Inspection Procedure 35
Charge Air Cooler Water Spray SystemCharge Air Cooler Water Spray Circuit Part 1:
Charge Air Cooler Water Spray Circuit Part 2:
Charge Air Cooler Water Spray Circuit Part 3:
CIRCUIT OPERATION
- A battery positive voltage is applied to the charge air cooler water spray switch (MANUAL) output terminal (terminal No. 3) from the ECM (terminal No. 91) via the resistor in the ECM.
- A battery positive voltage is applied to the charge air cooler water spray switch (AUTO) output terminal (terminal No. 5) from the ECM (terminal No. 44) via the resistor in the ECM.
- A battery positive voltage is applied on the charge air cooler water spray relay (terminal 1, 3) from ignition switch-IG2.
- While the manual switch of the charge air cooler water spray switch turned ON or the engine is operating with a high load with the auto switch of the charge air cooler water spray switch turned ON, the PCM turns ON the power transistor in the ECM to ground the charge air cooler water spray relay coil. Consequently, the charge air cooler water spray relay turns ON and the charge air cooler water spray relay (terminal No. 2) supplies the battery positive voltage to the charge air cooler water spray motor.
TROUBLESHOOTING HINTS (The most likely causes for this code to be set are:)
- Malfunction of charge air cooler water spray switch.
- Malfunction of charge air cooler water spray relay.
- Malfunction of charge air cooler water spray motor.
- Improper connector contact, open or short-circuited harness wire.
- Malfunction of the ECM.
DIAGNOSIS
STEP 1. Check the operation of the charge air cooler water spray motor.
1. Turn the ignition switch to the "ON" position.
2. Turn ON the manual switch of the charge air cooler water spray switch.
- An operation sound of the charge air cooler water spray motor should be heard.
3. Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is the charge air cooler water spray motor operating properly?
YES: Go to Step 4.
NO: Go to Step 2.
STEP 2. Check harness connector C-117 at ECM for damage.
Q: Is the harness connector in good condition?
YES: Go to Step 3.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 3. Check the operation of the charge air cooler water spray motor.
1. Disconnect ECM connector C-117.
2. Using the jumper wire, connect terminal No. 57 to ground.
3. Turn the ignition switch to the "ON" position.
- An operation sound of the charge air cooler water spray motor should be heard.
4. Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is the charge air cooler water spray motor operating properly?
YES: Go to Step 10.
NO: Go to Step 16.
STEP 4. Check connector D-39 at charge air cooler water spray switch for damage.
Q: Is the connector in good condition?
YES: Go to Step 5.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 5. Check harness connector C-119 at ECM for damage.
Q: Is the harness connector in good condition?
YES: Go to Step 6.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 6. Measure the power supply voltage at charge air cooler water spray switch harness side connector D-39.
1. Disconnect the connector D-39 and measure the harness side.
2. Turn the ignition switch to the "ON" position.
3. Measure the voltage between terminal No. 5 and ground.
- Voltage should be battery positive voltage.
4. Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is battery positive voltage (approximately 12 volts) present?
YES: Go to Step 7.
NO: Go to Step 9.
STEP 7. Charge air cooler water spray switch check.
Refer to Charge Air Cooler Water Spray.
Q: Is the charge air cooler water spray switch normal?
YES: Go to Step 8.
NO: Replace the charge air cooler water spray switch. Then confirm that the malfunction symptom is eliminated.
STEP 8. Check for harness damage between charge air cooler water spray switch connector D-39 (terminal No. 5) and ECM connector C-119 (terminal No. 44).
NOTE: Check the harness after checking intermediate connector C-124. If the intermediate connector is damaged, repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
Q: Is the harness wire in good condition?
YES: It can be assumed that this malfunction is intermittent. Refer to How to Use Troubleshooting / Inspection Service Points.
NO: Repair it. Then confirm that the malfunction symptom is eliminated.
STEP 9. Check for open circuit and short circuit to ground and harness damage between charge air cooler water spray switch connector D-39 (terminal No. 5) and ECM connector C-119 (terminal No. 44).
NOTE: Check the harness after checking intermediate connector C-124. If the intermediate connector is damaged, repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
Q: Is the harness wire in good condition?
YES: Replace the ECM.
NO: Repair it. Then confirm that the malfunction symptom is eliminated.
STEP 10. Check connector D-39 at charge air cooler water spray switch for damage.
Q: Is the connector in good condition?
YES: Go to Step 11.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 11. Check harness connector C-115 at ECM for damage.
Q: Is the harness connector in good condition?
YES: Go to Step 12.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 12. Measure the power supply voltage at charge air cooler water spray switch harness side connector D-39.
1. Disconnect the connector D-39 and measure the harness side.
2. Turn the ignition switch to the "ON" position.
3. Measure the voltage between terminal 3 and ground.
- Voltage should be battery positive voltage.
4. Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is battery positive voltage (approximately 12 volts) present?
YES: Go to Step 13.
NO: Go to Step 15.
STEP 13. Charge air cooler water spray switch check.
Refer to Charge Air Cooler Water Spray.
Q: Is the charge air cooler water spray switch normal?
YES: Go to Step 14.
NO: Replace the charge air cooler water spray switch. Then confirm that the malfunction symptom is eliminated.
STEP 14. Check for open circuit and harness damage between charge air cooler water spray switch connector D-39 (terminal No. 2) and ground.
Q: Is the harness wire in good condition?
YES: Check harness connector C-124 at the intermediate connector for damage, and repair or replace as required. Refer to Harness Connector Inspection.If intermediate connector C-124 is in good condition, repair the harness wire between charge air cooler water spray switch connector D-39 terminal No. 3 and ECM connector C-115 terminal No. 91 because of harness damage. Then confirm that the malfunction symptom is eliminated.
NO: Repair it. Then confirm that the malfunction symptom is eliminated.
STEP 15. Check for open circuit and short circuit to ground and harness damage between charge air cooler water spray switch connector D-39 (terminal No. 3) and ECM connector C-115 (terminal No. 91).
NOTE: Check the harness after checking intermediate connector C-124. If the intermediate connector is damaged, repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
Q: Is the harness wire in good condition?
YES: Replace the ECM.
NO: Repair it. Then confirm that the malfunction symptom is eliminated.
STEP 16. Check connector C-222 at the charge air cooler water spray relay for damage.
Q: Is the connector in good condition?
YES: Go to Step 17.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 17. Charge air cooler water spray relay check.
1. Remove the charge air cooler water spray relay.
2. Check for continuity between the charge air cooler water spray relay terminal No. 2 and No. 3.
- There should be continuity. (Approximately 70 Ohms)
3. Use jumper wires to connect charge air cooler water spray relay terminal No. 3) to the positive battery terminal and terminal No. 2 to the negative battery terminal.
4. Check for continuity between the charge air cooler water spray relay terminals No. 1 and No. 4 while connecting and disconnecting the jumper wire at the negative battery terminal.
- Should be less than 2 Ohms. (Negative battery terminal connected)
- Should be open loop. (Negative battery terminal disconnected)
5. Install the charge air cooler water spray relay.
Q: Are the resistance and the operation normal?
YES: Go to Step 18.
NO: Replace the charge air cooler water spray relay. Then confirm that the malfunction symptom is eliminated.
STEP 18. Measure the power supply voltage at charge air cooler water spray relay harness side connector C-222.
1. Disconnect the connector C-222 and measure the harness side.
2. Turn the ignition switch to the "ON" position.
3. Measure the voltage between terminal No. 3, No. 4 and ground.
- Voltage should be battery positive voltage.
4. Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is battery positive voltage (approximately 12 volts) present?
YES: Go to Step 19.
NO: Check harness connectors C-101, C-209, C-210 at the intermediate connector for damage, and repair or replace as required. Refer to Harness Connector Inspection. If intermediate connectors C-101, C-209, C-210 are in good condition, repair an open circuit between ignition switch connector C-208 terminal No. 4 and charge air cooler water spray relay connector C-222 terminal No. 3, No. 4. Then confirm that the malfunction symptom is eliminated.
STEP 19. Measure the power supply voltage at ECM harness side connector C-117.
1. Disconnect the connector C-117 and measure the harness side.
2. Turn the ignition switch to the "ON" position.
3. Measure the voltage between terminal 57 and ground.
- Voltage should be battery positive voltage.
4. Turn the ignition switch to the "LOCK"(OFF) position.
Q: Is battery positive voltage (approximately 12 volts) present?
YES: Go to Step 20.
NO: Check harness connectors C-124, C-209 at intermediate connector for damage, and repair or replace as required. Refer to Harness Connector Inspection. If intermediate connectors C-124, C-209 are in good condition, repair an open circuit between charge air cooler water spray relay connector C-222 terminal No. 2 and ECM connector C-117 terminal No. 57. Then confirm that the malfunction symptom is eliminated.
STEP 20. Check connector A-30 at charge air cooler water spray relay for damage.
Q: Is the connector in good condition?
YES: Go to Step 21.
NO: Repair or replace it. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
STEP 21. Charge air cooler water spray motor check.
1. Disconnect the charge air cooler water spray motor connector A-30.
2. Use jumper wires to connect fuel pump connector terminal No. 1 to the positive battery terminal and terminal No. 2 to the negative battery terminal.
- An operation sound of the charge air cooler water spray motor should be heard.
Q: Is the charge air cooler water spray motor operating properly?
YES: Go to Step 22.
NO: Replace the charge air cooler water spray motor. Then confirm that the malfunction symptom is eliminated.
STEP 22. Check for continuity at charge air cooler water spray motor harness side connector A-30.
1. Disconnect the connector A-30 and measure the harness side.
2. Check for the continuity between terminal No. 2 and ground.
- Should be less than 2 Ohms.
Q: Does continuity exist?
YES: Go to Step 23.
NO: Repair harness wire between charge air cooler water spray connector A-30 terminal No. 2 and ground because of open circuit or harness damage. Then confirm that the malfunction symptom is eliminated.
STEP 23. Check for open circuit and short circuit to ground and harness damage between charge air cooler water spray relay connector C-222 (terminal No. 1) and charge air cooler water spray motor connector A-30 (terminal No. 1).
NOTE: Check the harness after checking intermediate connectors C-129, C-209. If any of the intermediate connectors are damaged, repair or replace them. Refer to Harness Connector Inspection. Then confirm that the malfunction symptom is eliminated.
Q: Is the harness wire in good condition?
YES: Replace the ECM.
NO: Repair it. Then confirm that the malfunction symptom is eliminated.