Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 107

1A-375 Engine General Information and Diagnosis: For Diesel Engine Model

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: For F9Q Engine 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: For Diesel 
Engine Model 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: 
For Diesel Engine Model”).

 

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: For Diesel Engine Model 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

Engine General Information and Diagnosis: For Diesel Engine Model 1A-376

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: 
For Diesel Engine Model”).

 

Is there in good condition?

Fuel injector correct.

Repair as necessary.

Step

Action

Yes

No

1A-377 Engine General Information and Diagnosis: For Diesel Engine Model

Special Tools and Equipment

Special Tool

S6JB0A1128001

09912–96540

SUZUKI scan tool

Injector flow measuring kit

—

Mot. 1711 )

This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12. )

Aux. Emission Control Devices: For Petrol Engine Model 1B-1

Engine

Aux. Emission Control Devices

For Petrol Engine Model

Diagnostic Information and Procedures

EGR System Inspection

S6JB0A1214001

1) Connect SUZUKI scan tool to data link connector 

(DLC) with ignition switch turned OFF.

2) Turn ON ignition switch and erase DTC using 

“CLEAR DTC” in “TROUBLE CODES” menu.

3) Start engine and warm it up to normal operating 

temperature, then select “DATA LIST” mode on scan 
tool.

4) Make sure that vehicle condition is as follows.

• Vehicle speed = 0 km/h (0 mph)
• Engine speed 

≤ 900 rpm

• Engine coolant temp. 

≥ 90 °C, 194 °F

5) With engine idling (without depressing accelerator 

pedal), open EGR valve by using “STEP EGR” mode 
in “MISC TEST” menu. In this state, as EGR valve 
opening increases engine idle speed drops. If not, 
possible cause is clogged EGR gas passage, stuck 
or faulty EGR valve.

Repair Instructions

EVAP Canister Purge Inspection

S6JB0A1216001

NOTE
Before inspection, check to make sure that 
gear shift lever is in neutral position (with A/T 
model, selector lever in “P” range) and that 
parking brake lever is pulled all the way up.

 

1) Hoist vehicle.
2) Disconnect purge hose (1) from EVAP canister (2).
3) Place finger against the end of disconnected hose 

and check that vacuum is not felt there when engine 
is cool and running at idle speed. If check result is 
not satisfactory, check EVAP canister purge valve, 
wire harness and ECM.

1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full open)

Step EGR

Step EGR Flow Duty                          21 %
Step EGR   (con)                                23% 
Engine Speed                                   771 RPM
Desired Idle                                      698 RPM
IAC Flow Duty                                 20.0 %     
Ignition Advance                              11.5  BTDC 
Closed Throttle Pos                             ON

1

2

I5JB0A120001-01

1

2

I5JB0A120002-01