01580-05357 Suzuki BOLT

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The Electronic Control Module (ECM) contains no moving parts. Replacement of the ECM can be costly. Replacement can also be a time consuming task. Follow the troubleshooting procedures in this manual in order to be sure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem.Note: Ensure that the ECM is receiving power and that the ECM is properly wired to the negative battery circuit before a replacement of the ECM is attempted. Refer to Troubleshooting, "Electrical Power Supply Circuit - Test".A test ECM can be used to determine if the ECM is faulty. Refer to Troubleshooting, "Test ECM Mode" for more information. Install a test ECM in place of the suspect ECM. Flash program the correct flash file into the test ECM. Program the configuration parameters for normal operation. The configuration parameters must match the configuration parameters in the suspect ECM. Refer to the following test steps for details. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the ECM.Note: When a new ECM is not available, you may need to remove an ECM from an engine that is not in service. Ensure that the replacement ECM and the flash file from the replacement ECM matches the suspect ECM. Be sure to record the configuration parameters from the replacement ECM on a "Parameters Worksheet" for later use. Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on the Caterpillar Electronic Technician (ET).
If the flash file and engine application are not matched, engine damage may result.
Perform the following procedure in order to replace the ECM.
Print the parameters from the "Configuration" screen on Cat ET. If a printer is unavailable, record all of the parameters. Record any logged diagnostic codes and logged event codes for your records. Record the injectors' serial numbers from the "Calibrations" screen under the "Service" menu on Cat ET. Note: The injectors' serial numbers are necessary for obtaining the correct trim file. A trim file is specific for each unit injector. The ECM uses these files to compensate for manufacturing variations between individual injectors. If you replace any of the unit injectors, you must program the trim files for the new injectors. Also, if you replace the ECM, you must program all of the trim files. For instructions, refer to Troubleshooting, "Injector Code - Calibrate".
Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on Cat ET. Select "Load from ECM" in order to copy the configuration from the suspect ECM.Note: If the "Copy Configuration" process fails and the parameters were not obtained in Step 1, the parameters must be obtained elsewhere. Some parameters are stamped on the engine information plate, but most parameters must be obtained from the factory.
Remove the ECM.
Remove all battery power to the ECM.
Disconnect the ECM connectors J1/P1 and J2/P2.
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Remove the fuel lines from the ECM (if equipped).
Remove the mounting bolts from the ECM.
Disconnect the ECM ground strap from the engine.
Install the replacement ECM.
Use the old mounting hardware to install the replacement ECM. The mounting hardware must be free of damage.
Reconnect the fuel lines (if equipped).
Ensure that the ECM mounting hardware is installed correctly. The fuel lines must not put tension on the ECM. The rubber grommets are used to protect the ECM from excessive vibration. The ECM must be able to drift in the rubber grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines (if equipped) are not pulling the ECM against one side of the grommets.
Install the ECM ground strap on the engine.
Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Flash program the flash file into the ECM. Refer to Troubleshooting, "Flash Programming" for the correct procedure.
Use Cat ET to match the engine application and the flash file if the replacement ECM was used for a different application.
Configure the ECM.
If the "Copy Configuration" process from Step 2 was successful, return to the "Copy Configuration/ECM Replacement" screen on Cat ET and select "Program ECM". Proceed to Step 9.
If the "Copy Configuration" process was unsuccessful, program the ECM parameters. The parameters must match the parameters from Step 1.Note: If the "Copy Configuration" process fails and the parameters were not obtained in Step 1, the parameters must be obtained elsewhere. Some parameters are stamped on the engine information plate, but most parameters must be obtained from the factory.
If necessary, program the engine monitoring system.
Calibrate the fuel injectors. Refer to Troubleshooting, "Injector Code - Calibrate".
Calibrate the injection timing. Refer to Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".
Check for diagnostic codes and for event codes.