Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 97

1A-335 Engine General Information and Diagnosis: For Diesel Engine Model

Troubleshooting for D1: Internal electronic fault, D2: External diagnostics and D3: Values out of range

NOTE
After any inlet throttle valve procedures, it is necessary to perform “Initialize inlet throttle valve data” 
on SUZUKI scan tool.
Inlet throttle valve fault adaptives. Then turn OFF ignition switch and wait 40 seconds.

 

DTC P0641: Sensor Reference Voltage 1 Circuit

S6JB0A1124126

CAUTION

!

 

• This fault may appear if the wiring harness has been damaged.

Follow the procedure described in “Electrical Circuit Inspection Procedure in Section 00”.

• 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 following a road test or after attempting to start the engine several 
times.

• If the fault is present:

– The cruise control / speed limiter function is deactivated.
– Turbocharging is disabled.
– Engine speed is restricted.
– The Injection warning light (gravity 1 warning light) is lit.

• 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 of the inlet throttle valve.
Check the ECM connections.
Repair if necessary.
Check the continuity, absence of interference resistance and insulation on the following connection:
• Between “C75-1” wire of inlet throttle valve connector and vehicle body ground
• Between “C75-2” wire of inlet throttle valve connector and “E33-6” wire of main relay mounting connector
• Between “C75-3” wire of inlet throttle valve connector and “C86-40” terminal of ECM connector
• Between “C75-4” wire of inlet throttle valve connector and “C86-27” terminal of ECM connector
Repair if necessary.
• Perform “Initialize inlet throttle valve data” on SUZUKI scan tool.
• If the fault is still present, check that the ECM output stage is working correctly.
• Connected inlet throttle valve:

– Connect the negative terminal of the voltmeter to “C75-3” wire of the inlet throttle valve
– Connect the positive terminal of the voltmeter to “C75-2” wire of the inlet throttle valve
– Perform output test “Electronic Throttle Control” on SUZUKI scan tool:

The voltmeter should display five cycles of two successive voltages: ~ 3.15 V (Opening Cyclic Ratio of 25%) 
then ~ 9.45V (Opening Cyclic Ratio of 75%).
If the voltmeter indicates above voltage, but inlet throttle valve does not operate, replace inlet throttle valve.
If the voltmeter does not indicate any control while the command is running (five cycles), substitute a known-
good ECM and recheck.

Displaying on SUZUKI scan tool

Detecting condition

D1

Sensor reference voltage too low

D2

Sensor reference voltage too high

Engine General Information and Diagnosis: For Diesel Engine Model 1A-336

Troubleshooting

NOTE
Priorities when dealing with a number of faults:
If fault “DTC P0225: APP Sensor (Main) Circuit: For Diesel Engine Model” is present at the same time, 
check that the sensor is connected correctly.
In the event of the simultaneous presence of fault “DTC P0235: Boost Pressure Sensor Circuit: For 
Diesel Engine Model” or “DTC P0470: Differential Sensor Circuit: For Diesel Engine Model”, check that 
the boost pressure sensor circuit connector is connected correctly.

 

The sensors connected to supply No.1 are:
• Differential pressure sensor.
• Boost pressure sensor.
• Accelerator pedal position (APP) sensor (main).
To locate any faulty sensor and/or connection, disconnect one of these sensors then check whether the fault 
becomes stored.
If the fault is still present, start the operation again with the other sensor.
(Wait a few seconds between each disconnection to allow the ECM to make the measurement).
If the fault is stored after a disconnection, change the faulty sensor or repair its connection.
Clear the faults created by the multiple disconnections.
If the fault is still present when both these sensors have been disconnected:
1. Check the insulation against vehicle body ground of the following connections:

– Between “C76-3” wire of boost pressure sensor connector and “C86-42” terminal of ECM connector
– Between “C76-4” wire of boost pressure sensor connector and “C86-19” terminal of ECM connector
– Between “E68-2” wire of accelerator pedal position (APP) sensor connector and “E66-4” terminal of ECM 

connector

– Between “E68-3” wire of accelerator pedal position (APP) sensor connector and “E66-3” terminal of ECM 

connector

– Between “C89-1” wire of differential pressure sensor connector and “C86-42” terminal of ECM connector
– Between “C89-3” wire of differential pressure sensor connector and “C85-14” terminal of ECM connector

Repair if necessary.

2. Check the insulation against +12 V of the following connections:

– Between “C76-4” wire of boost pressure sensor connector and “C86-19” terminal of ECM connector
– Between “C76-1” wire of boost pressure sensor connector and “C86-45” terminal of ECM connector
– Between “C76-3” wire of boost pressure sensor connector and “C86-42” terminal of ECM connector
– Between “E68-4” wire of accelerator pedal position (APP) sensor connector and “E66-5” 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 “C89-1” wire of differential pressure sensor connector and “C86-42” terminal of ECM connector
– Between “C89-3” wire of differential pressure sensor connector and “C85-14” terminal of ECM connector
– Between “C89-2” wire of differential pressure sensor connector and “C85-12” terminal of ECM connector

Repair if necessary.

3. Check the insulation between the following connections after disconnecting the sensors and ECM:

– “E68-1” and “E68-4” wires of the accelerator pedal position (APP) sensor connector.
– “C76-1” and “C76-3” wires of the boost pressure sensor connector.
– “C89-2” and “C89-1” wires of differential pressure sensor connector.

If these checks do not produce the correct results, replace the faulty sensor(s).
If the fault is still present, substitute a known-good ECM and recheck.

1A-337 Engine General Information and Diagnosis: For Diesel Engine Model

DTC P0645: A/C Compressor Relay Control Circuit

S6JB0A1124149

NOTE

• For vehicle not equipped with A/C system, it is not abnormal even if the DTC is detected.
• 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 CO0: Open circuit or short circuit to vehicle body ground

Troubleshooting for CC1: Short circuit to +12 V

Displaying on SUZUKI scan tool

Detecting condition

CO0

Open circuit or short circuit to vehicle body ground

CC1

Short circuit to +12 V

Check the condition of the A/C compressor relay.
Check the ECM connections.
Repair if necessary.
Check the A/C compressor relay mounting connections.
If these checks are correct,
Check the continuity and insulation from vehicle body ground of the following connections:
• Between “E33-12” wire of A/C compressor relay mounting connector and “E66-13” terminal of ECM connector
• Between “E33-11” wire of A/C compressor relay 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 A/C compressor relay.
Check the ECM connections.
Repair if necessary.
Check the A/C compressor relay mounting connections.
Check the continuity and insulation from +12 V of the following connection:
• Between “E33-12” wire of A/C compressor relay mounting connector and “E66-13” terminal of ECM connector
Repair if necessary.
If the fault is still present, substitute a known-good ECM and recheck.

Engine General Information and Diagnosis: For Diesel Engine Model 1A-338

DTC P0651: Sensor Reference Voltage 2 Circuit

S6JB0A1124127

CAUTION

!

 

• This fault may appear if the wiring harness has been damaged.

Follow the procedure described in “Electrical Circuit Inspection Procedure in Section 00”.

• 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 following a road test or after attempting to start the engine several 
times.

• If the fault is present:

– The EGR functions is inhibited.
– The cruise control function is deactivated.
– Engine speed is limited.
– The Injection warning light (gravity 1 warning light) is lit.
– The Malfunction indicator light (MIL) will light up after three consecutive cycles (starting +5 

seconds + turn OFF ignition switch and wait 40 second).

• 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

Displaying on SUZUKI scan tool

Detecting condition

D1

Sensor reference voltage too low

D2

Sensor reference voltage too high