01517-08258 Suzuki Bolt

During the following procedure, refer to the electrical schematic for the application.Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check that the fuses are not blown.
B. Inspect the terminals on the ECM power relay. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the ECM power relay.
D. Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).
E. Check the harness for abrasion and pinch points from the ECM power relay back to the ECM.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all of the seals are properly in place and ensure that the connectors are correctly coupled.
Replace any blown fuses.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points. The fuses are not blown.
Proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the keyswitch to the ON position.
Note: Do not start the engine.
C. Use the electronic service tool to check for active diagnostic codes.
Diagnostic codes
Result: Diagnostic code 2634-5 or 3467-5 is active or recently logged.
Proceed to Test Step 3.
Result: Diagnostic code 2634-6 or 3467-6 is active or recently logged.
Proceed to Test Step 6.
3. Check the Battery Supply Voltage at the Relay Connector
A. Turn the keyswitch to the OFF position.
B. Turn the keyswitch to the ON position. Do not start the engine.
C. Measure the voltage between the battery input terminal on the relay and a suitable ground.
At least 11 VDC for a 12 VDC system. At least 22 VDC for a 24 VDC system.
Result: The voltage is not within the expected range.
Repair: Repair or replace the battery supply wiring to the ECM power relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The voltage is within the expected range.
Proceed to Test Step 4.
4. Create a Short Circuit at the Relay Connector
A. Turn the keyswitch to the OFF position.
B. Remove the ECM power relay.
C. Fabricate a jumper wire. Install the jumper wire between terminal 1 and terminal 2 on the harness connector for the ECM power relay.
D. Turn the keyswitch to the ON position.
E. Use the electronic service tool to check for active diagnostic codes. Wait at least 30 seconds for activation of the diagnostic codes.
F. Turn the keyswitch to the OFF position and remove the jumper wire.
Diagnostic code
Result: A 2634-6 or 3467-6 diagnostic code is active with the jumper installed.
Repair: Install a replacement ECM power relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The 2634-5 or 3467-5 diagnostic code is still active.
Proceed to Test Step 5.
5. Check the Relay Control Wiring for an Open Circuit
A. Verify that the keyswitch is in the OFF position.
B. Disconnect the P1 connector from the ECM.
C. Inspect the P1 connector. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.
D. Measure the resistance between Terminal 1 on the harness connector for the ECM power relay and the "ECM Power Relay Control" terminal on the P1 connector.
E. Measure the resistance between Terminal 2 on the harness connector for the ECM power relay and ground.
Less than five Ohms
Result: At least one of the resistance measurements is greater than five Ohms - the fault is in the wiring for the ECM power relay control circuit.
Repair: Repair the faulty wiring or replace the faulty wiring.
Result: Both resistance measurements are less than five Ohms.
Contact the Dealer Solutions Network (DSN).
6. Create an Open Circuit at the Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the ECM power relay.
C. Use the electronic service tool to check for active diagnostic codes. Wait at least 30 seconds for activation of the diagnostic codes.
Diagnostic codes
Result: A 2634-5 or 3467-5 diagnostic code is active with the relay disconnected.
Repair: Install a replacement ECM power relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The 2634-6 or 3467-6 diagnostic code is still active with the relay disconnected.
Proceed to Test Step 7.
7. Check the Wiring Between the Relay and the ECM for a Short Circuit
A. Disconnect the P1 connector.
B. Inspect the P1 connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Measure the resistance between the "ECM Power Relay Control" terminal and all other terminals on the P1 connector.
Greater than one k Ohm
Result: At least one of the resistance measurements is less than one k Ohm. There is a short in the wiring between the relay and the ECM.
Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All resistance measurements are greater than one k Ohm.
Contact the Dealer Solutions Network (DSN).