Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 103

1A-359 Engine General Information and Diagnosis: For Diesel Engine Model

Table 1: No dialogue with the ECM

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Troubleshooting

Table 2: The Engine Does Not Start

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Troubleshooting

Try the scan tool on another vehicle.
Check the ECM earth point.
Check:
• Check the connection between the scan tool and the data link connector
• Check the main and circuit fuses
Check the voltage (12 volts) between the following terminals (ignition switch turned ON):
• Between “G20-16” wire and “G20-4” wire of data link connector
• Between “G20-16” wire and “G20-5” wire of data link connector
Repair if necessary.
Check the insulation, continuity and absence of interference resistance of the connections:
• Between “C86-41” terminal of ECM connector and “E33-8” wire of main relay mounting connector (relay 

control)

• Between “C86-3” terminal of ECM connector and “E33-6” wire of main relay mounting connector
• Between “E66-2” terminal of ECM connector and “E33-6” wire of main relay mounting connector
• Between “E66-11” terminal of ECM connector and “E82-23” wire of BCM connector
• Between “E66-1” terminal of ECM connector and vehicle body ground
• Between “E66-7” terminal of ECM connector and vehicle body ground
• Between “E66-8” terminal of ECM connector and vehicle body ground
• Between “E66-31” terminal of ECM connector and “G20-7” wire of data link connector (K-line)
Repair if necessary.

Step

Action

Yes

No

1

Check that the fuel tank is correctly filled and that the fuel 
type is suitable.

Is the fuel type suitable and the tank correctly filled?

Go to Step 2.

Refill the fuel tank 
correctly. Bleed the low 
and high pressure 
diesel circuit.

2

Is the starter motor working properly?

Go to Step 3.

Carry out the required 
repairs.

3

Is the immobilizer system working properly?

Go to Table 3 referring 
to “Table 3: The Engine 
Starts with Difficulty: For 
Diesel Engine Model”.

Carry out the required 
repairs.

Engine General Information and Diagnosis: For Diesel Engine Model 1A-360

Table 3: The Engine Starts with Difficulty

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Troubleshooting

Step

Action

Yes

No

1

Check that the fuel tank is correctly filled and that the fuel 
type is suitable.

Is the fuel type suitable and the tank correctly filled?

Go to Step 2.

Refill the fuel tank 
correctly. Bleed the low 
and high pressure 
diesel circuit.

2

Check the engine earths.
Check that engine speed reaches 250 rpm under the starter 
motor, as displayed on SUZUKI scan tool.

Is the starter motor working properly?

Go to Step 3.

Carry out the required 
repairs.

3

Check ECM for DTC(s).

Is there DTC P0335?

Go to “DTC P0335: 
CKP Sensor Circuit: For 
Diesel Engine Model”.

Go to Step 4.

4

Check ECM for DTC(s).

Is there DTC P0016?

Go to “DTC P0016: 
CKP – CMP Correlation: 
For Diesel Engine 
Model”.

Go to Step 5.

5

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 6.

Repair or replace the 
defective part.

6

Check that the fuel circuit is leak-tight.
If the fault is still present, refer to “DTC P0089: Fuel Flow 
Actuator Performance: For Diesel Engine Model” of 
troubleshooting for 2.DEF: Measured pressure too low.

Is there in good condition?

Go to Step 7.

Repair or replace the 
defective part.

7

Check the following:
• Check that the heater plugs are actuated using “Pre/post 

Heater Relay Control” on SUZUKI scan tool.

• Check that the fuel flow actuator are actuated using “IMV/

Flow actuator” on SUZUKI scan tool.

• Check the exhaust system referring to “Test 1: Exhaust 

system check: For Diesel Engine Model”. 

• Check the low pressure circuit referring to “Test 2: Low 

pressure circuit check: For Diesel Engine Model”.

• Check for leaks in the high pressure circuit referring to 

“Test 8: Injector malfunction: For Diesel Engine Model”.

• Check the turbocharged air inlet circuit referring to “Test 3: 

Checking the turbocharged air inlet circuit: For Diesel 
Engine Model”.

• Check the MAF sensor referring to “Test 4: MAF sensor: 

For Diesel Engine Model”.

• Check the consistency of the signal from the engine 

coolant temperature sensor.

• Check that the injectors are working properly (return 

leakage too high, clogging, sticking) referring to “Test 8: 
Injector malfunction: For Diesel Engine Model”.

• Check the engine timing (and the position of the high 

pressure pump sprocket).

Is there in good condition?

Go to Step 8.

Repair or replace the 
defective part.

8

Are the compressions correct?

End of fault finding.

Carry out the required 
repairs.

1A-361 Engine General Information and Diagnosis: For Diesel Engine Model

Table 4: Injection Noise

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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: For Diesel 
Engine Model”.

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: For Diesel Engine Model”.
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.

Engine General Information and Diagnosis: For Diesel Engine Model 1A-362

Table 5: Poor Performance with Smoke

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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: For Diesel 
Engine Model”.

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: For Diesel 
Engine Model”.
The condition of the MAF sensor referring to “Test 4: MAF 
sensor: For Diesel Engine Model”.
The turbocharger referring to “Test 5: Variable geometry 
turbocharger control: For Diesel Engine Model” and “Test 6: 
Rotating part of a turbocharger: For Diesel Engine Model”.
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: For 
Diesel Engine Model”.

Replace turbocharger.