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

WARNING: This page does not describe the selected car, but rather 80 other vehicles, including the 2008 Suzuki Reno, 2008 Suzuki Grand Vitara, 2008 Suzuki Forenza, 2007 Suzuki Reno, and 2007 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

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.
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.
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.