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EGR System Test (Federal)

  1. Before checking EGR system, ensure pressure sensor is operating correctly. See PRESSURE SENSOR under ENGINE SENSORS & SWITCHES  . Ensure no lock-up signal (A/T) is applied to ECM. The ECM is located at upper left corner of instrument panel.
  2. On A/T models to check lock-up signal, check for voltage at terminal A11 (White/Yellow wire) of ECM. If voltage is present, check lock-up solenoid circuit. See WIRING DIAGRAMS article in the ENGINE PERFORMANCE Section.
  3. Place transmission in Park (A/T) or Neutral (M/T). Apply parking brake. With coolant temperature less than 118°F (48°C), start engine and operate at high RPM. EGR valve diaphragm should not move.
  4. Warm engine to normal operating temperature. Operate engine at high RPM. EGR valve diaphragm should move up.
  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 (backpressure transducer). See EGR VALVE and EGR MODULATOR (BACKPRESSURE TRANSDUCER) under EXHAUST GAS RECIRCULATION (EGR)  .
  6. If EGR valve and EGR modulator (backpressure transducer) are okay, check EGR Vacuum Switching Valve (VSV). See EGR VACUUM SWITCHING VALVE (VSV) under EXHAUST GAS RECIRCULATION (EGR)  . 7 If VSV is okay, disconnect 18-pin connector from ECM. Turn ignition on. Check for battery voltage on terminal B5 (Light/Green Yellow wire) of ECM connector. If battery voltage is present, go to step 10).
  7. If battery voltage is not present, check for open in Blue/Black wire to VSV. See Fig 1 . Check for open or short in Blue/Black wire. If wiring is okay, check control relay. See CONTROL RELAY under RELAYS & SOLENOIDS  . Repair as necessary.
  8. If battery voltage is present as described in step 8), install connector on ECM. With engine running, check for battery voltage on terminal B5 (Light Green/Yellow wire) of ECM connector.
  9. With coolant temperature less than 140°F (60°C), no voltage should be present. if no voltage is present, ECM is okay. If voltage is present, check coolant temperature sensor. See COOLANT (WATER) TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES  .
  10. Replace coolant temperature sensor if defective. If coolant temperature sensor is okay, check for proper connections at ECM. If connections are okay, substitute a known good ECM and recheck.
Fig 1: EGR Control System Wiring & Vacuum Diagram
G90G17398Courtesy of SUZUKI OF AMERICA CORP.
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