1990 Suzuki SamuraiFACTORY OEM SERVICE PROCEDURE

Control Relay (Sidekick)

  1. Relay is located behind left side of dash. Terminals "A" through "F" are found on 6-wire connector. Terminals "G" through "J" are found on 4-wire connector. See appropriate WIRING DIAGRAMS article.
  2. With ignition on, check for battery voltage at terminals "B" and "F". If battery voltage is not present, check fuse No. 8 in fuse box. If fuse is okay, check for open in Black/White wire between fuse box and relay. If fuse is blown, repair short to ground in Black/White wire between fuse box and control relay. See appropriate WIRING DIAGRAMS article.
  3. While cranking engine, check for battery voltage at terminal "H". If battery voltage is present, go to next step. If battery voltage is not present, check for open or short in Black/Yellow wire between starter and relay.
    NOTE: Relay solenoid windings are present in the circuits between terminals "B" and "D", "I" and "F", and "J" and "H". When checking continuity between these terminals, ohmmeter reading will indicate some resistance in these circuits. Resistance values are not available from manufacturer.
  4. Turn ignition off. Disconnect relay connector. Remove relay. Check continuity between terminals "B" and "D". There is a diode present in this circuit, check continuity in both directions.
  5. If there is no continuity in either direction or if there is continuity in both directions, replace relay. If there is continuity in only one direction, go to next step. Check continuity between terminals "I" and "F", "J" and "H", and "E" and "C". If there is no continuity, replace control relay.
  6. Energize solenoid by applying battery voltage to terminal "B" and ground to terminal "D". Check for voltage at terminals "C" and "E". If battery voltage is present at both terminals, go to next step. If battery voltage is not present at both terminals, replace relay.
  7. Energize solenoid by applying battery voltage to terminal "F" and ground to terminal "I". Check for voltage at terminal "G". If battery voltage is present, go to next step. If battery voltage is not present, replace control relay.
  8. Energize solenoid by applying battery voltage to terminal "H" and ground to terminal "J". Check for battery voltage at terminal "G". If battery voltage is present, relay is okay. If battery voltage is not present, replace control relay.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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