Engine Controls - Erroneous MIL ON/DTC's O0441/P0496
Section Title: EngineTSB No. TS 08 12177R
Division: Automotive
Category: Technical
SUBJECT:
P0441 OR P0496 (EVAPORATIVE EMISSION SYSTEM CONTINUOUS PURGE FLOW)
MODEL(S):
FORENZA, FORENZA WAGON, RENO (RQ420)
YEAR:
2004~2008
REVISION:
ADDED 2007 AND 2008 MY. NEW SOFTWARE IS AVAILABLE FOR THIS CONCERN, USE SAME PROCEDURE BELOW. STEP 7 ADDED FOR RELEARN PROCEDURES.
CONDITION:
The ECM software calibration may cause unnecessary illumination of the Malfunction Indicator Lamp (MIL) and store DTC P0441 (04 MY) or P0496 (05 and 08 MY), (Evaporative Emission System Continuous purge flow).
CAUSE:
ECM software logic.
CORRECTION:
Perform diagnostic procedure below to determine if a purge control valve defect is actually causing the DTC and then perform reprogram procedure below to reprogram the ECM. Refer to the General TSB 05 XXXXX "ECM (ECU)
Reprogramming Verification Procedure Using the Suzuki SDS Tool" to verify
the version installed in your PC.
REQUIRED TOOLS AND SOFTWARE:
PARTS INFORMATION:
WARRANTY CLAIM INFORMATION INSPECTION ONLY:
WARRANTY CLAIM INFORMATION INSPECTION AND REPLACEMENT:
Smoke Test Procedure for Purge Control Valve:
1. Connect smoke tester to the vehicle.
2. To close the vent valve for testing, connect a jumper wire from the blue wire directly to a good body ground. Do not disconnect the vent valve electrical connector.
3. Verify the connection by turning the key ON with the engine OFF. A click sound should be heard from the vent solenoid.
4. Remove the purge valve by bending the tab then sliding the valve up.
5. Disconnect the port in the intake side of the purge valve. Do not disconnect the other side.
6. Turn ignition key ON and with the engine OFF.
NOTE:
Make sure the vent solenoid valve is shut by listening for the click noise when the ignition key is turned ON. If not, the smoke will exit through the vent valve.
7. Activate the smoke tester.
8. A leak from the purge valve will be indicated by smoke exiting from the purge valve nipple along with a fuel smell.
9. Replace the purge control valve if a leak is detected
10. Reprogram the ECM.
Reprogramming Procedure:
1. Log onto the Suzuki Connect and access the Suzuki Pitstop.
2. Download and review the Suzuki Pass-Thru Reprogramming Tool Operator's Manual. This must be read and understood COMPLETELY before attempting to reprogram the ECM.
3. Following the procedure outlined in the Suzuki Pass-Thru Reprogramming Tool Operator's Manual, download and install the Pass-Thru Reprogramming Software "SOFTWARE.EXE" in your PC, (if it is not already installed).
4. Follow the procedure in Section 3.2 of the Operator's Manual to update the Database files. Download and unzip Suzuki Pass-Thru Reprogramming Data Base "DATABASE.EXE" in your PC. This step is only required to be done once to accommodate all vehicles covered under this TSB.
NOTE:
This Database "DATABASE.EXE" has been updated with newer data for reprogramming without changing the file name. You are requested to download in order to update the database in your PC.
5. Following the procedures outlined in the Suzuki Pass-Thru Reprogramming Tool Operator's Manual, hook up the SDS Interface Tool P/N 09910-06520 to the vehicle and run the ECM reprogramming software. Continue to step 6. If the message "[4028] ECU already has the latest version" appears, click "OK". No further action is required. The glove box label should already be in the glove box.
6. Fill out the Reprogram Label P/N 99963-01501-224 (the part number and version will be displayed at the "The reprogramming is successful" screen). Then affix the label to the back of the glove box door as pictured below.
7. Perform the idle relearn after reprogramming as follows.
a. Turn the ignition ON.
b. Turn the ignition OFF for 15 seconds.
c. Turn the ignition ON for 5 seconds.
d. Turn the ignition OFF for 15 seconds.
e. Start the engine in Park/Neutral.
f. Allow the engine to run until the engine coolant is above 85 °C (185 °F).
g. Turn the A/C ON for 10 seconds, if equipped.
h. Apply the parking brake. While pressing the brake pedal, place the transaxle in D (Drive) for 10 seconds.
i. Turn the A/C OFF for 10 seconds, if equipped.
j. Place the transaxle in Park/Neutral.
k. Turn the ignition OFF. The idle learn procedure is complete.
l. Perform Tooth Error Correction (TEC) relearn by using the Tech 2.
NOTE:
If the symptom remains after reflashing, contact the S.M.A.R.T. Hotline (Techline) for assistance.
Disclaimer