32000-95J00 Suzuki PLUG ASSY, LIGHTING

Illustration 1 g01394951
Schematic for the ignition keyswitch and battery supply circuit
Illustration 2 g01193796
Typical rear view of the pin locations for the ignition keyswitch and battery supply circuit
(1) Battery ground (GND)
(2) Battery ground (GND)
(3) Battery ground (GND)
(7) Battery+
(8) Battery+
(9) Battery ground (GND)
(10) Battery ground (GND)
(15) Battery+
(16) Battery+
(40) Ignition key switch Test Step 1. Inspect Electrical Connectors and Wiring
Thoroughly inspect connector P1, the battery connections and the connections to the keyswitch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the following connections:
P1: 7, 8, 15, 16 (Unswitched Battery+)
P1: 1, 2, 3, 9, 10 (Battery-)
P1:40 (keyswitch)
Use the electronic service tool to perform a "Wiggle Test". Special attention must be paid to the following connections:
P1: 7, 8, 15, 16
P1: 1, 2, 3, 9, 10
P1:40
Check the ECM connector for the correct torque of 5.0 N m (44 lb in).
Check the harness for abrasion and for pinch points from the battery to the ECM, and from the keyswitch to the ECM. Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a fault with the connectors and/or the harness.Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are completely coupled.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 2. Check for Active Diagnostic Codes or Logged Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes or logged diagnostic codes. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.Expected Result:One of the following diagnostic codes is active or logged:
168-0 Electrical System Voltage high
168-1 Electrical System Voltage low
168-2 Electrical System Voltage erratic, intermittent, or incorrectResults:
OK - Diagnostic code 168-2 is active or logged. Proceed to Test Step 3.
Not OK - No diagnostic code is active.Repair: The fault is no longer present. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 3. Check the Battery Voltage at the ECM Connector
Disconnect P1 from the ECM connector.
Turn the keyswitch to the ON position.
Measure the voltage between P1:7 (Unswitched Battery+) and P1:1 (Battery-).
Measure the voltage between P1:8 (Unswitched Battery+) and P1:2 (Battery-).
Measure the voltage between P1:15 (Unswitched Battery+) and P1:9 (Battery-).
Measure the voltage between P1:16 (keyswitch) and P1:10 (Battery-).
Measure the voltage between P1:40 (keyswitch) and P1:3 (Battery-).
Turn the keyswitch to the OFF position. Expected Result:The measured voltage is a constant 22.0 to 27.0 Volts DC with no suspected intermittent faults at this time.Results:
OK - The ECM is receiving the correct voltage. Repair: If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The ECM is not receiving the correct voltage. - Repair: Check for continuity in the harness for the keyswitch from P1:40 through the keyswitch circuit to the batteries. Check the circuit protection for the circuit. Refer to the service manual for the instructions on troubleshooting the circuit for the keyswitch.For intermittent problems such as intermittent shutdowns that could be caused by the application wiring, temporarily bypassing the application wiring may be an effective means of determining the root cause.Proceed to Test Step 5.
Not OK - No Voltage on P1: 7, 8, 15, 16 - No voltage was present on P1: 7, 8, 15, 16.Repair: Check for continuity in the harness for the unswitched Battery+ from the ECM to the batteries. Check the circuit protection for the circuit. Check for continuity in the harness for the Battery- from the ECM to the batteries.For intermittent problems such as intermittent shutdowns that could be caused by the application wiring, temporarily bypassing the application wiring may be an effective means of determining the root cause.Proceed to Test Step 5.
Not OK - Battery voltage is out of range - Proceed to Test Step 4.Test Step 4. Check the Batteries
Measure no-load battery voltage at the battery terminals.
Load test the batteries. Use a suitable battery load tester. Expected Result:The batteries pass the load test. The measured voltage is at least 22.0 Volts DC.Results:
OK - The batteries pass the load test. The measured voltage is at least 22.0 Volts DC.Repair: Refer to the service manual for the application for instructions on troubleshooting the application harness. Troubleshoot the application harness and repair the application harness, as required.Verify that the repairs eliminate the fault.STOP
Not OK - The batteries do not pass the load test. The measured voltage is less than 22.0 Volts DC.Repair: Recharge or replace the faulty batteries.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 5. Bypass the Application Harness
Batteries give off flammable fumes which can explode.To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.