57311-92D03 Suzuki PINION GEAR

Illustration 1 g01120020
ECM
(1) J2/P2 connectors
(2) J1/P1 connectors
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Remove the electrical power from the ECM.
B. Thoroughly inspect connectors (1) and (2). Inspect the battery connections. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
C. Check the allen head screw on each ECM connector for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
D. Check the harnesses and the wiring for abrasion and for pinch points.
Electrical Connectors and Wiring
Result: The harnesses and the connectors appear to be OK.
Proceed to Test Step 2.
Result: The wiring and/or a connector are not OK.
Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors arecompletely coupled.
STOP
2. Check For Diagnostic Codes
A. Connect the Cat™ Electronic Technician (ET) to the service tool connector. Refer to electronic troubleshooting Troubleshooting, "Electronic Service Tools".
B. Restore the electrical power to the ECM.
C. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes may become active. Look for these codes:
• 253-02
• 268-02
D. Verify that the engine's configuration parameters are not scrambled.
Diagnostic Codes
Repair: A 253-02 diagnostic code is active.
Proceed to Test Step 3.
Result: A 268-02 diagnostic code is active.
Proceed to Test Step 4.
Result: The configuration parameters are scrambled.
Proceed to Test Step 5.
3. Check the Part Number of the Flash File
A. Verify that the flash file agrees with the original engine arrangement.
Flash File
Result: The correct flash file is installed in the ECM.
Repair: The engine will not start until the 253-02 diagnostic code is cleared. Clearing this code requires factory passwords.
Acquire factory passwords. Clear the 253-02 diagnostic code. Return the engine to service.
STOP
Result: The correct flash file is not installed in the ECM.
Repair: Program the correct flash file into the ECM. Refer to programming parameters Troubleshooting, "Flash Programming". Verify that the problem is resolved.
STOP
4. Determine the Parameters that Require Programming
A. Verify that the configuration parameters are correct for the engine's application. Refer to Troubleshooting, "System Configuration Parameters".
B. Verify that the injector trim files are correct for the engine's application. Refer to programming parameters Troubleshooting, "Injector Trim File".
Parameters
Result: The configuration parameters and the injector trim files are correct.
Repair: Clear the diagnostic code and return the engine to service.
STOP
Result: The configuration parameters and/or the injector trim files are not correct.
Repair: The 268-02 diagnostic code cannot be cleared until all of the parameters and/or all of the injector trim files are programmed with the correct values. The engine may use a default torque map or the ECM may limit the engine to low idle until this diagnostic code is cleared.
Try to program the configuration parameters and/or try to program the injector trim files. Refer to system configuration parameters Troubleshooting and/or refer to programming parameters Troubleshooting, "Injector Trim File".
If the programming is successful, clear the code and return the engine to service.
If the parameters cannot be programmed, replace the ECM. Refer to electronic troubleshooting Troubleshooting, "Replacing the ECM". Clear the diagnostic code and return the engine to service.
STOP
5. Review the Parameters and Data
A. Review the system configuration parameters and the engine lifetime totals.
Parameters and Data
Result: The parameters and totals are correct.
Return the engine to service.
STOP
Result: The parameters and/or the totals are incorrect.
Repair: Try to program the suspect parameter or parameters. Refer to system configuration parametersTroubleshooting.
If the programming is successful, clear the code and return the engine to service.
If the parameters cannot be programmed, replace the ECM. Refer to electronic troubleshooting Troubleshooting, "Replacing the ECM". Clear the diagnostic code and return the engine to service.
STOP
Test Step 1. Results:
The procedure corrected the issue. - STOP
The procedure did not correct the issue. - Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).STOP