is not stuck or jammed in one 

position.

• Switch ON the ignition again.
• Check the movement of the valve with displaying “EGR 

position sensor” on Data List of SUZUKI scan tool (0 to 
2.5 mm travel for an opening cyclic ratio of 40% and when 
fully open, ~ 5 mm, for an opening cyclic ratio of 95%).

• Check that the EGR valve flap closes completely.

Is there in good condition?

Go to Step 2.

Replace the EGR valve 
referring to “EGR Valve 
Removal and 
Installation in Section 
1D”.

2

EGR VALVE BUSHING FAULT FINDING:
Remove the EGR valve referring to “EGR Valve Removal 
and Installation in Section 1D” the EGR valve should not 
contain a cluster of soot between the base and the valve.
Clean the EGR valve sleeve if necessary.

Is there in good condition?

Go to Step 3.

Replace the EGR valve 
referring to “EGR Valve 
Removal and 
Installation in Section 
1D”.

1A-110 Engine General Information and Diagnosis: 

Test 8: Injector malfunction

S5JB0B1104173

WARNING

!

 

When servicing fuel system, be sure to observe WARNING in “Precautions on Fuel System Service in 
Section 1G” to reduce the risk of fire and personal injury.

 

3

1) Use “Initialize EGR valve data” on SUZUKI scan tool 

command to try to reinitialise the operating values of the 
EGR valve.

2) Check the air circuit referring to “Test 3: Checking the 

turbocharged air inlet circuit”.

3) Check the MAF sensor referring to “Test 4: MAF sensor”.

Is there in good condition?

Go to Step 4.

Repair as necessary.

4

Confirmation of the fault finding:
• Start the vehicle.
• Leave the engine at idling speed for 1 min.
• Accelerate very slowly up to 1500 rpm for 2 mins until the 

exhaust gas recirculation function becomes active.

• Carry out a vehicle test at low speed, without accelerating 

heavily, then normally.

• Check for faults using SUZUKI scan tool.

Does customer complaint or the faults recur?

Substitute a known-
good ECM and recheck.

Exhaust gas 
recirculation valve 
correct.

Step

Action

Yes

No

Step

Action

Yes

No

1

CHECK THE FUEL REGULATION BALANCE, INJECTOR 
BY INJECTOR
• With the engine at idle speed, coolant temperature > 80 

°C, 176 °F, display the each injector fuel flow correction 
values “Cyl # FF Correction” on Data List of SUZUKI scan 
tool.

The normal value for fuel flow correction for an injector is 

± 

1.0 mm

3

/stroke.

This tolerance may increase with time, but indicates an 
injector/cylinder fault if it exceeds 

± 5.0 mm

3

/ stroke.

Do one of these values exceed 

±

 5.0 mm

3

/stroke?

Go to Step 2.

Go to Step 4.

Engine General Information and Diagnosis:  1A-111

2

CHECK THE FUEL REGULATION BALANCE, INJECTOR 
BY INJECTOR:
1) If at least one of these values is > +5.0 mm

3

/stroke

• Check the valve clearance.
• Check the engine compression referring to 

“Compression Check in Section 1D”.
– If the compression test reveals a cylinder fault, 

carry out the necessary repairs.

– If the compression is in order, check the conformity 

of the assembly of the injector referring to “Fuel 
Injector Removal and Installation in Section 1G”, 
then check the fuel regulation again, injector by 
injector. If the customer complaint is still present, 
replace the injector

2) If at least one of these values is < –5.0 mm

3

/stroke

• Check the valve clearance.
• Check the level and condition of the engine oil.
• Remove the injector with the largest adjustment.
• If there is pollution via the diesel, check the condition 

of the cylinder concerned (cylinder, piston, valves).

• Replace the injector.

NOTE
Before replacing an injector, check for the 
presence and conformity of its sealing washer 
(refer to “Table 5: Poor Performance with 
Smoke”).

 

After replacing an injector, enter the code into an fuel 
injector that has not been programmed referring to 
“Registration Procedure for the Fuel Injector Calibration 
Code in Section 1C”.

Is there in good condition?

Go to Step 3.

Repair as necessary.

3

CONFIRMATION OF THE FAULT FINDING FOR THE 
CORRECTION OF THE FLOW, INJECTOR BY INJECTOR:
Clear the fault(s) and carry out a test with the engine at idle 
speed, coolant temperature > 80 

°C, 176 °F and check that 

no faults appear on the diagnostic tool and the fuel flow 
correction values do not reach 

± 5.0 mm

3

/stroke to confirm 

the repair.
• If any other cylinders have injector fuel flow correction 

values > 

± 5.0 mm

3

/stroke, follow the fault finding 

procedure in Step 2 of this test.

• If the repairs carried out have not repaired the engine, 

substitute a known-good ECM and recheck.

Is there in good condition?

Go to step 4.

Repair as necessary.

Step

Action

Yes

No

1A-112 Engine General Information and Diagnosis: 

4

INJECTOR RETURN FLOW BALANCE CHECK:
• Allow the engine to heat up to a coolant temperature of > 

80 

°C, 176 °F.

• Switch OFF the ignition.
• Protect the upper engine edges with rags (mainly around 

the injectors).

• Disconnect the injector return pipes.
• Connect special tool (09912 – 96540) to injector.
• Start the engine and let it idle.
• Disconnect the fuel pressure regulator.
• Start the ignition and perform a starting sequence 

(activate the starter motor for 5 seconds),

• The flow of fuel on the return is normally very weak.
Otherwise, replace the injector.
• Clear the fault caused by the disconnection of the fuel 

flow actuator.

• Refit the injector fuel return pipes after checking that the 

seals and pipes are in good condition.

• If this is not the case, replace the injector fuel return 

pipes.

• Confirm the repairs by means of a road test.

Special tool
(A):  09912–96540

Is there in good condition?

Go to Step 5.

Repair as necessary.

5

INJECTOR NOZZLE SEALING TEST:
• Check the level and condition of the engine oil:
• If there is pollution via the diesel fuel, the injector nozzle 

which is leaking will be “greasy”.

• Disconnect the preheating relay.
Check that this is not caused by rising engine oil by checking 
the engine compression values.
Check the condition of the heater plug: this must not be 
humid. If this is the case, change the defective injector.
If the compression values are in order, locate the faulty 
injector by examining the condition of the cylinders and the 
pistons via the heater plug wells (greasy cylinder, 
overheating, starting to disintegrate, etc.).
If the cylinder-piston examination is not conclusive, remove 
the injectors and change the one with the “greasy” nozzle.

NOTE
Before replacing an injector, check for the 
presence and conformity of its sealing washer 
(refer to “Table 5: Poor Performance with 
Smoke”).

 

Is there in good condition?

Fuel injector correct.

Repair as necessary.

Step

Action

Yes

No