09481-15101 Suzuki FUSE (15A)

Illustration 1 g01163938
SchematicTest Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect ECM connector J1/P1, ECM connector J2/P2, machine connector J3/P3, and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.
Check the allen head screw for each ECM connector for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Supply Voltage at the Sensor Connector
Disconnect the suspect sensor.
Turn the keyswitch to the ON position.
Use a multimeter to measure the voltage across terminal A (+5V analog supply) and terminal B (sensor return) at the harness side of the suspect sensor connector.
Turn the keyswitch to the OFF/RESET position.
Reconnect all sensors.Expected Result:The voltage is 5.0 0.2 VDC.Results:
OK - The voltage is 5.0 0.2 VDC. The voltage is correct. Proceed to Test Step 3.
Not OK - The voltage is not 5.0 0.16 VDC.Repair: The voltage is incorrect. Refer to Troubleshooting, "Analog Sensor Supply Circuit - Test" for the appropriate troubleshooting procedure.STOPTest Step 3. Check for Active Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to an open circuit diagnostic code 03 or a short circuit diagnostic code 04.
Turn the keyswitch to the OFF/RESET position.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A short circuit diagnostic code (04) is active at this time. Proceed to Test Step 4.
Not OK - An open circuit diagnostic code (03) is active at this time. Proceed to Test Step 5.Test Step 4. Disconnect the Suspect Sensor in Order to Create an Open Circuit
Disconnect the sensor connector of the sensor with the short circuit diagnostic code (04).
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen on Cat ET. Check for an active open circuit diagnostic code (03).
Turn the keyswitch to the OFF/RESET position.Expected Result:An open circuit diagnostic code 03 is now active for the disconnected sensor.Results:
OK - A short circuit diagnostic code (04) was active before disconnecting the sensor. An open circuit diagnostic code (03) became active after disconnecting the sensor.Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes.STOP
Not OK - There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 7.Test Step 5. Check the Signal Wire for a Short Circuit
Turn the keyswitch to the OFF position.
Disconnect ECM connectors P1 and P2.
Disconnect the connector for the sensor.
Measure the resistance between the terminal for the sensor signal wire at the ECM and every terminal on ECM connector P1 and ECM connector P2.
Measure the resistance between the terminal for the sensor signal wire at the ECM and engine ground.
Turn the keyswitch to the OFF/RESET position.
Reconnect ECM connector P1 and ECM connector P2.Expected Result:The resistance indicates an open circuit for all measurements.Results:
OK - An open circuit was indicated for all measurements. Proceed to Test Step 6.
Not OK - An open circuit was not indicated for at least one measurement.Repair: The resistance measurement indicates a low resistance between two or more wires. Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 6. Create a Short at the Suspect Sensor Connector
Turn the keyswitch to the OFF/RESET position.
Install a jumper wire between terminal B (sensor return) and terminal C (sensor signal) on the connector for the suspect sensor. Connect the jumper on the harness side of the connector.
Turn the keyswitch to the ON position.
Wait at least 15 seconds for activation of the short circuit diagnostic code 04.Note: Monitor the "Active Diagnostic Codes" screen on Cat ET before installing the jumper wire and after installing the jumper wire.
Remove the jumper wire.
Turn the keyswitch to the OFF/RESET position.Expected Result:A short circuit diagnostic code 04 is active when the jumper wire is installed. An open circuit diagnostic code 03 is active when the jumper wire is removed.Results:
OK - The engine harness and the ECM are OK.Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes.STOP
Not OK - The open circuit diagnostic code 03 remains active with the jumper in place. The open circuit is between the ECM and the sensor connector. Proceed to Test Step 7.Test Step 7. Check the Operation of the ECM
Turn the keyswitch to the OFF/RESET position.
Check the operation of the ECM by creat