09116-08158 Suzuki BOLT (8X35)

Troubleshooting Problems
Problem 1: Check Engine Light Is On While the Engine Is Running Probable Cause:1. Low Engine Oil Pressure Follow electronic control system engine Diagnostic Code 46.2. Electronic Control System Component Fault Follow Electronic Control System Engine Test Procedure P-200 to determine the diagnostic code.3. Wiring Harness Fault Between The Electronic Control System Control Module And The Check Engine Lamp Troubleshooting the wiring harness. Problem 2: Engine Crankshaft Will Not Turn When Start Switch Is On Probable Cause:1. Problem Inside The Engine Prevents Crankshaft From Turning If the crankshaft can not be turned after disconnecting any accessories remove the fuel injection nozzles and check for fluid in the cylinders while turning the crankshaft. If fluid in the cylinders is not the problem, the engine must be disassembled to check for other inside problems. Some of these inside problems are bearing seizure, and valves making contact with pistons. Problem 3: Engine Will Not Start Follow Electronic Control System Engine Test Procedure P-109. Probable Cause:1. Starting Motor Turns Too Slow The causes can be similar or the same as those that keep the crankshaft from turning. Check the items listed in Problem 2.2. No Fuel To The Cylinders Loosen a fuel injection line nut at the through the head adapter. With power switch(es) in the ON position and accelerator in the FUEL ON position, turn the crankshaft with the starting motor to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, follow Steps (a) through (c) until the problem is corrected.a. Use the priming pump to make sure the fuel lines and fuel injection pump housing are full of fuel.b. If you are not using a good quality of fuel at temperatures below -12°C (10°F), it is possible that the fuel in the system can "wax" (not have correct flow characteristics) and cause a restriction in the fuel system. Install a new fuel filter. It may be necessary to drain the complete fuel system and replace with a No. 1 grade of fuel.c. Check for fuel supply line restriction by removing the fuel supply line for the fuel filter base. Put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
If there is no fuel, or only a weak flow of fuel from the fuel supply line, there is a restriction in the fuel supply line and/or the fuel tank.3. Low Quality Or Water In Fuel Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with a good quality fuel. For more information refer to Diesel Fuels And Your Engine, SEBD0717.Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If the engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary.4. No Or Low Electrical Power Supply To Electronic Control System Control System Follow Electronic Control System Engine Test Procedure P-109.5. Electronic Control System Component Fault Follow Electronic Control System Engine Test Procedure P-200 to determine the diagnostic code.6. Optional Safety Shut Down System Is Preventing Engine Start Follow check out procedure for safety shut down system, if used.7. Wrong Fuel Injection Timing Follow Electronic Control System Engine Test Procedure P-400.8. No Air To Cylinders Check for a plugged air cleaner element or blockage in the air lines. Refer to Restriction Of Air Inlet And Exhaust in the Testing & Adjusting section. Also, check inlet and exhaust valve operation. Problem 4: Engine Misfires Or Runs Rough Follow Electronic Control System Engine Test Procedure P-107 Probable Cause:1. Low Fuel Pressure Change the primary and secondary fuel filters and check to make sure the fuel lines are not plugged or damaged. If the filters or lines are not the cause, a repair or replacement of the fuel transfer pump is needed.2. Air In Fuel System With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.3. Leak Or Break In Fuel Injection Line Between Fuel Injection Pump And Fuel Injection Nozzle Check fuel lines for leaks, tighten fittings or replace lines.4. Defective Fuel Injection Nozzle Find a defective fuel injection nozzle by running the engine at the rpm where it runs rough. Loosen a fuel line nut, at the through the head adapter, enough to stop fuel supply to that cylinder. Each cylinder