32900-87D60 Suzuki CDI UNIT ASSEMBLY

LOGGED Diagnostic Codes Other Symptoms Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems!P-101: Engine Will Not Crank
Probable root causes: This is NOT an EUI system problem. Perform the following tests in order: For details of tests below, see Testing and Adjusting section of Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.1. Charge batteries (see Special Instruction SEH7633, for Battery Test Procedure).2. Load test batteries (see Special Instruction SEH9249, for Use Of 4C4911 Battery Load Tester).3. Check machine wiring to starter solenoid.4. Inspect starter cables for damage or loose connections.5. Remove and clean starter cables and connections if corroded.6. Test starter solenoid operation. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.7. Test starter motor operation. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.8. Check for fluid in cylinders by removing individual nozzles.9. Remove and inspect starter ring gear for damage.10. Disassemble engine to inspect internal components that may be seized, broken, out of alignment, etc. Refer to Disassembly & Assembly, 3508 EUI Engine, SENR5192.P-102: Engine Cranks But Will Not Start
Probable root causes: Perform the following tests in order:1. Make sure the User Defined Shutdown input is not active. If the User Defined Shutdown input was active then determine the reason for activation of the input. After correcting the problem turn the keyswitch OFF for at least 15 seconds before trying to restart the engine. Use the ECAP tool "Display Status" screen number 4 to verify the condition of the input.2. Make sure the Crank W/O Inject inputs are not active. If the Crank W/O Inject input is active then change the connector J24/P24 back to plug HHH. The engine may be started at anytime. Use the ECAP tool "Display Status" screen number 4 to verify the correct position of plug J24/P24.3. P-503: Electrical Power Supply Functional Test.4. If ECAP does not communicate with ECM, refer to P-523: CAT Data Link in this manual.5. Check Fuel Pressure. Also, check that fuel system is primed and that fuel supply and return lines are not restricted. In temperatures below 0°C (32°F), check for congealed fuel (wax).6. Check that J3/P3 thru J10/P10 (injector connectors) are installed correctly. Do P-515: Injector Solenoid Test, Step 1, as a quick check to confirm that the ECM can energize the injector solenoids.7. P-514: Engine Speed/Timing Sensor Functional Test. Also be sure that the timing reference gear is installed correctly [if the gear was installed backward (flipped over) during reassembly, the engine will not run]. Also the reference gear must be properly keyed to the camshaft by means of the locating dowel.8. Check for combustion problems (too cold or mechanical problem).P-103: Engine Misfires, Runs Rough, Or Is Unstable
If the problem is intermittent and cannot be re-created, refer to P-111: Intermittent Low Power Or Power Cutouts.If the problem is consistent and can be re-created, continue with this procedure. Probable root causes: If the problem only occurs under certain conditions (high engine speed, full load, etc) test the engine under those conditions. Troubleshooting the symptoms under other conditions can give misleading results. Perform the following tests in order:1. Isolate misfiring cylinder - refer to P-515: Injector Solenoid Functional Test, in this manual.2. Check the throttle switch signal by following P-504: Throttle Switch Functional Test, in this manual.3. Check the decelerator position sensor signal by following P-534: Decelerator Position Sensor Functional Test, in this manual.4. Check fuel quality. Refer to Diesel Fuels and Your Engine, SEBD0717.5. Inspect fuel system and check fuel pressure. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.6. Check for air in fuel. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.7. Check for restrictions in the air inlet and exhaust systems. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.P-104: Low Power/Poor Or No Response To Throttle Switch/Decelerator
Probable root causes: Perform the following tests in order:1. Troubleshoot any ACTIVE diagnostic codes. CID-FMI Codes 262-03 or 04, 263-03 or 04, 273-03 or 04 or 13, 274-03 or 04 or 13, 275-03 or 04 or 13 and 276-03 or 04 or 13 limit power or RPM or both. CID-FMI Code 91-00 or 02, 264-08 limits engine speed between 1000 rpm and low idle.2. Verify that engine has shifted out of Cold Mode.3. P-504: Throttle Switch Functional Test.4. P-534: Decelerator Position Sensor Functional Test.5. P-517: Turbo Compressor Outlet Pressure Sensor Functional Test.6. P-518: Right Turbo Compressor Inlet Pressure Sensor Functional Test.7. P-525: Left Turbo Compressor Inlet Pressure Sensor Functional Test.8. P-519: Atmospheric Pressure Sensor Functional Test.9. Inspect fuel system components and check for correct fuel pressure and quality. Refer to Diesel Fuels and Your Engine, SEBD0717.10. Check air inlet and exhaust systems for restrictions and leaks. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.11. Isolate misfiring cylinder. Refer to P515: Injector Solenoid Functional Test, in this manual.12. Check FRC value. Refer to Systems Operation, Testing & Adjusting, 3508 EUI Engine, SENR5589.P-110: Intermittent Engine Shutdowns
Use this procedure only if the engine shuts down completely and had to be restarted using the keyswitch. Probable root causes: Perform the following steps in order:1. Check external wiring harness and connectors (refer to P-501: Inspecting Electrical Connectors).2. Check ground lug on LH engine block and battery negative posts for loose or corroded connections.3. Check for correct installation of J1/P1 (70 Pin-ECM connector) & J2/P2 (40 Pin-Machine connector).4. P-503: Electrical Power Supply Functional Test.5. Check fuel line for restrictions and fuel tanks for foreign objects which may block fuel supply.6. P-514: Engine Speed/Timing Sensor Functional Test.7. P-535: User Defined Shutdown Input Functional Test.8. P-536: Crank W/O Inject Input Functional Test.P-111: Intermittent Low Power Or Power Cutouts
Use this procedure only if engine DOES NOT completely shut down (that is, it did NOT need to be restarted using the key switch). Probable root causes: Perform the following tests in order:1. Check external wiring harness and connectors (refer to P-501: Inspecting Electrical Connectors).2. P-503: Electrical Power Supply Functional