2006 SUZUKI SWIFT valve egr

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-43
Poor gasoline mileageLeaks or loose connection of high-
tension cord “High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (improper gap, heavy
deposits and burned electrodes, etc.) “Spark Plug Inspection in Section 1H”
Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”
High idle speed Condition “Improper engine idling or engine
fails to idle”
Poor performance of ECT sensor or
MAF sensor “ECT Sensor Inspection in Section 1C” or
“MAF and IAT Sensor Inspection in Section
1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty fuel injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Low compression “Compression Check in Section 1D”
Poor valve seating “Valves and Valve Guides Inspection in
Section 1D”
Dragging brakes Condition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C”
Thermostat out of order “Thermostat Inspection in Section 1F”
Improper tire pressure “Tires Description in Section 2D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Excessive engine oil
consumption – Oil
leakage Blown cylinder head gasket
“Cylinder Head Inspection in Section 1D”
Leaky camshaft oil seals “Camshaft, Tappet and Shim Inspection in
Section 1D”
Excessive engine oil
consumption – Oil
entering combustion
chamber Sticky piston ring
“Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston and cylinder “Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Worn piston ring groove and ring “Cylinders, Pistons and Piston Rings
Inspection in Section 1D”
Improper location of piston ring gap “Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly in
Section 1D”
Worn or damaged valve stem seal “Valves and Valve Guides Inspection in
Section 1D”
Worn valve stem “Valves and Valve Guides Inspection in
Section 1D”
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-44 Engine General Information and Diagnosis:
Engine hesitates –
Momentary lack of
response as accelerator
is depressed. Can occur
at all vehicle speeds.
Usually most severe when
first trying to make
vehicle move, as from a
stop sign.Spark plug faulty
“Spark Plug Inspection in Section 1H”
Leaky high-tension cord “High-Tension Cord Inspection in Section 1H”
Fuel pressure out of specification “Fuel Pressure Check”
Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”
Poor performance of ECT sensor or
MAF sensor “ECT Sensor Inspection in Section 1C” or
“MAF and IAT Sensor Inspection in Section
1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty fuel injector “Fuel Injector Circuit Check”
Faulty ECM
Engine overheating Condition “Engine overheating”
Low compression “Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Surge – Engine power
variation under steady
throttle or cruise. Feels
like vehicle speeds up
and down with no change
in accelerator pedal. Leaky or loosely connected high-tension
cord
“High-Tension Cord Removal and Installation
in Section 1H”
Faulty spark plug (excess carbon
deposits, improper gap, burned
electrodes, etc.) “Spark Plug Inspection in Section 1H”
Variable fuel pressure “Fuel Pressure Check”
Kinky or damaged fuel hose and lines
Faulty fuel pump (clogged fuel filter)
Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”
Poor performance of MAF sensor “MAF and IAT Sensor Inspection in Section
1C”
Faulty fuel injector “Fuel Injector Circuit Check”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty ECM
Excessive detonation –
Engine makes
continuously sharp
metallic knocks that
change with throttle
opening. Sounds like pop
corn popping. Faulty spark plug
“Spark Plug Inspection in Section 1H”
Loose connection of high-tension cord “High-Tension Cord Removal and Installation
in Section 1H”
Engine overheating Condition “Engine overheating”
Clogged fuel filter (faulty fuel pump) or
fuel lines “Fuel Pressure Check” or “Fuel Pump and Its
Circuit Check”
Air drawn in through intake manifold or
throttle body gasket
Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”
Poor performance of knock sensor, ECT
sensor or MAF sensor “DTC P0327 / P0328: Knock Sensor 1 Circuit
Low / High”, “ECT Sensor Inspection in
Section 1C” or “MAF and IAT Sensor
Inspection in Section 1C”
Faulty fuel injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Excessive combustion chamber
deposits “Cylinders, Pistons and Piston Rings
Inspection in Section 1D” and/or “Piston Pins
and Connecting Rods In
spection in Section
1D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-45
Engine has no powerFaulty spark plug “Spark Plug Inspection in Section 1H”
Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor)
Inspection in Section 1H”
Leaks, loose connection or
disconnection of high-tension cord “High-Tension Cord Removal and Installation
in Section 1H”
Faulty knock sensor “DTC P0327 / P0328: Knock Sensor 1 Circuit
Low / High”
Clogged fuel hose or pipe “Fuel Pressure Check”
Malfunctioning fuel pump “Fuel Pump and Its Circuit Check”
Air drawn in through intake manifold
gasket or throttle body gasket
Engine overheating Condition “Engine overheating”
Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”
Poor performance of ECT sensor or
MAF sensor “ECT Sensor Inspection in Section 1C” or
“MAF and IAT Sensor Inspection in Section
1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty fuel injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Dragging brakes Condition “Dragging brakes” in “Brakes
Symptom Diagnosis in Section 4A”
Slipping clutch Condition “Slipping clutch” in “Clutch System
Symptom Diagnosis in Section 5C”
Low compression “Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Improper engine idling or
engine fails to idle Faulty spark plug
“Spark Plug Inspection in Section 1H”
Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor)
Inspection in Section 1H”
Fuel pressure out of specification “Fuel Pressure Check”
Leaky manifold, throttle body, or cylinder
head gasket
Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”
Faulty evaporative emission control
system “EVAP Canister Purge Inspection in Section
1B”
Faulty EGR system “EGR System Inspection in Section 1B”
Faulty fuel injector(s) “Fuel Injector Circuit Check”
Poor performance of ECT sensor or
MAF sensor “ECT Sensor Inspection in Section 1C” or
“MAF and IAT Sensor Inspection in Section
1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty ECM
Loose connection or disconnection of
vacuum hoses
Malfunctioning PCV valve “PCV Valve Inspection in Section 1B”
Engine overheating Condition “Engine overheating”
Low compression “Compression Check in Section 1D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 1A-46 Engine General Information and Diagnosis:
Excessive hydrocarbon
(HC) emission or carbon
monoxide (CO)Faulty spark plug
“Spark Plug Inspection in Section 1H”
Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation
in Section 1H”
Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor)
Inspection in Section 1H”
Low compression “Compression Check in Section 1D”
Lead contamination of three way
catalytic converter Check for absence of f
iller neck restrictor.
Faulty evaporative emission control
system “EVAP Canister Purge Inspection in Section
1B”
Fuel pressure out of specification “Fuel Pressure Check”
Closed loop system (A/F feedback
compensation) fails (Faulty TP sensor,
Poor performance of ECT sensor or
MAF sensor) “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”, “ECT Sensor
Inspection in Section 1C” or “MAF and IAT
Sensor Inspection in Section 1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Engine not at normal operating
temperature
Clogged air cleaner “Air Cleaner Element Inspection and Cleaning
in Section 1D”
Vacuum leaks “Engine Vacuum Check in Section 1D”
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Excessive nitrogen
oxides (NOx) emission Improper ignition timing
“Ignition Timing Inspection in Section 1H”
Lead contamination of catalytic
converter Check for absence of f
iller neck restrictor.
Faulty EGR system “EGR System Inspection in Section 1B”
Fuel pressure out of specification “Fuel Pressure Check”
Closed loop system (A/F feedback
compensation) fails (Faulty TP sensor,
Poor performance of ECT sensor or
MAF sensor) “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”, “ECT Sensor
Inspection in Section 1C” or “MAF and IAT
Sensor Inspection in Section 1C”
Faulty electric throttle body assembly “Electric Throttle Body Assembly On-Vehicle
Inspection in Section 1C”
Faulty APP sensor assembly “APP Sensor Assembly Inspection in Section
1C”
Faulty injector(s) “Fuel Injector Circuit Check”
Faulty ECM
Camshaft position control (VVT) system
out of order “Oil Control Valve Inspection in Section 1D”
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-105
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1
/ Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected
S7RS0B1104039
System Description
ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each
cylinder. If it detects a large change in the angle speed of the crankshaft, it concludes occurrence of a misfire. When
the number of misfire is counted by ECM beyond the DTC de tecting condition, it determines the cylinder where the
misfire occurred and output it as DTC.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temp.: –10 °C, 14 °F or higher
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and print Freeze Frame Data or write them down using scan tool.
3) Clear DTC using scan tool.
4) Drive vehicle under freeze frame data condition as noted for 1 min. or more.
5) Stop vehicle and check DTC and pending DTC. 11
Electric throttle body check
1) Check TP sensor referring to “Throttle Position Sensor
Performance Check” under “Electric Throttle Body
Assembly On-Vehicle Inspection in Section 1C”.
Is output voltage within specified value? Substitute a known-
good ECM and recheck.
Replace electric throttle
body.
Step Action Yes No
DTC detecting condition
Trouble area
DTC P0300:
• Misfire, which causes catalyst to overheat during 200 engine revolutions, is detected at 2 or more cylinders. (MIL flashes as lo ng as this misfire occurs continuously.)
or
• Misfire, which affects exhaust emission adv ersely during 1000 engine revolution, is
detected at 2 or more cylinders. (2 driving cycle detection logic) • Ignition system
• Fuel injector and its circuit
• Fuel pressure
• EGR system
• Abnormal air drawn in
• Engine compression
• Valve lash adjuster
• Valve timing
• Fuel shortage
• Exhaust system
• Fuel of poor quality
DTC P0301, P0302, P0303, P0304:
• Misfire, which causes catalyst to overheat during 200 engine revolutions, is detected
at 1 cylinder. (MIL flashes as long as this misfire occurs continuously.)
or
• Misfire, which affects exhaust emission adv ersely during 1000 engine revolution, is
detected at 1 cylinder. (2 driving cycle detection logic)

Downloaded from www.Manualslib.com manuals search engine 1A-116 Engine General Information and Diagnosis:
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive DetectedS7RS0B1104044
System and Wiring Diagram
I6RS0C110019-02
1. EGR valve5. Fresh air 9. Ignition switch
2. Intake manifold 6. Exhaust gas10. Main relay
3. ECM 7. “IG COIL” fuse11. “FI” fuse
4. Sensed information 8. Main fuse box12. “IG ACC” fuse

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-117
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

NOTE
Check to make sure that following conditions ar e satisfied when using this “DTC confirmation
procedure”.
• Intake air temperature at engine start: –10 °C (14 ° F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temperature: 70 °C (158 °F) to 150 °C (302 °F)
• Altitude (barometric pressure): 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up to normal operating temperature.
4) Run engine at idle for 10 min.
5) Drive vehicle and increase engine speed 3000 rpm in 3rd gear.
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 sec. or more. (Keep fuel cut condition for 5 sec. or more) If fuel cut condition is not ke pt for 5 sec. or more, coast down a slope in engine speed
1000 – 3000 rpm for 5 sec. or more.
7) Stop vehicle and run engine at idle.
8) Check DTC and pending DTC by using scan tool.
DTC Troubleshooting
NOTE
• When measuring circuit voltage, resistance and/ or pulse signal at ECM connector, connect the
special tool to ECM and/or the ECM connectors re ferring to “Inspection of ECM and Its Circuits”.
• Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.

DTC detecting condition Trouble area
DTC P0401:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is smaller than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle)
DTC P0402:
Difference in intake manifold absolute pressure between opened EGR valve
and closed EGR valve is la rger than specified value.
(*2 driving cycle detection logic, monitoring once per driving cycle) •EGR valve
• EGR passage
• MAP sensor
•ECM
Step
Action YesNo
1 Was “Engine and Emission Control System Check”
performed? Go to Step 2.
Go to “Engine and
Emission Control
System Check”.
2 Do you have SUZUKI scan tool? Go to Step 3.Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine 1A-118 Engine General Information and Diagnosis:
DTC P0403: Exhaust Gas Recirculation Control CircuitS7RS0B1104045
Wiring Diagram
Refer to “DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected”.
DTC Detecting Condition and Trouble Area
DTC Confirmation Procedure
WARNING!
• When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
• Road test should be carried out by 2 persons, a driver and a tester, on a level road.

1) With ignition switch turned OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and run it for 30 seconds.
4) Check DTC. 3
EGR valve operation check
1) With ignition switch turned OF F, install SUZUKI scan tool
to DTC.
2) Check EGR system referring to “EGR System Inspection
in Section 1B”.
Is it in good condition? Go to Step 4. Go to Step 5.
4 MAP sensor check
1) Check MAP sensor for performance referring to “MAP
Sensor Inspection in Section 1C”.
Is check result satisfactory? Intermittent trouble or
faulty ECM.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.Replace MAP sensor.
5 EGR valve control circuit check
1) Check that EGR valve control circuits are in good
condition referring to Step 2 to 5 of “DTC P0403:
Exhaust Gas Recirculation Control Circuit”
Are circuits in good condition? Go to Step 6. Repair or replace EGR
valve control circuit(s).
6 EGR valve check
1) Check EGR valve referring to “EGR Valve Inspection in
Section 1B”.
Is check result satisfactory? Go to Step 7. Faulty EGR valve.
7 MAP sensor check
1) Check MAP sensor for performance referring to “MAP
Sensor Inspection in Section 1C”.
Is check result satisfactory? EGR passage clogged.
If OK, substitute a
known-good ECM and
recheck.
Replace MAP sensor.
Step Action Yes No
DTC detecting condition
Trouble area
EGR valve output voltage is differ ent from output command with more
than one pole out of 4 poles.
(1 driving cycle detection logic) • EGR valve circuit open
•EGR valve
•ECM