38100-87J11 Suzuki MOTOR ASSY, PTT

Illustration 1 g00919579
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check for LOGGED Diagnostic Codes.
Connect the Cat ET to the service tool connector J42/P42.
Turn the battery disconnect switch to the ON position.
Turn the keyswitch to the STOP position.
Observe the diagnostic codes on the Cat ET.Expected Result:A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 should not be logged.Results:
OK - A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 is not logged. Proceed to test step 3.
Not OK - A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 is logged. Proceed to test step 5.Test Step 3. Perform the Cylinder Cutout Test.
Engine power is reduced when a properly functioning cylinder is cut out. Make sure that you will not damage auxiliary or driven equipment if the engine power is suddenly reduced.
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Verify that the ECM connector J2/P2 and the injector connectors J4/P4 through J19/P19 are properly connected.
Install the Cat ET.
Turn the battery disconnect switch to the ON position.
Turn the keyswitch to the START position.
Start the engine.
Apply a load to the engine.
Perform the following steps on all suspect cylinders (solenoids).
Use the diagnostic tests on the Cat ET to initiate the Cylinder Cutout Test.
Check for a difference in the sound, feel, or power of the engine as each cylinder is cut out. The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or a bad cylinder.
Disable the override.Expected Result:The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or a bad cylinder.Results:
OK - There was a noticeable change in engine performance during the Cylinder Cutout Test.Repair: The injectors are firing in all cylinders. Reset the system and check for diagnostic codes. Stop.
Not OK - There was no noticeable change in engine performance during the Cylinder Cutout Test. Proceed to test step 4.Test Step 4. Check the Injector Lash and the Engine Valve Lash Setting.
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Check the injector and the engine valve lash setting. Refer to Testing and Adjusting, "Fuel Injector Adjustment".Expected Result:The engine valve lash setting is correct. The injectors are okay.Results:
OK - The injector is okay. Proceed to test step 5.
Not OK - The injector is not okay. A problem is found with the injector.Repair: Repair the injector. If the problem is still present, replace the injector. If the new injector has a 4 Digit code that is different from the old injector, change the code in the ECM. Stop.Test Step 5. Check the Resistance of the Harness from the Solenoid to the ECM Connector.
This engine uses high voltage to control the fuel injectors.Disconnect electronic fuel injector enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
Turn the keyswitch to the OFF position.
Turn the battery disconnect switch to the OFF position.
Disconnect ECM connector J2/P2 and injector connectors J4/P4 through J19/P19.
Measure the resistance at ECM connector P2 between the sockets for power output and the solenoid return for the individual solenoid. Refer to Illustration 1.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 6.
Not OK - The resistance is less than 20,000 Ohms.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 6. Check for Shorts in the Harness to Engine Ground.
This engine uses high voltage to control the fuel injectors.Disconnect electronic fuel injector enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
Measure the resistance at the ECM connector between the following points and engine ground: P2-4, P2-5, P2-6, P2-10, P2-11, P2-12, P2-16, P2-17, P2-18, P2-21, P2-22, P2-26, P2-27, P2-28, P2-30, P2-31, P2-32, P2-33, P2-34, P2-36, P2-37, P2-38, P2-39 and P2-40.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 7.
Not OK - The resistance is less than 20,000 Ohms.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 7. Check for Open Circuits in the Harness.
Use a suitable piece of wire to short socket 1 to socket 2 at each injector connector.
Measure the resistance at ECM connector P2 between the sockets for power output and the solenoid return for the individual solenoid. Refer to Illustration 1.Expected Result:The resistance should be less than 10 Ohms.Results:
OK - The resistance is less than 10 Ohms. Proceed to test step 8