09116-10131 Suzuki BOLT (10X35)

Illustration 1 g00795938
SchematicTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J2/P2 ECM connector, the connector for the fuel level buffer, the connector for the fuel level sender, and any other connectors in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.Expected Result:All connectors, pins, and sockets should be completely inserted and coupled. The harness and wiring should be free of corrosion, abrasion, and pinch points. All connections and grounds should be tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 2. Check the Fuel Level
Visually check the fuel level in the tank.
Compare the fuel level in the tank to the indicator on the fuel level sender.Expected Result:The fuel level in the tank should correlate with the indicator on the fuel level sender.Results:
OK - Proceed to Test Step 3.
Not OK - The indicator on the fuel level sender does not reflect the actual fuel level in the tank.Repair: Replace the fuel level sender.Verify that the repair eliminates the problem. Stop.Test Step 3. Check the Status of the Fuel Level on ET
Turn the keyswitch to the OFF/RESET position.
Connect ET to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status of "Fuel Gauge" on ET.Note: The status of "Fuel Gauge" on ET represents the percentage of fuel level in the tank.
Turn the keyswitch to the OFF/RESET position.Expected Result:The status of "Fuel Gauge" should correlate with the fuel level in the tank.Results:
OK - The fuel level sensor appears to be operating correctly at this time.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent. Stop.
Not OK - Proceed to Test Step 4.Test Step 4. Check the Resistance of the Fuel Level Sender.
Disconnect the fuel level sender from the fuel level buffer.
Measure the resistance between the terminals on the receptacle for the fuel level sender.
Reconnect the fuel level sender.Expected Result:The resistance should be less than 100 Ohms.Note: The resistance should be between 0 and 15 Ohms when the indicator is on "F". The resistance should be between 85 and 100 Ohms when the indicator is on "E".Results:
OK - The fuel level sender appears to be OK. Proceed to Test Step 5.
Not OK - The resistance is out of range.Repair: Replace the fuel level sender.Verify that the repair eliminates the problem. Stop.Test Step 5. Check the Supply Voltage to the Buffer
Install a 7X-6370 Adapter Cable (3 Pin DT Breakout) at the connector for the fuel level buffer.
Turn the keyswitch to the ON position.
Measure the voltage across terminal A (+24 VDC) and terminal B (Digital Return) at the breakout.Expected Result:The supply voltage should be approximately 24 VDC.Results:
OK - The buffer is receiving the correct supply voltage. Proceed to Test Step 6.
Not OK - The buffer is not receiving the correct supply voltage.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 6. Check the Isolated Signal Frequency and the Duty Cycle
Remove the F713-OR wire from the harness side of the connector for the fuel level buffer. Leave the breakout in place.
Turn the keyswitch to the ON position.
Measure the frequency and the duty cycle between terminal B (Digital Return) and terminal C (Signal) at the breakout.
Turn the keyswitch to the OFF/RESET position.
Reinstall the signal wire in the connector and remove the breakout. Leave the connector disconnected.Expected Result:The frequency should be between 5 and 6.5 kHz. The duty cycle should be between 20 and 95 percent.Results:
OK - The buffer is producing a valid signal. Proceed to Test Step 7.
Not OK - The buffer is not producing a valid signal.Repair: Replace the fuel level buffer.Verify that the repair eliminates the problem. Stop.Test Step 7. Check the Harness for Shorts
Illustration 2 g00798465
P1 ECM connector
Illustration 3 g00798466
P2 ECM connector
Ensure that the keyswitch is in the OFF/RESET position and that the fuel level buffer is disconnected from the harness.
Disconnect the J1/P1 and J2/P2 ECM connectors.
Measure the resistance between P1:29 (Digital Sensor Return) and P2:32 (Fuel Level).
Leave the connectors disconnected.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The harness is not shorted. Proceed to Test Step 8.
Not OK - There is a short in the harness.Repair: Repair the harness.Verify that the repair eliminates the problem. Stop.Test Step 8. Check for Opens in the Harness
Illustration 4 g00798465
P1 ECM connector
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P2 ECM connector
Install a jumper wire between P1:29 (Digital Sensor Return) and P2:32 (Fuel Level).
Check the resistance at the plug for the fuel level buffer between terminal B (Digital Return) and terminal C (Signal).
Remove the jumper wire and reconnect the fuel level buffer.Expected Result:The resistance should be less than 10 Ohms.Results:
OK - The harness is good. Proceed to Test Step 9.
Not OK - There is an open in the harness.Repair: Repair the harness.Verify that the repair eliminates the problem. Stop.Test Step 9. Check the Signal Frequency and the Duty Cycle at the ECM
Illustration 6 g00798465
J1/P1 breakout