Suzuki Grand Vitara 2011 Manual page 364

1A-295 Engine General Information and Diagnosis: For Diesel Engine Model
Troubleshooting for D2: Measured pressure too low, D3: Measured pressure too high, D4: Insufficient
pressure, D5: Pressure < minimum and D6: Pressure > maximum
Check the fuel flow actuator connector.
Check the ECM connections.
Check the low pressure circuit and that the correct fuel is being used using fault finding
• Tests Test 2 referring to "Test 2: Low pressure circuit check: For Diesel Engine Model".
Repair if necessary.
Measure the fuel flow actuator resistance between "C83-2" wire and "C83-1" wire.
If the resistance is not 2.9 – 3.1 Ω at 20 °C, 68 °F, replace the fuel flow actuator.
Check the continuity and for the absence of interference resistance on the following connections:
• Between "C83-2" wire of fuel flow actuator connector and "C86-7" terminal of ECM connector
• Between "C83-1" wire of fuel flow actuator connector and "E33-6" wire of main relay mounting connector
Repair if necessary.
• In the event of rail overpressure:
Check the operation of the injectors referring to "Test 8: Injector malfunction: For Diesel Engine Model".
Check that the fuel pressure sensor is operating correctly using command "IMV/Flow actuator" on SUZUKI
scan tool.
Display the parameter "Fuel pressure" on Data List of SUZUKI scan tool, and refer to "SUZUKI Scan Tool
Data" to check the operating values.
If these checks do not reveal any faults, and if the fault is still present, replace the fuel pressure sensor.
• In the event of rail underpressure:
Check that the fuel pressure sensor is operating correctly using command "IMV/Flow actuator" on SUZUKI
scan tool.
Display the parameter "Fuel pressure" on Data List of SUZUKI scan tool, and refer to "SUZUKI Scan Tool
Data" to check the operating values.
Check the priming of the low pressure fuel circuit.
Check the conformity of the fuel filter connections.
Check the condition of the fuel filter (clogging and water saturation).
Check that there are no air bubbles between the fuel filter and the high pressure pump.
Check the low and high pressure fuel circuit sealing (visual checks, odour, etc.): pump casing, pressure relief
valve, pipes, rail and fuel injector unions, fuel injector wells, etc.
Check the conformity of the seal fitting on the fuel flow actuator.
Check the operation of the injectors referring to "Test 8: Injector malfunction: For Diesel Engine Model".
Carry out the necessary operations.
If the fault is still present replace the fuel flow actuator.