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Home >> Suzuki >> 2005 >> XL-7 EX, 4WD >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine General Information And Diagnosis >> H25 Engine >> Diagnostic Information and Procedures >> DTC P0401 / P0402: Exhaust Gas Recirculation (EGR) Flow Insufficient Detected / Excessive Detected >> DTC Troubleshooting
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DTC Troubleshooting

DTC TROUBLESHOOTING

Step Action Yes No
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 4.
3 EGR valve operation check 
  1. With ignition switch OFF, install SUZUKI scan tool.
  2. Check EGR system referring to "EGR SYSTEM INSPECTION (USING SUZUKI SCAN TOOL) ".

Is it in good condition? 
Intermittent trouble. If OK, substitute a known-good ECM (PCM) and recheck. Go to Step 4.
4 EGR valve power supply circuit check 
  1. With ignition switch OFF, disconnect EGR valve coupler (1)-2) With ignition switch ON, check EGR valve harness terminal voltage between "BLU/BLK" wire terminal "b" and ground, "BLU/BLK" wire terminal "e" and ground.
G04097408

Is each voltage 10 - 14 V? 
Go to Step 5. Faulty "BLU/BLK" wire.
5 EGR valve stepper motor coil circuit check 
  1. With ignition switch OFF, connect EGR coupler (2) to EGR valve (1) and disconnect ECM (PCM) couplers.
  2. Check resistance between "C51-2-20" and "C51-2-4", "C51-2-5", "C51-2-16", "C51-2-17".
G04097409

Is each resistance 20 - 24 D? 
Stuck or faulty EGR valve. Clogged EGR gas passage. MAP sensor malfunction. If OK, substitute a known-good ECM (PCM) and recheck. Faulty "LT GRN", "LT GRN/WHT", "LT GRN/ RED", "LT GRN/YEL" wire or EGR valve.
6 MAP sensor performance check 
  1. Check voltage between "C51 -3-13" and "C51 -3-20" terminal.

    MAP sensor output voltage specifications 

    Ignition switch ON leaving engine OFF: 3.3 - 4.3 V 

    Ignition switch ON, leaving engine idling: Less than 3.3 V 


Is each value satisfied? 
Substitute a known-good ECM (PCM) and recheck. MAP performance problem. Refer to "DTC P0107/P0108: MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT LOW / HIGH INPUT  ".