09116-06215 Suzuki BOLT (W/WASHER)

Illustration 1 g01218953
Schematic for the digital sensor supply
Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove electrical power from the engine ECM.
Illustration 2 g01142692
J1/P1 ECM Connectors
Thoroughly inspect connectors (1). Inspect the connectors for the throttle position sensor. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01214474
Terminal locations at the P1 ECM connector for the digital sensor supply
(P1-4) 8 VDC supply
(P1-5) Digital return
(P1-66) Throttle position
Illustration 4 g01159881
Terminal locations at the sensor connector for the digital sensor supply
(Terminal A) 8 VDC supply
(Terminal B) Digital return
(Terminal C) Throttle position
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the digital sensor supply.
Check the allen head screw from each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque value.
Check the harness and wiring for abrasions and for pinch points from the throttle position sensor to the ECM. Expected Result:All of the connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with a connector and/or the wiring.Repair: Repair the connector and/or the wiring. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the problem is resolved.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Restore electrical power to the engine ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes that are related to the digital supply. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.Expected Result:There are no active diagnostic codes for the digital supply.Results:
OK - No diagnostic code for the digital supply is active. A problem is suspected with a sensor output signal. In order to verify that the sensor is receiving the correct supply voltage, proceed to Test Step 3.
Active 41-03 code - A 41-03 diagnostic code is active. The ECM is detecting a short to the +Battery in the wiring for the digital supply. Proceed to Test Step 3.
Active 41-04 code - A 41-04 diagnostic code is active. The ECM is detecting a short to ground in the wiring for the digital supply. Proceed to Test Step 4.Test Step 3. Check the Supply Voltage at the Sensor Connector
Remove electrical power from the engine ECM.
Disconnect the harness connectors for the throttle position sensor.
Restore electrical power to the engine ECM.
Measure the voltage between terminals A (8 V digital supply) and terminal B (digital return) at the sensor connector. Expected Result:The voltage measurement is 8.0 0.4 VDC.Results:
OK - The voltage is 8.0 0.4 VDC.Repair: The voltage is correct. Restore all wires to the original configuration. Clear all diagnostic codes. The problem seems to be resolved. There may be an intermittent problem in the circuit. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect" for details.STOP
Not OK - The voltage is not 8.0 0.4 VDC. The voltage is incorrect at the sensor connector. Proceed to Test Step 5.Test Step 4. Disconnect the Throttle Position Sensor and Check for Active Diagnostic Codes
Remove electrical power from the engine ECM.
Ensure that the throttle position sensor is disconnected at the sensor connector.
Restore electrical power to the engine ECM.
Use Cat ET to check an active 41-04 diagnostic code. Note: Wait for 30 seconds after the sensor is disconnected. Check for an active diagnostic code on Cat ET.Expected Result:The 41-04 diagnostic code deactivates while the sensor is disconnected from the circuit.Results:
OK - The 41-04 diagnostic code deactivates while the sensor is disconnected.Repair: The harness and the ECM are OK. There is a problem with the sensor. Replace the sensor. Ensure that the code does not return with the new sensor prior to installing the new sensor. Verify that the repair eliminates the problem.STOP
Not OK - The 41-04 diagnostic code remains after the throttle position sensor is disconnected. Leave the sensor disconnected. Proceed to Test Step 5.Test Step 5. Check the +8 V Supply Wire at the ECM Connector for a Short in the Harness
Remove electrical power from the engine ECM.
Disconnect the J1/P1 connectors.
Ensure that the throttle position sensor is disconnected at the sensor connector. Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Measure the resistance between P1-4 (+8 V digital supply) and every terminal on the P1 ECM connector. Expected Result:Each resistance measurement indicates that an open circuit condition exists.Results:
OK - Each check of the resistance indicates an open circuit. Leave the connector disconnected. There is not a short circuit in the harness or a short to engine ground. Proceed to Test Step 6.
Not OK - One of the resistance measurements does not indicate an open circuit condition.Repair: The wire for the digital supply is shorted to another wire in the harness or the wire is shorted to engine ground. There may be a problem with a connector in the circuit. Repair the harness and/or the connector. Replace parts, if necessary. Clear all logged diagnostic codes. Restore the wiring to the original configuration. Verify that the repair eliminates the problem.STOPTest Step 6. Check the +8 V Supply Wire at the ECM Connector for an Open in the Harness
Fabricate a jumper wire that is long enough to connect two terminals at the ECM connector. Crimp connector pins to each end of the jumper wire.
Install the jumper wire between terminals P1-4 (+8 V digital supply) and P1-5 (digital return) on the harness side of the ECM connector. Note: Wiggle the harness during the following measurements in order to reveal an intermittent open condition.
Measure the resistance between terminal A and terminal B at the connector for the throttle position sensor.
Remove the wire jumper. Expected Result:The measurement indicates that a short