67310-98540 Suzuki Cable Assembly, Throttle

Use this procedure in order to troubleshoot the position sensors for the following valves:
EGR valve
Engine intake throttle valveEach position sensor is an integral part of the associated valve. If the following procedure indicates a fault with the position sensor, then the entire valve must be replaced.The following background information is related to this procedure:The troubleshooting procedures for the diagnostic codes of each position sensor are identical. The ECM supplies 5 VDC to terminal "1" of the engine intake throttle valve connector and to terminal "6" of the EGR valve connector. The sensor common from the ECM connector goes to terminal "3" of the engine intake throttle valve connector and to terminal "4" of the EGR valve connector. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM. The signal voltage from terminal "5" of the engine intake throttle valve and from terminal "2" of the EGR valve is supplied to the appropriate terminal at the P2/J2 ECM connector.
Illustration 1 g03734119
Schematic diagram for the valve position sensors
Illustration 2 g03728447
Typical view of the pin locations on the 62-pin engine interface connector for the motorized valves
(29) EGR valve PWM signal
(30) EGR valve return
(33) EGR valve position sensor 5 VDC supply
(34) EGR valve position sensor signal
(35) EGR valve position sensor ground
(37) Intake throttle valve PWM signal
(38) Intake throttle valve return
(41) Intake throttle valve position sensor 5 VDC supply
(42) Intake throttle valve position sensor signal
(43) Intake throttle valve position sensor ground
Illustration 3 g03616849
Typical view of the pin locations on the J2 connector for the valve position sensors.
(8) Intake throttle valve position sensor 5 VDC supply
(9) EGR valve position sensor 5 VDC supply
(24) EGR valve position sensor ground
(34) Intake throttle valve return
(35) EGR valve return
(37) Intake throttle valve position sensor ground
(39) EGR valve position sensor signal
(49) Intake throttle valve PWM signal
(50) EGR valve PWM signal
(53) Engine intake throttle valve position sensor signal
Table 2
Troubleshooting Test Steps Values Results
1. Verify All Active and Recently Logged Diagnostic Codes
A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.
B. Verify if any of the diagnostic codes that are listed in Table 1 are active or recently logged.
Diagnostic codes
Result: None of the preceding diagnostic codes are active or recently logged.
Repair: The fault may be intermittent. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.
Result: One or more of the preceding diagnostic codes are active or recently logged.
Proceed to Test Step 2.
2. Inspect Electrical Connectors And Wiring
A. Thoroughly inspect the terminal connections on the P2/J2 ECM connectors.
B. Thoroughly inspect the connectors for the valves.
C. Thoroughly inspect the 62-pin connector.
D. Refer to Troubleshooting, "Electrical Connectors - Inspect".
E. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector, the 62-pin engine interface connector, and the valve connectors that are associated with the active diagnostic code.
F. Check the harness for abrasions and for pinch points from the valves back to the ECM.
Damaged wire or connector
Result: A damaged wire or damaged connector was found.
Repair: Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 3.
3. Measure the Sensor Supply Voltage at the Valve Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the suspect valve from the engine harness.
C. Turn the keyswitch to the ON position.
D. Measure the voltage at the harness connector for the valve from the 5 VDC supply terminal of the position sensor to the sensor ground terminal.
4.9 v to 5.1 V
Result: The measured voltage is not within the expected range.
Proceed to Test Step 4.
Result: The measured voltage is within the expected range.
Proceed to Test Step 5.
4. Measure the Supply Voltage at the 62-Pin Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the 62-pin connector.
C. Turn the keyswitch to the ON position.
D. Use a suitable voltmeter to measure the voltage at the 62-pin connector. Measure the voltage between the 5 VDC supply pin and the ground pin for the suspect valve.
E. Reconnect the 62-pin connector.
4.9 V to 5.1 V
Result: The voltage is within the expected range.
The fault is in the 5 VDC supply wire or the ground wire between the valve connector and the 62-pin engine interface connector.
Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The voltage is not within the expected range.
The fault is in the 5 VDC supply wire