EGR Function Testing - Suzuki Suzuki Swift II

All Models (Ported EGR Valve)

1. Check vacuum hoses for correct routing. Warm engine to operating temperature. Disconnect vacuum hose from carburetor/throttle body. Connect a hand-held vacuum pump to hose. Apply 14 in. Hg to EGR valve. If vacuum holds and idle becomes unstable or engine stalls, EGR valve is functioning properly.
2. Reconnect vacuum hose. Using a jumper wire, ground signal wire at EGR vacuum solenoid to engine control computer. Increase engine speed 2000-3000 RPM. EGR valve stem should move at least 1/8". If system operates as indicated, system is functioning properly.

EGR System Test (Sidekick & Tracker '89-'95)

1. Hoist vehicle so that rear wheels rotate freely.
2. Set M/T or A/T in "Neutral" and transfer in "2H".
3. Start engine, release parking brake lever and check that rear propeller shaft (tires) is turning.
4. Warm up engine to normal operating temperature and race it after warming up. Then check to be sure that diaphram moves to open valve during acceleration and closes valve during deceleration. If EGR valve fails to operate properly, check vacuum hoses, EGR valve, EGR modulator, EGR SV valve, wire harness and ECM.
5. Keep engine running at idle speed and open EGR valve by hand, and engine should either stop or reduce its speed. If neither occurs, EGR passage is clogged.

EGR System Test (Esteem & Swift)

1. Place transaxle in Park (A/T) or Neutral (M/T). Apply parking brake. With coolant temperature less than 104°F (40°C), start engine and operate at high RPM. EGR valve diaphragm should not move/retract.
2. Warm engine to normal operating temperature. Operate engine at high RPM. EGR valve diaphragm should move up and return to closed position on deceleration to normal idle.
3. If EGR valve does not operate as specified, check for misrouted, restricted, clogged or deteriorated vacuum hoses. If vacuum hoses are okay, check EGR valve, EGR solenoid vacuum valve and EGR pressure transducer.
4. If a Diagnostic Trouble Code (DTC) is present, see appropriate DTC chart in SELF-DIAGNOSTICS article in ENGINE PERFORMANCE in the appropriate manual.

EGR System Test (Samurai Calif.)

ECM will set Code 51 if EGR system failure is present. Signal comes from Exhaust Gas Recirculation Temperature (EGRT) sensor. See SELF-DIAGNOSTICS article in the appropriate manual.

EGR System Test (Samurai Federal)

1. Before checking EGR system, ensure throttle position sensor, coolant temperature sensor and pressure sensor are operating correctly.
2. Check for 5th gear switch signal at ECM terminal A5 (Light Blue wire). ECM is located behind glove compartment. If voltage is present, check 5th gear switch circuit.
3. To check EGR system, place transmission in Neutral. Apply parking brake. With coolant temperature less than 127°F (53°C), start engine and operate at high RPM. EGR diaphragm should not move.
4. Warm engine to normal operating temperature. Operate engine at high RPM. EGR valve diaphragm should retract during acceleration.
5. If EGR valve does not operate as specified, check for misrouted, restricted, clogged or deteriorated vacuum hoses. If vacuum hoses are okay, check EGR valve and EGR modulator. If EGR valve and EGR modulator are okay, check EGR Vacuum Switching Valve (VSV).
6. If VSV is okay, check for open or short in wiring circuit. Check for defective connections at ECM and VSV. If connections are okay, check MFI main relay. If all components and wiring are okay, substitute a known-good ECM and recheck.

EGR System Test (Sidekick, Tracker & X-90 Calif.)

ECM will set Code 51 or P0400 if EGR system failure is present. Signal comes from Exhaust Gas Recirculation Temperature (EGRT) sensor. See SELF-DIAGNOSTICS article in the appropriate manual.

EGR System Test (Sidekick, Tracker & X-90 Federal)

1. Place transmission in Park (A/T) or Neutral (M/T) and transfer case lever in 2H position. Apply parking brake. With coolant temperature less than 131°F (55°C), start engine and operate at high RPM. EGR valve diaphragm should not retract.
2. Warm engine to normal operating temperature. Operate engine at high RPM. EGR valve diaphragm should retract. If EGR valve does not operate as specified, check for misrouted, restricted, clogged or deteriorated vacuum hoses. If vacuum hoses are okay, check EGR valve, EGR modulator, VSV, wire harness and ECM.
3. If EGR valve and EGR modulator are okay, check EGR Vacuum Switching Valve (VSV). If VSV is okay, disconnect ECM connector. On MFI engines, check Light Green/White wire from terminal A15. On TBI engines, check Light Green/Yellow wire from terminal A5 for short to ground, an open circuit, or poor connections at ECM or VSV connectors. On all engines, if wires and connections are okay, substitute with a known-good ECM and retest.

TEST 4

For EGR function testing, see appropriate or in ENGINE PERFORMANCE section of electronic information product.