09420-03005 Suzuki Key

Recommended Actions
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Note: The procedures have been listed in order of probability. Complete the procedures in order.Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high engine speed, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
Note: Certain diagnostic codes and/or event codes may cause poor performance. Refer to in the electronic service tool.
A. Use the electronic service tool to check for active or logged codes.
B. Use the electronic service tool to check the histogram information if the engine has been derated.
Note: If the histograms contain engine derates and no diagnostic codes are present, then the engine is operating normally.
Engine Derate or Diagnostic Codes
Result: A diagnostic code is present.
Repair: Troubleshoot the code and then reset the histogram.
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Parameters in the Electronic Control Module (ECM)
A. Use the electronic service tool to verify that the correct parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Parameters
Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Result: The parameters are correct.
Proceed to Test Step 3.
3. Electrical connectors
A. Turn the start switch to the ON position.
B. Use the electronic service tool to check the intake manifold pressure.
C. Run the engine until the speed is equal to the maximum no-load speed.
D. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.
Electrical connections
Result: The intake manifold pressure is not zero 0.5 kPa (zero 0.070 psi).
Repair: Check the 5 VDC sensor supply for the intake manifold pressure. Refer to Troubleshooting, "Sensor Supply - Test".
Result: The throttle response is not as expected.
Repair: If the maximum no-load speed cannot be obtained, refer to Troubleshooting, "Switch Circuits - Test" and Troubleshooting, "Mode Selection - Test".
If the engine speed is erratic, refer to Troubleshooting, "Speed Control - Test".
Result: All responses are normal.
Proceed to Test Step 4.
4. Air Intake and Exhaust System
A. Observe the check engine lamp. Check for an air filter restriction indicator, if equipped. Replace a plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
Restrictions
Result: There are restrictions in the air inlet or exhaust system.
Repair: Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information.
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 5.
5. Valve Lash
Note: The valve lash can affect the performance of the engine.
A. Check the valve lash.
Valve lash
Result: The valve lash is not correct.
Repair: Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect" for the correct procedure.
Result: The valve lash is correct.
Proceed to Test Step 6.
6. Turbochargers
Note: The turbochargers that are installed on the engine are nonserviceable items. If any mechanical fault exists, then the faulty turbocharger must be replaced.
A. Ensure that the mounting bolts for the turbochargers are tight.
B. Check that the oil drains for the turbochargers are not blocked or restricted.
C. Check that the compressor housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged.
D. Check that the turbine housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged.
E. Check that the turbine blades rotate freely in the turbochargers.
F. Ensure that the wastegate on the high-pressure turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the high-pressure turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Turbochargers
Result: There is a fault on one of the turbochargers.
Repair: Repair the faulty turbocharger or replace the faulty turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Result: The turbochargers are OK.
Proceed to Test Step 7.
7. Fuel Supply
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
E. Check the primary filter/water separator for water in the fuel.
F. Check for fuel supply lines that are restricted.
G. Check that the low-pressure fuel lines are tight and secured properly.
H. Check that the Electric Fuel Lift Pump (EFLP) is operating. If the EFLP is suspect, refer to Troubleshooting, "Fuel Transfer Pump - Test".
I. Replace the in-line fuel filter that is upstream of the primary fuel filter.
J. Replace the primary and secondary fuel filters.
K. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
L. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
M. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Fuel system
Result: The fuel supply is not OK.
Repair: Repair the fuel system or replace the fuel system components, as necessary.
Result: The fuel supply is OK.
Proceed to Test Step 8.
Illustration 1 g03750256
Transfer Pump Inlet Regulator (TPIR) components
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port
Illustration 2 g02355128
Minimum TPIR flow rate in a 12 VDC system