09492-80003 Suzuki Jet, Pilot 80

Illustration 1 g03805325
Schematic of the diagnostic connector and the data link connector for a diagnostic connector that is mounted off engine
Illustration 2 g03705767
Schematic of the diagnostic connector and the data link connector for an engine mounted diagnostic connector
Table 1
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Turn the keyswitch to the OFF position.
B. Inspect the connectors in the circuit for the data link.
Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the CAN data link.
D. Check the screw for the P1 and P2 ECM connectors for correct torque of 6 N m (53 lb in).
E. Check all of the wiring associated with the data link for abrasions and pinch points.
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: A damaged wire or damaged connector was not found.
Proceed to Test Step 2.
2. Determine the Type of Fault in the Data Link
A. Connect the electronic service tool to the diagnostic connector that is on the engine harness or on the application.
B. Turn the keyswitch to the ON position.
Power to the comms adapter
Result: The power lamp illuminates on the communications adapter. The communications adapter is currently receiving the correct voltage.
Proceed to Test Step 5.
Result: The power lamp is not illuminated on the communications adapter. The communications adapter is not currently receiving the correct voltage.
Proceed to Test Step 3.
3. Check the Battery Voltage at the Diagnostic Connector
A. Turn the keyswitch to the ON position.
B. Use a multimeter in order to measure the voltage from pin A (battery+) and pin B (ground) of the diagnostic connector.
11.0 VDC and 13.5 VDC for a 12 VDC system. 22.0 VDC and 27.0 VDC for a 24 VDC system.
Result: The voltage is between 22.0 VDC and 27.0 VDC for a 24 V system. The voltage is between 11.0 VDC and 13.5 VDC for a 12 V system. The diagnostic connector is currently receiving the correct voltage.
Proceed to Test Step 5.
Result: The voltage is not between 22.0 VDC and 27.0 VDC for a 24 V system. The voltage is not between 11.0 VDC and 13.5 VDC for a 12 V system. The diagnostic connector is not currently receiving the correct voltage.
Proceed to Test Step 4.
Illustration 3 g03705906
Typical view of the diagnostic connector from the wire side
(A) Switched battery +
(B) Battery ground (GND)
(D) Data link +
(E) Data link -
Table 2
Troubleshooting Test Steps Values Results
4. Bypass the Wiring for the Diagnostic Connector
A. Disconnect the wires from pin A and pin B of the diagnostic connector.
Note: If the diagnostic connector is mounted on the engine, perform steps B to D. If the diagnostic connector is mounted off the engine, perform step E.
B. Disconnect the wires from P2:56 and P2:64.
C. Fabricate a jumper wire in order to connect pin A of the diagnostic connector to P2:56.
D. Fabricate a jumper wire in order to connect pin B of the diagnostic connector to P2:64.
E. Fabricate a jumper wire in order to connect pin "A" of the diagnostic connector to battery+ and pin "B" to the battery-.
F. Connect the electronic service tool to the diagnostic connector that is on the engine harness or on the application.
G. Turn the keyswitch to the ON position. The power lamp should illuminate on the communications adapter.
Other devices are OK
Result: The power lamp is illuminated. The fault is in the harness.
Repair: Repair the faulty harness or replace the faulty harness.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The power lamp is not illuminated.
Proceed to Test Step 6.
5. Check the Data Link Connections
A. Turn the keyswitch to the OFF position.
B. Disconnect the communications adapter from the diagnostic connector.
C. If the diagnostic connector is installed on the application, disconnect connector P1 from the ECM. Check the resistance between P1:20 and pin "D" on the diagnostic connector. Check the resistance between P1:28 and pin "E" on the diagnostic connector.
D. If the diagnostic connector is installed on the engine, disconnect P2 from the ECM. Check the resistance between P2:47 and pin "D" on the diagnostic connector. Check the resistance between P2:55 and pin "E" on the diagnostic connector.
Less than 10 Ohms
Result: The resistances are less than 10 Ohms.
Proceed to Test Step 6.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: At least one of the resistances is greater than 10 Ohms.
Repair : Repair the connectors and/or the harness, or replace the connectors and/or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
6. Change the Electronic Service Tool Components
A. If another electronic engine is available, connect the electronic service tool to the other engine. Ensure that the same cables are used.
B. Turn the keyswitch to the ON position. Determine if the electronic service tool operates correctly on the other engine.
C. If another engine is not available, obtain a replacement communications adapter and a replacement set of cables. Ensure that the cables for the electronic service tool are a complete set.
D. Install the replacement communications adapter and the set of cables for the electronic service tool and connect to the diagnostic connector.
E. Turn the keyswitch to the ON position.
F. If changing the communications adapter or the cables allows the electronic service tool to operate correctly, perform steps G to H.
G. Replace the components from the new set of cables with components from the original set of cables. Replace one component at a time.
H. Apply power to the electronic service tool after each of the components is replaced. Use this method to identify the faulty component.
I. If changing the cables does not allow the electronic service tool to