32500-95721 Regulator Assembly, voltage Suzuki
20ELB, 20ELC, 20ELN, 25ELB, 25ELC, 25ELN, 25ELT, 25ELX, DT15 MLE, DT15ELD, DT15ELE, DT15ELF, DT15ESD, DT15ESE, DT15ESF, DT15MLD, DT15MLF, DT15MSD, DT15MSE, DT15MSF, DT16LT, DT16LT, DT16LT, DT16ST, DT16ST, DT16ST, DT20ESB, DT20ESC, DT20ESN, DT20MLB, D
Regulator
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Compatible models:
20ELB
20ELC
20ELN
25ELB
25ELC
25ELN
25ELT
25ELX
DT15 MLE
DT15ELD
DT15ELE
DT15ELF
DT15ESD
DT15ESE
DT15ESF
DT15MLD
DT15MLF
DT15MSD
DT15MSE
DT15MSF
DT16LT
DT16ST
DT20ESB
DT20ESC
DT20ESN
DT20MLB
DT20MLC
DT20MLN
DT20MSB
DT20MSC
DT20MSN
DT25ELZ
DT25ESB
DT25ESC
DT25ESN
DT25EST
DT25ESX
DT25ESZ
DT25MLB
DT25MLC
DT25MLN
DT25MLT
DT25MLX
DT25MLZ
DT25MSB
DT25MSC
DT25MSN
DT25MST
DT25MSX
DT25MSZ
DT28F
DT28G
DT28J
DT28Z
DT35ELT
DT35ELX
DT35ELZ
DT35EST
DT35ESX
DT35ESZ
DT35MLT
DT35MLX
DT35MLZ
DT35MST
DT35MSX
DT35MSZ
DT40
DT40ELT
DT40ELX
DT40ELZ
DT40EST
DT40ESX
DT40ESZ
DT40MLT
DT40MLX
DT40MLZ
DT40MSX
DT40MSZ
DT50
DT50ELB
DT50ELC
DT50ELN
DT50ESB
DT50ESC
DT50ESN
DT50M
DT50MLC
DT50MLN
DT50MSC
DT50MSN
DT50W
DT65
DT65ELC
DT65ELN
DT65ESC
DT65ESN
DT85TELN
DT9.9ELD
DT9.9ELE
DT9.9ELF
DT9.9ESD
DT9.9ESE
DT9.9ESF
DT9.9LT
DT9.9LX
DT9.9LZ
DT9.9MLD
DT9.9MLE
DT9.9MLF
DT9.9MSD
DT9.9MSE
DT9.9MSF
DT9.9ST
DT9.9SX
DT9.9SZ
Suzuki
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Information:
Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Active Codes and Logged Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
Codes
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
Result: There are no active codes.
Proceed to Test Step 2.
2. Electrical Connections
A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the fuel injector connectors.
Connectors
Result: There are suspect connectors.
Repair: Repair connectors that are suspect or replace connectors that are suspect.
Perform the "Wiggle Test" on the electronic service tool.
Result: There are no suspect connectors.
Proceed to Test Step 3.
3. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test".
Cylinder compression
Result: The results of the compression test are outside the specifications.
Repair: Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the following list:
Loose glow plugs
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Result: The results of the compression test are OK.
Proceed to Test Step 4.
4. Electronic Unit Injectors
A. Use the electronic service tool to perform the automatic "Cylinder Cutout Test". Refer to Troubleshooting, Service Tool Features for more information.
Note: If the compression test that was performed in Test Step 4 was satisfactory, the "Cylinder Cutout Test" will identify any faulty injectors.
Note: To make a judgment on the results from the "Cylinder Cutout Test", refer to Troubleshooting, Service Tool Features, 'Evaluating the "Automatic Cylinder Cutout Test" Fuel Measurements'.
Electronic Unit Injectors
Result: A faulty injector is indicated.
Repair: Remove any faulty electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove".
Install new electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Repeat the automatic "Cylinder Cutout Test". If the fault is still apparent, remove the replacement electronic unit injector and install the original electronic unit injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install".
Result: All injectors are OK.
Proceed to Test Step 5.
5. Fuel Quality
A. Refer to Operation and Maintenance Manual for information on the correct characteristics of the fuel for the engine. If necessary, obtain a fuel analysis to confirm that the correct fuel is being used for the engine. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test" for the correct procedure.
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 6.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated the fault.
6. Lubrication
A. Check for sufficient lubrication of the valve components.
B. Check for blocked oil passages. Oil passages must be clean. Clean any oil passages that are suspect. Refer to the Disassembly and Assembly for additional information.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an oil analysis.
Note: The analysis will contribute to a better understanding of oil contamination and the origin of the contamination.
Lubrication
Result: The oil passages are not blocked and the engine has sufficient lubrication.
Proceed to Test Step 7.
Result: The oil passages are blocked or the engine does not have sufficient lubrication.
Repair: Make the necessary repairs, Verify that the repair eliminated the fault.
7. Isolate the Source of the Noise
A. If the source of the noise is an engine accessory, remove and inspect the suspect item.
Engine accessory
Result An engine accessory is the source of the noise.
Repair: Repair and/or replace the engine accessory, if necessary.
Result An engine accessory is not the source of the noise.
Proceed to Test Step 8.
8. Valve Train Components
A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:
Camshaft
Valve springs
Camshaft followers
Rocker shaft
Valve bridges
Pushrods
Injectors
Refer to Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves.
Refer to Disassembly and Assembly for additional information.
Valve train
Result: The valve train components are not damaged.
Proceed to Test Step 9.
Result: The valve train components are damaged.
Repair: Make the necessary repairs, Verify that the repair eliminated the fault.
9. Pistons and Connecting Rods
A. Inspect the pistons for damage and wear.
B. Inspect the connecting rod bearings for damage and wear.
Pistons and connecting rods
Result: One or more components are worn or damaged.
Replace any worn or damaged parts.
Verify that the repair has eliminated the noise.
Result: All components are OK.
Proceed to Test Step 10.
10. Crankshaft
A. Inspect the crankshaft and the related components. Look for worn thrust plates and wear on the crankshaft.
B. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position.
Crankshaft
Result: The crankshaft or the related components are damaged or worn.
Repair: Repair or replace any damaged parts. Verify that the repair eliminated the fault.
Result: All components are OK.
Contact the Dealer Solutions Network (DSN).
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Active Codes and Logged Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
Codes
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
Result: There are no active codes.
Proceed to Test Step 2.
2. Electrical Connections
A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the fuel injector connectors.
Connectors
Result: There are suspect connectors.
Repair: Repair connectors that are suspect or replace connectors that are suspect.
Perform the "Wiggle Test" on the electronic service tool.
Result: There are no suspect connectors.
Proceed to Test Step 3.
3. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test".
Cylinder compression
Result: The results of the compression test are outside the specifications.
Repair: Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the following list:
Loose glow plugs
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Result: The results of the compression test are OK.
Proceed to Test Step 4.
4. Electronic Unit Injectors
A. Use the electronic service tool to perform the automatic "Cylinder Cutout Test". Refer to Troubleshooting, Service Tool Features for more information.
Note: If the compression test that was performed in Test Step 4 was satisfactory, the "Cylinder Cutout Test" will identify any faulty injectors.
Note: To make a judgment on the results from the "Cylinder Cutout Test", refer to Troubleshooting, Service Tool Features, 'Evaluating the "Automatic Cylinder Cutout Test" Fuel Measurements'.
Electronic Unit Injectors
Result: A faulty injector is indicated.
Repair: Remove any faulty electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove".
Install new electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Repeat the automatic "Cylinder Cutout Test". If the fault is still apparent, remove the replacement electronic unit injector and install the original electronic unit injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install".
Result: All injectors are OK.
Proceed to Test Step 5.
5. Fuel Quality
A. Refer to Operation and Maintenance Manual for information on the correct characteristics of the fuel for the engine. If necessary, obtain a fuel analysis to confirm that the correct fuel is being used for the engine. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test" for the correct procedure.
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 6.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated the fault.
6. Lubrication
A. Check for sufficient lubrication of the valve components.
B. Check for blocked oil passages. Oil passages must be clean. Clean any oil passages that are suspect. Refer to the Disassembly and Assembly for additional information.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an oil analysis.
Note: The analysis will contribute to a better understanding of oil contamination and the origin of the contamination.
Lubrication
Result: The oil passages are not blocked and the engine has sufficient lubrication.
Proceed to Test Step 7.
Result: The oil passages are blocked or the engine does not have sufficient lubrication.
Repair: Make the necessary repairs, Verify that the repair eliminated the fault.
7. Isolate the Source of the Noise
A. If the source of the noise is an engine accessory, remove and inspect the suspect item.
Engine accessory
Result An engine accessory is the source of the noise.
Repair: Repair and/or replace the engine accessory, if necessary.
Result An engine accessory is not the source of the noise.
Proceed to Test Step 8.
8. Valve Train Components
A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:
Camshaft
Valve springs
Camshaft followers
Rocker shaft
Valve bridges
Pushrods
Injectors
Refer to Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves.
Refer to Disassembly and Assembly for additional information.
Valve train
Result: The valve train components are not damaged.
Proceed to Test Step 9.
Result: The valve train components are damaged.
Repair: Make the necessary repairs, Verify that the repair eliminated the fault.
9. Pistons and Connecting Rods
A. Inspect the pistons for damage and wear.
B. Inspect the connecting rod bearings for damage and wear.
Pistons and connecting rods
Result: One or more components are worn or damaged.
Replace any worn or damaged parts.
Verify that the repair has eliminated the noise.
Result: All components are OK.
Proceed to Test Step 10.
10. Crankshaft
A. Inspect the crankshaft and the related components. Look for worn thrust plates and wear on the crankshaft.
B. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position.
Crankshaft
Result: The crankshaft or the related components are damaged or worn.
Repair: Repair or replace any damaged parts. Verify that the repair eliminated the fault.
Result: All components are OK.
Contact the Dealer Solutions Network (DSN).