2006 SUZUKI SX4 engine

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-119
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive DetectedS6RW0D1104043
System and Wiring Diagram7CMP sensor check
1) Check CMP sensor and signal rotor tooth referring to
“Camshaft Position (CMP) Sensor Inspection in Section
1C”.
Is check result satisfactory?Substitute a known-
good ECM and recheck.Replace CMP sensor
and/or intake camshaft. Step Action Yes No
I6RW0D110034-01
1. EGR valve 4. Sensed information 7. “IG COIL” fuse 10. Main relay
2. Intake manifold 5. Fresh air 8. Main fuse box 11. “FI” fuse
3. ECM 6. Exhaust gas 9. Ignition switch 12. “IGN” fuse

Downloaded from www.Manualslib.com manuals search engine 1A-120 Engine General Information and Diagnosis:
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 are 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) or more
• Altitude (barometric pressure): 2500 m, 8200 ft or less (560 mmHg, 74.4 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 or “3” range.
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 kept 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) For european market model, check whether EGR system readiness/monitoring test has completed or not by using
scan tool.
If evaporative system readiness/monitoring test has not completed, check vehicle conditions (environmental) and
repeat Steps 3) through 7).
9) Check DTC and pending DTC.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 / 1 driving)
DTC P0402:
Difference in intake manifold absolute pressure between opened EGR valve and closed
EGR valve is larger than specified value.
(2 driving cycle detection logic, monitoring once / 1 driving)• EGR valve
• EGR passage
• MAP sensor
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-121
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.
2Do you have SUZUKI scan tool?Go to Step 3. Go to Step 5.
3EGR valve operation check
1) With ignition switch turned OFF, install SUZUKI scan tool
to DTC.
2) Check EGR system referring to “EGR System Inspection
(If Equipped) in Section 1B”.
Is it in good condition?Go to Step 4. Go to Step 5.
4MAP sensor check
1) Check MAP sensor for performance referring to
“Manifold Absolute Pressure (MAP) Sensor Inspection
(If Equipped) 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.
5EGR 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).
6EGR valve check
1) Check EGR valve referring to “EGR Valve Inspection (If
Equipped) in Section 1B”.
Is check result satisfactory?Go to Step 7. Faulty EGR valve.
7MAP sensor check
1) Check MAP sensor for performance referring to
“Manifold Absolute Pressure (MAP) Sensor Inspection
(If Equipped) in Section 1C”.
Is check result satisfactory?EGR passage clogged.
If OK, substitute a
known-good ECM and
recheck.Replace MAP sensor.

Downloaded from www.Manualslib.com manuals search engine 1A-122 Engine General Information and Diagnosis:
DTC P0403: Exhaust Gas Recirculation Control CircuitS6RW0D1104044
Wiring Diagram
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 warm it up to normal operating temperature.
4) Drive vehicle in 2000 – 3500 rpm of engine speed.
5) Keep above vehicle speed for 1 min. (Throttle valve opening is kept constant in this step.)
6) Stop vehicle and check DTC and pending DTC.
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V5V
4
1 65E01-29
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
E01-16 2BLK/RED
C01-4
C01-3
C01-19
C01-18
BLK/RED
BLK/RED
BLK/RED
GRN/RED
GRN/ORN
WHT/RED
BRN/YEL
37 8
E01-31 BLK
I6RW0D110037-01
1. Main relay 3. Main fuse box 5. ECM 7. “FI” fuse
2. EGR valve 4. Ignition switch6. “IG COIL” fuse 8. “IGN” fuse
DTC detecting condition Trouble area
EGR valve output voltage is different from output command with more than one pole
out of 4 poles.
(1 driving cycle detection logic)• EGR valve circuit open
• EGR valve
•ECM

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-123
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Description”.
2EGR valve power supply circuit check
1) Remove air intake pipe.
2) With ignition switch turned OFF, disconnect EGR valve
connector.
3) With ignition switch turned ON, measure voltage
between “BLK/RED” wire terminal of EGR valve
connector and vehicle body ground.
Is check voltage 10 – 14 V?Go to Step 3. “BLK/RED” wire is open
circuit.
3Wire circuit check
1) Disconnect connectors from ECM with ignition switch
turned OFF.
2) Turn ON ignition switch.
3) Measure voltage between engine ground and each
“GRN/RED”, “GRN/ORN”, “WHT/RED”, “BRN/YEL” wire
terminals of EGR valve connector.
Is each voltage 0 V?Go to Step 4. Faulty wire(s) are
shorted to other circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
4Wire circuit check
1) With ignition switch turned OFF, measure resistance
between engine ground and each “GRN/RED”, “GRN/
ORN”, “WHT/RED”, “BRN/YEL” wire terminals of EGR
valve connector.
Is resistance infinity?Go to Step 5. Faulty wire(s) are
shorted to ground
circuit.
If wires are OK,
substitute a known-
good ECM and recheck.
5Short circuit check for EGR valve control circuit
1) With ignition turned OFF, measure resistance between
each EGR valve control circuit wire (“GRN/RED”, “GRN/
ORN”, “WHT/RED” and “BRN/YEL” wire) and each EGR
valve control circuit wire.
Is each resistance infinity?Go to Step 6. Faulty wire(s) are short
circuit.
6EGR valve stepper motor coil circuit check
1) With ignition switch turned OFF, connect EGR valve
connector.
2) Measure resistance between “E01-1/16” and each “C01-
4”, “C013”, “C01-19”, “C01-18” terminals of ECM
connector.
Is each resistance 20 – 31
Ω at 20 °C, 68 °F?Faulty ECM. Substitute
a known-good ECM and
recheck.Go to Step 7.
7EGR valve check
1) Check EGR valve resistance referring to “EGR Valve
Inspection (If Equipped) in Section 1B”.
Is resistance within specified value?Faulty wire(s) are open
or high resistance
circuit. If wires are OK,
substitute a known-
good ECM and recheck.Faulty EGR valve.

Downloaded from www.Manualslib.com manuals search engine 1A-124 Engine General Information and Diagnosis:
DTC P0420: Catalyst System Efficiency below ThresholdS6RW0D1104045
System and Wiring Diagram
Circuit Description
ECM monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter
by HO2S-2. When the catalyst is functioning properly, the variation cycle of HO2S-2 output voltage (oxygen
concentration) is slower than that of HO2S-1 output voltage because of the amount of oxygen in the exhaust gas
which has been stored in warm up three way catalytic converter.
DTC Detecting Condition and Trouble Area
C01-11
C01-10
C01-57
WHT
BRN
1
32
4
5 VORNORN
BLUWHTBLUWHT5
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
I6RW0D110038-01
1. HO2S-1 3. Warm up three way catalytic converter 5. ECM
2. HO2S-2 4. Three way catalytic converter
DTC detecting condition Trouble area
• While vehicle running at constant speed under other than high load.
• Time from rich or lean switching command is output till HO2S-2
output voltage crosses 0.45 V is less than specified value.
(2 driving cycle detection logic, monitoring once / 1 driving)• Exhaust gas leak
• Warm up three way catalytic converter
malfunction
• HO2S-2 malfunction
• HO2S-1 malfunction

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-125
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 are satisfied when using this “DTC Confirmation
Procedure”.
• Intake air temperature at engine start: –10 (14 °F) to 80 °C (176 °F)
• Intake air temperature: –10 °C (14 °F) to 70 °C (158 °F)
• Engine coolant temp.: 70 °C, 158 °F or more
• Altitude (barometric pressure): 2500 m, 8200 ft or less (560 mmHg, 74.4 kPa or more)

1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Increase vehicle speed to 40 – 50 mph, 60 – 80 km/h.
4) Keep above vehicle speed for 10 min. or more (Throttle valve opening is kept constant in this step).
5) Stop vehicle.
6) For european market model, check whether catalyst monitoring readiness/monitoring test has completed or not by
using scan tool.
If evaporative system readiness/monitoring test has not completed, check vehicle conditions (environmental) and
repeat Steps 3) through 5).
7) Check DTC and pending DTC.
DTC Troubleshooting
NOTE
Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to
“Precautions for DTC Troubleshooting”.

Step Action Yes No
1Was “Engine and Emission Control System Check”
performed?Go to Step 2. Go to “Engine and
Emission Control
System Check”.
2Exhaust system visual check
1) Check exhaust system for leaks, damage and loose
connection.
Is it in good condition?Go to Step 3. Repair or replace
defective part.
3HO2S-2 output voltage check
1) Check output voltage of HO2S-2 referring to “DTC
P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage /
High Voltage (Sensor-2)”.
Is check result satisfactory?Replace exhaust
manifold (built in warm
up three way catalytic
converter) and exhaust
center pipe (built in
three way catalytic
converter).Check “BRN” and / or
“ORN” wires for open
and short, and
connections for poor
connection.
If wires and connections
are OK, replace HO2S-
2.

Downloaded from www.Manualslib.com manuals search engine 1A-126 Engine General Information and Diagnosis:
DTC P0443: Evaporative Emission System Purge Control Valve CircuitS6RW0D1104046
Wiring Diagram
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 OFF, connect scan tool to DLC.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and warm up normal operating temperature.
4) Drive vehicle at more than 40 km/h, 25 mph for 5 min. or more.
5) Check DTC and pending DTC.
E01C01
3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238 3 4
18 19 5 6 7 10 11
17 20
47 46 49 50 51 21 22
5216 259
24 14
29
55 57 54 53 59
60 582
26 27 28 15
30
56 4832 31 34 35 36 37 40 42 39 38 44
45 43 41 331 12 13
238
BLK/WHT
BLK/RED
BLK/RED
WHTBLK/YELBLK/YEL
BLK/YEL
GRN
BRN/WHT
12V5V
5
42 36E01-29
E01-1
E01-60
C01-58
C01-15 C01-30
BLK/ORN
BLKBLK
7 8
BLK/REDBLK/REDE01-16
1
C01-29 BLU/BLK
BLKE01-31
I6RW0D110039-01
1. EVAP canister purge valve 3. “IG COIL” fuse 5. Ignition switch 7. “FI” fuse
2. Main relay 4. Main fuse box 6. ECM 8. “IGN” fuse
DTC detecting condition Trouble area
Monitor signal of EVAP canister purge valve is different from command signal.
(Circuit open or short)
(2 driving cycle detection logic)• EVAP canister purge valve
• EVAP canister purge valve circuit
•ECM