09116-06175 Suzuki BOLT (6X42)

Illustration 1 g00927851
Location of pressure sensors
Illustration 2 g00933710
SchematicTest Step 1. Inspect Electrical Connectors and Wiring
Illustration 3 g00933750
ECM connectors (wire side)
Illustration 4 g00933752
ECM connectors (ECM side)
Thoroughly inspect the J1/P1 ECM connector, the J2/P2 ECM connector, and the connectors for each pressure sensor.Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the +5 V sensor supply.Refer to Illustration 3.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and pinch points from the sensors back to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem. Stop.Test Step 2. Check for Active Diagnostic Codes
Connect the electronic service tool to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.Expected Result:Note the condition of the following codes:
262-03 5 Volt Sensor Supply short to +batt
262-04 5 Volt Sensor Supply short to groundResults:
262-03 Active - Proceed to Test Step 3.
262-04 Active - Proceed to Test Step 4.
262-03 or 262-04 Logged ONLY - Proceed to Test Step 6.
Not Active or Logged - The +5 V supply is operating correctly at this time. Stop.Test Step 3. Short the Output at the ECM
Turn the keyswitch to the OFF position.
Remove the 997-OR wire from P1:2 (Engine Pressure Sensor +5V). Remove the G828-WH wire from P2:2 (Engine Pressure Sensor +5V) and remove the G826-BR wire from P2:41 (Engine Pressure Sensor +5V).
Install a jumper wire between P1:2 (Engine Pressure Sensor +5V) and the ECM ground strap. Install a jumper wire between P2:2 (Engine Pressure Sensor +5V) and the ECM ground strap. Install another jumper wire between P2:41 (Engine Pressure Sensor +5V) and the ECM ground strap.
Turn the keyswitch to the ON position.
Check for active diagnostic codes on the electronic service tool.Expected Result:The 262-03 5 Volt Sensor Supply short to +batt should change to a 262-04 5 Volt Sensor Supply short to ground when the jumper wire is installed.Results:
OK - The ECM is responding correctly. Proceed to Test Step 5.
Not OK - The ECM is not responding correctly.Repair: Verify your results before replacing the ECM. Refer to Troubleshooting, "Replacing the ECM" before you replace the ECM. Stop.Test Step 4. Open the Output at the ECM
Turn the keyswitch to the OFF position.
Remove the 997-OR wire from P1:2 (Engine Pressure Sensor +5V). Remove the G828-GH wire from P2:2 (Engine Pressure Sensor +5V) and remove the G826-BR wire from P2:41 (Engine Pressure Sensor +5V).
Turn the keyswitch to the ON position.
Check for active diagnostic codes on the electronic service tool.Expected Result:The 262-04 5 Volt Sensor Supply short to ground should no longer be active when the wires are removed from the ECM connectors.Results:
OK - The ECM is responding correctly. Proceed to Test Step 5.
Not OK - The ECM is not responding correctly.Repair: Verify your results before replacing the ECM. Refer to Troubleshooting, "Replacing the ECM" before you replace the ECM. Stop.Test Step 5. Disconnect the +5 V Pressure Sensors while You Monitor the Active Diagnostic Codes
Connect the electronic service tool to the service tool connector.
Turn the keyswitch to the ON position.
Access the active diagnostic code screen on the electronic service tool. Verify that one of the following diagnostic codes is active:
262-03 5 Volt Sensor Supply short to +batt
262-04 5 Volt Sensor Supply short to ground
Disconnect the following sensors one at a time:
J200/P200 Turbo outlet pressure sensor
J201/P201 Engine oil pressure sensor
J203/P203 Atmospheric pressure sensor
J204/P204 Injection actuation pressure sensor
J220/P220 Turbo inlet air pressure sensor
Wait for 30 seconds after each pressure sensor is disconnected while you monitor the active diagnostics screen on the electronic service tool in order to verify that the disconnection of a specific sensor deactivates the +5 V diagnostic code.Note: When the sensors are disconnected and the keyswitch is in the ON position, open circuit diagnostic codes will be active or logged when the +5 V diagnostic codes are no longer active. This is normal. Clear these diagnostic codes after this test step is completed.Expected Result:The original +5 V diagnostic code remains active.Results:
OK - The +5 V diagnostic code is still active. The harness is the cause of the problem. Leave the sensors disconnected. Proceed to Test Step 6.
Not OK - The +5 V diagnostic code is not active when a specific sensor is disconnected.Repair: Reconnect the sensor that is suspected of causing the problem. If the problem returns after the reconnection of the sensor, disconnect the sensor. If the problem disappears after the disconnection of the sensor, replace the sensor.Clear all diagnostic codes. Verify that the repair eliminates the problem. Stop.Test Step 6. Check the Wiring Harness for Shorts
Illustration 5 g00927597
ECM connectors (ECM side)
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 and J2/P2 ECM connectors. Verify that all of the following +5 V engine pressure sensors that are attached to the ECM connectors are disconnected:
J200/P200 Turbo outlet pressure sensor
J201/P201 Engine oil pressure sensor
J203/P203 Atmospheric pressure sensor
J204/P204 Injection actuation