Terminal and Connector Inspection
Check for Wiring Harness
1.

Check for damaged harness and terminals including rubber seals :

-. contact resistance, oxidation, corrosion, bent or broken terminals

-. harness connector connection, loose wires etc.

2.

Check for poor connection between ECM and component :

-. backed out terminal, improper mating, broken locks and poor terminal to wire connection

3.

ARE THE WIRES O.K ? & ARE THE CONNECTIONS O.K ?

YES

a.

Go to "Signal Circuit Inspection" procedure

NO

a.

Repair as necessary and go to " Verification of Vehicle Repair " procedure

Signal Circuit Inspection
Problem Verification
1.

DTCs listed below is stored in the scan tool

P1635/C018_C019

2.

Check items with the scan tool and the multimeter

① Wiring harness inspection

② Check the fuse

③ Check the relay resistance

3.

Specification

1)

Resitance : below 1 Ω for open in the wire

2)

Resitance : infinite for short to ground in the wire

3)

Voltage : below 0.5V for short to power in the wire

note

Refer to the component and full circuit for connector configrations details

C018 Water heater relay - Short Curcuit
4.

Disconnect the water heater relay No.1 and No.2 then turn the ignition switch ON, measure the voltage at the water relay No.1 terminal 2,5 and the water relay No.2 terminal 2,5 individually.

5.

ARE THERE THE BATTERY VOLTAGE ?

YES

a.

Go to step 4

NO

a.

Go to step 3

6.

ARE THE FUSES BLOWN ?

YES

a.

Repair short in the wire between the heater relay No.1 terminal 2 and ECM fuse No.1(20A)

b.

Repair short in the wire between the heater relay No.2 terminal 2 and ECM fuse No.1(20A)

c.

Repair short in the wire between the heater relay No.1 terminal 5 and heater fuse No.1(60A)

d.

Repair short in the wire between the heater relay No.2 terminal 5 and heater fuse No.2(30A)

e.

Repair short in the wire between the heater relay No.1 terminal 4 and the ECM terminal 23/C230-1

f.

Replace the fuse if the fuse is broken

g.

Replace the relay if the relay is defective after checking continuity between the relay terminal 2 and terminal 4 for the water heater relay No.1

h.

Replace the relay if the relay is defective after checking continuity between the relay terminal 2 and terminal 4 for the water heater relay No.2. For more detailed information, Go to "Component Inspection" procedure

i.

Go to step 4

NO

a.

Go to step 4

7.

Start the engine for checking the relay operation.

note

To be sure the water heater relay test, the coolant should be below 65℃(149℉) at least.

8.

ARE THERE THE WATER HEATER RELAYS ON ?

YES

a.

Go to "Verification of Vehicle Repair" procedure

NO

a.

Go to step 6

9.

Connect the CH A,B probe of scan tool to the ECM terminal 23/C230-1 and the water heater relay terminal 1 for the water heater relay No.1 or No. 2 individually in order to check the signal waveform.

10.

Check the signal waveform after starting the engine

11.

IS THERE THE SIGNAL WAVEFORM DISPLAYED ?

YES

a.

Go to "Verification of Vehicle Repair" procedure

NO

a.

Recheck short in the wire between the water heater relay No.1 terminal 4 and ECM terminal 23/C230-1.

b.

Recheck short in the wire between the water heater relay No.2 terminal 4 and the ECM terminal 23/C230-1

c.

Replace a known - good ECM and recheck. If the problem is verified, replace the ECM.

YES

a.

Go to "Verification of Vehicle Repair" procedure

C019 Water heater relay - Open or Short Curcuit
12.

Disconnect the water heater relay No.1 and No.2 then turn the ignition switch ON, measure the voltage at the water relay No.1 terminal 2,5 and the the water relay No.2 terminal 2,5 individually.

13.

ARE THERE THE BATTERY VOLTAGE ?

YES

a.

Go to step 4

NO

a.

Go to step 3

14.

ARE THE FUSES BLOWN ?

YES

a.

Repair open or short in the wire between the heater relay No.1 terminal 2 and ECM fuse No.1(20A)

b.

Repair open or short in the wire between the heater relay No.2 terminal 2 and ECM fuse No.1(20A)

c.

Repair open or short in the wire between the heater relay No.1 terminal 5 and heater fuse No.1(60A)

d.

Repair open or short in the wire between the heater relay No.2 terminal 5 and heater fuse No.2(30A)

e.

Repair open or short in the wire between the heater relay No.1 terminal 4 and the ECM terminal 23/C230-1

f.

Replace the fuse if the fuse is broken

g.

Replace the relay if the relay is defective after checking continuity between the relay terminal 2 and terminal 4 for the water heater relay No.1

h.

Replace the relay if the relay is defective after checking continuity between the relay terminal 2 and terminal 4 for the water heater relay No.2. For more detailed information, Go to "Component Inspection" procedure

i.

Go to step 4

NO

a.

Go to step 4

15.

Start the engine for checking the relay operation.

note

To be sure the water heater relay test, the coolant should be below 65℃ at least.

16.

ARE THERE THE WATER HEATER RELAYS ON ?

YES

a.

Go to "Verification of Vehicle Repair" procedure

NO

a.

Go to step 6

17.

Connect the CH A,B probe of scan tool to the ECM terminal 23/C230-1 and the water heater relay terminal 1 for the water heater relay No.1 or No. 2 individually in order to check the signal waveform.

18.

Check the signal waveform after starting the engine.

19.

IS THERE THE SIGNAL WAVEFORM DISPLAYED ?

YES

a.

Go to "Verification of Vehicle Repair" procedure

NO

a.

Recheck open or short in the wire between the water heater relay No.1 terminal 4 and ECM terminal 23/C230-1.

b.

Recheck open or short in the wire between the water heater relay No.2 terminal 4 and the ECM terminal 23/C230-1

c.

Replace a known - good ECM and recheck. If the problem is verified, replace the ECM.

YES

a.

Go to "Verification of Vehicle Repair" procedure

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