GM Service Manual Online
For 1990-2009 cars only

Diagnostic Instructions

    • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
    • Review Strategy Based Diagnosis for an overview of the diagnostic approach.
    •  Diagnostic Procedure Instructions provides an overview of each diagnostic category.

Diagnostic Fault Information

Circuit

Short to Ground

Open/High Resistance

Short to Voltage

Signal Performance

A/C Relay Switch B+

1

1

--

--

A/C Relay Coil Ignition

1

1

--

--

A/C Relay Switched Output Control

1

1

2

--

A/C Compressor Clutch Relay Control

P0645

P0645

P0645

--

A/C Compressor Clutch Ground

--

1

--

--

1. A/C Compressor Inoperative

2. A/C Compressor Always On

Circuit System Description

When the A/C switch is pressed, the HVAC control module sends a serial data message to the ECM. This input will request the engine control module (ECM) to ground the A/C compressor clutch relay control circuit, which will switch the A/C CMPRSR CLUTCH relay on. With the relay contacts closed, battery voltage is supplied to the A/C compressor clutch assembly.

Diagnostic Aids

The following conditions must be met in order for the ECM to turn on the compressor clutch:

    • Battery voltage is between 9-18 volts
    • Engine coolant temperature (ECT) is less than 123°C (253°F)
    • Engine speed is greater than 600 RPM
    • Engine speed is less than 4,760 RPM
    • A/C high side pressure is between 2929-269 kPa (39-425 psi) Air Conditioning (A/C) System Performance Test
    • Throttle position is less than 100 percent
    • Evaporator temperature is greater than 0°C (32°F)
    • ECM does not detect excessive torque load
    • ECM does not detect insufficient idle quality
    •  The ambient temperature is above 1°C (34°F)

Reference Information

Schematic Reference

HVAC Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

    •  Air Temperature Description and Operation
    •  Air Delivery Description and Operation

Electrical Information Reference

    •  Circuit Testing
    •  Connector Repairs
    •  Testing for Intermittent Conditions and Poor Connections
    •  Wiring Repairs

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

Engine running place the mode switch in the defrost position. The A/C compressor clutch should engage.

If the clutch does not engage refer to Air Conditioning (A/C) System Performance Test

Circuit/System Testing

  1. Ignition OFF, disconnect the A/C relay.
  2. Ignition ON, verify that a test lamp does not illuminate between the control circuit terminal 86 and ground.
  3. If the test lamp illuminates, test the control circuit for a short to voltage.
  4. Verify that a test lamp illuminates between the ignition circuit terminal 85 and ground.
  5. If the test lamp does not illuminate, test the ignition circuit for a short to ground or a open/high resistance. If the circuit tests normal and ignition circuit fuse is open, test all components connected to the ignition circuit and replace as necessary.
  6. Verify that a test lamp illuminates between the relay B+ circuit terminal 30 and ground.
  7. If the test lamp does not illuminate, test the B+ circuit for a short to ground or a open/high resistance. If the circuit tests normal and B+ circuit fuse is open, replace the A/C Clutch Relay.
  8. Disconnect the harness connector at the A/C clutch coil.
  9. Test for less than 1 ohm between the ground circuit terminal ground.
  10. If greater than the specified range, test the ground circuit for an open/high resistance.
  11. Connect the harness connector at the A/C clutch coil.
  12. Connect a 10-amp fused jumper wire between the B+ circuit terminal 30 and control circuit terminal 87. Verify the A/C clutch is activated.
  13. If the A/C clutch does not activate, test the control circuit for an open/high resistance. If the circuit tests normal, test or replace the A/C clutch.
  14. Connect a test lamp between the ignition circuit terminal 85 and the control circuit terminal 86.
  15. Command the A/C Relay output function ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states.
  16. If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM.
    If the test lamp is always OFF, test the control circuit for a short to voltage, or an open/high resistance. If the circuit tests normal, replace the ECM.
  17. If all circuits test normal, test or replace the A/C clutch relay.

Component Testing

Relay Test

  1. Ignition OFF, disconnect the A/C relay.
  2. Test for 60-200 ohms between terminal 85 and 86.
  3. If the resistance is not within the specified range, replace the relay.
  4. Test for infinite resistance between the following terminals:
  5. • 30 and 86
    • 30 and 87
    • 30 and 85
    • 85 and 87
    If not the specified value, replace the relay.
  6. Install a 15A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohms between terminals 30 and 87.
  7. If greater than the specified range, replace the relay.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

    •  Air Conditioning Compressor Replacement
    •  Relay Replacement
    •  Compressor Clutch Assembly Replacement
    •  Control Module References for HVAC control module and ECM replacement, setup, and programming