Precautions for Electrical Circuit Service: Notes

When replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to electrical parts and a fire.

Fig 1: Precautions For Electrical Circuit Service
Courtesy of SUZUKI OF AMERICA CORP.
Before disconnecting or connecting connectors, be sure to do either of the following depending on the type of power supply. Otherwise, the electrical parts to which the power is supplied may be damaged.
- Continuous power supply: Disconnect the negative cable from the battery.
- Ignition power supply: Push engine switch to change the ignition mode to "OFF".
When disconnecting connectors, never pull on the wiring harness. Unlock the connector lock first and then pull the male and female connectors apart by holding them.

Fig 2: Identifying Improper Connector Disengagement
Courtesy of SUZUKI OF AMERICA CORP.
When connecting male and female connectors, also hold connectors and put them together until they lock securely (a click is heard).

Fig 3: Identifying Proper Male And Female Connector Engagement
Courtesy of SUZUKI OF AMERICA CORP.
When installing a wiring harness, secure it with clamps so that no slack is left.

Fig 4: Precautions For Installing Wiring Harness
Courtesy of SUZUKI OF AMERICA CORP.
When installing vehicle parts, make sure so that they do not interfere with any wiring harness and they do not catch any wiring harness under them.

Fig 5: Identifying Improper Wiring Harness Routing
Courtesy of SUZUKI OF AMERICA CORP.
Protect the part of harness which may touch any edge by wrapping it with tape or the like.

Fig 6: Identifying Proper Harness Wrapping
Courtesy of SUZUKI OF AMERICA CORP.
Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P/S control module, etc.). The static electricity from your body can damage these parts.

Fig 7: Precaution For Not Touching Electrical Terminals Of Parts
Courtesy of SUZUKI OF AMERICA CORP.
Never connect any tester (voltmeter, ohmmeter or whatever) to terminals of an electronic control unit when its connector is disconnected. Doing so may cause damage to the electronic control unit.
Never connect an ohmmeter to an electronic control unit with its connector connected to it. Doing so may cause damage to electronic control unit and sensors.
Be sure to use only the specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained or personal injury may result. Where no voltmeter type is specified, use a voltmeter with high impedance (M Ω/V minimum) or a digital type voltmeter.
When taking measurements at electrical connectors using a tester probe, be sure to insert the probe (2) from the wire harness side (backside) of the connector (1).

Fig 8: Precautions For Inserting Probe From Wire Harness Side (Backside) Of Connector
Courtesy of SUZUKI OF AMERICA CORP.
When it is impossible to insert a tester probe from the harness side of connector, insert a properly sized male terminal with a lead into the connector and connect the tester probe to the lead as shown. Do not insert the probe directly into the connector, or the female terminal may be deformed.

Fig 9: Inserting Tester Probe From Harness Side Of Connector
Courtesy of SUZUKI OF AMERICA CORP.
When checking connection of terminals, check male terminals for bend, female terminals for excessive opening, and both for locking (looseness), corrosion, dust, etc.
Before measuring voltage at each terminal, make sure that battery voltage is 11 V or higher. Terminal voltage check at low battery voltage will lead to erroneous results.

Fig 10: Measuring Battery Voltage
Courtesy of SUZUKI OF AMERICA CORP.