09103-06276 Suzuki BOLT

Illustration 1 g01167840
Typical example
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the engine control to the OFF/RESET mode. Turn the engine battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connector J1/P1 and the machine connector J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Check the engine connector (allen head screw) for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Check the harness and the wiring for abrasion and for pinch points. Expected Result:The connectors and wiring are free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 2. Check for an "ACTIVE" diagnostic Code
Connect Caterpillar Electronic Technician (ET) to the service tool connector. Start Cat ET.
Turn the engine control to the STOP mode. Turn the engine battery disconnect switch to the ON position.
Access the logged diagnostic codes on Cat ET. Expected Result:The Cat ET screen indicates one of the following diagnostic codes: CID-FMI 190-02, CID-FMI 190-03 and CID-FMI 190-08.Results:
OK - A diagnostic code for the engine speed/timing sensor is present. Proceed to Test Step 3.Test Step 3. Check the Engine Speed/Timing Sensor
Be sure to extend the sliphead before you install the Engine Speed/Timing Sensor. Also check that the Timing Gear is in a position that will not allow the sliphead of the Engine Speed/Timing Sensor to protrude into one of the slots of the Timing Gear. This is done visually with a flashlight prior to the installation of the Engine Speed/Timing Sensor. Turn the crankshaft to rotate the Timing Gear, if necessary, to position the gear in a place that will not allow the sliphead to protrude into a slot. If the sensor sliphead does protrude into one of the slots, the sliphead wll be BKoken off as the gear begins to rotate.
Turn the engine control to the OFF/RESET mode. Turn the engine battery disconnect switch to the OFF position.
Disconnect connector J20/P20 and remove the engine speed/timing sensor.
Inspect the plastic sliphead for damage.
Check the tension. Gently extend the sliphead 3.5 mm (0.14 inch). Return the sliphead to the original position.
Extend the sliphead.
Install the engine speed/timing sensor. Expected Result:The sliphead requires at least 22 N (5 lb) of force in order to push in the sliphead from the extended position.Results:
OK - The sensor and the sliphead are undamaged. The tension on the sliphead is normal. Reinstall the sensor. Proceed to Test Step 4.
Not OK - The engine speed/timing sensor or the sliphead is damaged and/or the sliphead has insufficient tension.Repair: Replace the engine speed/timing sensor. Calibrate the sensor. Perform the calibration procedure Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".STOPTest Step 4. Check the Engine RPM on Cat ET
Turn the engine control to the STOP mode. Turn the engine battery disconnect switch to the ON position. Start the engine.
Observe the engine speed on Cat ET. Expected Result:Cat ET displays a steady engine speed between 100 and 250 rpm while the engine is cranking.Results:
OK - The Cat ET screen displays a steady engine speed between 100 and 250 rpm while the engine is cranking. The engine speed/timing sensor is operating normally at this time.Repair: There may be an intermittent problem. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The Cat ET screen does not display a steady engine speed between 100 and 250 rpm while the engine is cranking. The Cat ET screen does not display the correct engine rpm signal. Proceed to Test Step 5.Test Step 5. Check the Supply Voltage to the Sensor
Disconnect the engine speed/timing connector J20/P20.
Turn the engine control to the STOP mode. The engine should be off.
Measure the voltage at the connector for the engine speed/timing sensor between J20-A and J20-B. Expected Result:The supply voltage is 12.5 1.0 VDC.Results:
OK - The supply voltage is 12.5 1.0 VDC. The sensor is receiving the correct supply voltage. Proceed to Test Step 6.
Not OK - The supply voltage is not 12.5 1.0 VDC. The supply voltage is incorrect. Proceed to Test Step 8.Test Step 6. Check the Signal Voltage at the Sensor
Remove the signal wire 999-WH(White) from the sensor connector P20-C.
Reconnect connector J20/P20.
Turn the engine control to the STOP mode. Turn the engine battery disconnect switch to the ON position. The engine should be off.
Measure the voltage between the signal wire 999-WH(White) from the sensor connector P20-C and the engine ground.
Crank the engine. Measure the voltage between the signal wire 999-WH(White) from the sensor connector P20-C and the engine ground.
Turn the engine control to the OFF/RESET mode. Turn the engine battery disconnect switch to the OFF position.
Reinsert the sensor signal wire back into P20-C. Expected Result:The voltage measures less than 3 VDC or more than 9 VDC when the engine is not cranking. While the engine is cranking, the voltage is between 2.0 VDC and 7.0 VDC.Note: The voltage output is determined by the presence or the absence of a tooth on the timing gear.Results:
OK - The engine speed/timing sensor is producing the correct output signal. Proceed to Test Step 7.
Not OK - The engine speed/timing sensor is not producing the correct output signal.Repair: Replace the engine speed/timing sensor. Calibrate the sensor. Perform the calibration procedure Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".STOPTest Step 7. Check the Signal Voltage at the ECM