09800-81811 Suzuki TOOL SET

Illustration 1 g01013616
Schematic
Illustration 2 g01013618
P1 ECM connector
Test Step 1. Inspect Electrical Connectors and Wiring
Place the engine control in the OFF/RESET mode and thoroughly inspect the J61/P61 customer connector, and J1/P1 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the circuit that is associated with the digital sensor supply. Refer to Illustration 1.
Check the J61/P61 customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the ECM connector J1/P1 for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check for Active Diagnostic Codes
Connect Cat ET to the service tool connector.
Place the engine control in the ON mode.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.Expected Result:One of the following diagnostic codes is active:
263-03
263-04 Results:
OK - A 263-03 diagnostic code is active. Proceed to Test Step 3.
OK - A 263-04 diagnostic code is active. Proceed to Test Step 4.Test Step 3. Check the Voltage on the +8 V Supply Wire
Place the engine control in the OFF/RESET mode.
Disconnect all of the following digital sensors at the sensor connector:
Decelerator position sensorJ405/P405
Fan speed sensor J508/P508
Place the engine control in the ON mode.
Measure the voltage between pin A and pin B at the sensor connectors. Expected Result:The voltage is 8.0 0.4 VDC.Results:
OK - The voltage is correct.Repair: Replace all wires to the original configuration. Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The voltage is incorrect. Proceed to Test Step 5.Test Step 4. Disconnect the +8 V Sensors while you Monitor the Active Diagnostic Codes
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Disconnect the following sensors one at a time:
Decelerator position sensorJ405/P405
Fan speed sensor J508/P508
Wait for 15 seconds after each sensor is disconnected. Check for an active diagnostic code on the electronic service tool. Expected Result:The 263-04 diagnostic code deactivates.Results:
OK - The 263-04 diagnostic code deactivates. The diagnostic code is not active after a specific sensor is disconnected.Repair: Reconnect the sensor that is suspected of causing the problem. If the problem returns after the reconnection of the sensor, disconnect the sensor. If the problem disappears after the disconnection of the sensor, replace the sensor. Replace all wires to the original configuration. Clear all diagnostic codes. Verify that the repair eliminates the problem.STOP
Not OK - The 263-04 diagnostic code stays active. Leave the sensors disconnected. Proceed to Test Step 5.Test Step 5. Check the +8 V Supply Wire for a Short to Engine Ground or a Short to another Wire in the Harness
Place the engine control in the OFF/RESET mode.
Disconnect the J1/P1 ECM connector.
Leave the digital sensors disconnected at the sensor connectors. Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Check for continuity between P1:4 (+8 VDC Supply) to every pin on ECM connector P1.
Check for continuity between P1:4 (+8 VDC Supply) and engine ground. Expected Result:There is no continuity between P1:4 (+8 V Supply) to any pin on ECM connector P1 or to engine ground.Results:
OK - There is no continuity between any of the wires. The check does not indicate a short in the engine harness or a short to engine ground. Proceed to Test Step 6.
Not OK - There was continuity between one or more pins in the harness or to engine ground. The +8 V supply wire is shorted in the engine harness or the +8 V supply wire is shorted to engine ground.Repair: Repair the wire or replace the wire. Clear all logged diagnostic codes. Replace all wires to the original configuration. Verify that the repair eliminates the problem.STOPTest Step 6. Check the +8 V Supply and the Sensor Common for an Open Circuit
Install a wire jumper between pin P1:4 (+8 V Supply) and pin P1:5 (Analog Sensor Return). Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Check for continuity at the connector for the decelerator position sensor between pin A and pin B.
Install the wire jumper between pin P1:4 (+8 V Supply) and pin P1:5 (Digital Sensor Return). Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Check for continuity at the connector for the fan speed sensor between pin A and pin B.
Remove the wire jumpers. Expected Result:There was continuity between A and pin B when the wire jumper was installed.Results:
OK - There was continuity between A and pin B when the wire jumper was installed. The continuity check does not indicate an open circuit in the engine harness. Proceed to Test Step 7.
Not OK - There was not continuity between A and pin B when the wire jumper was installed. The +8 V supply wire or the sensor common has excessive resistance or an open circuit.Repair: Repair the wires or replace the wires. Clear all logged diagnostic codes. Replace all wires to the original configuration. Verify that the repair eliminates the problem.STOPTest Step 7. Check the +8 V Supply at the ECM
Remove