DTC P0480 or P0481. Saturn ION 2006

For 1990-2009 cars only

Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Restraints 🢒 SIR 🢒 DTC P0480 or P0481

DTC P0480 or P0481 2.2L L61

Circuit Description

Battery positive voltage is supplied to the cooling fan relay through the 30 A cooling fan fuse located in the underhood fuse block. The engine control module (ECM) controls the cooling fan relay by grounding the cooling fan relay control circuit through an internal solid state device called a driver. The primary function of the driver is to supply the ground for the component being controlled. Each driver has a fault line which is monitored by the ECM. When the ECM is commanding a component ON, the voltage potential of the control circuit should be low, near 0 volts. When the ECM is commanding the control circuit to a component OFF, the voltage potential of the circuit should be high, near battery voltage. If the fault detection circuit senses a voltage other than what is expected, the DTC will set.

The ECM will monitor the control circuit for the following conditions:

•	A short to ground

•	A short to voltage

•	An open circuit

•	An open relay coil

•	An internally shorted or excessively low resistance relay coil.

When the ECM detects any of the above conditions, the DTC will set and the affected driver will be disabled.

DTC Descriptors

This diagnostic procedure supports the following DTCs:

•	P0480 Low Speed Cooling Fan Relay Control Circuit

•	P0481 High Speed Cooling Fan Relay Control Circuit

•	P0691 Cooling Fan Relay Control Circuit

Conditions for Running the DTC

•	The ignition is ON.

•	The battery voltage is more than 9 volts.

Conditions for Setting the DTC

•	The ECM detects an open, a short to ground, or a short to voltage on the cooling fan relay control circuit.

•	The condition must be present for a minimum of 6 seconds.

Action Taken When the DTC Sets

•	The ECM will illuminate the malfunction indicator lamp (MIL) during the second consecutive trip in which the diagnostic test has been run and failed.

•	The ECM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.

Conditions for Clearing the MIL/DTC

•	The ECM will turn OFF the MIL during the third consecutive trip in which the diagnostic has been run and passed.

•	The History DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.

•	The DTC can be cleared by using the scan tool.

Diagnostic Aids

•	If the condition is not present, refer to Testing for Intermittent Conditions and Poor Connections.

•	Review the Freeze Frame/Failure Records vehicle mileage since the diagnostic test last failed. This may help determine how often the condition that caused the DTC to be set occurs.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Listen for an audible click when the cooling fan relay operates. Command both the ON and OFF states. Repeat the commands as necessary.

This step tests for voltage at the coil side of the cooling fan relay. The cool fan fuse supplies power to the cooling fan relay.

This step verifies that the ECM is providing ground to the cooling fan relay.

This step tests if ground is constantly being applied to the cooling fan relay.

Step	Action	Yes	No
Schematic Reference: Engine Cooling Schematics Connector End View Reference: Cooling System Connector End Views
1	Did you perform the Diagnostic System Check - Vehicle?	Go to Step 2	Go to Diagnostic System Check - Vehicle
2	Ignition ON, A/C OFF, if equipped. Engine temperature below 93°C (200°F). Observe that the fan is OFF. Disconnect the engine coolant tempearture (ECT) sensor connector. Observe that the fan activates. Was the fan OFF and then ON?	Go to Diagnostic Aids	Go to Step 3
3	Turn OFF the ignition. Disconnect the cooling fan relay. Turn ON the ignition, with the engine OFF. Probe the battery positive voltage circuit of the cooling fan relay with a test lamp that is connected to a good ground. Does the test lamp illuminate?	Go to Step 4	Go to Step 8
4	Connect a test lamp between the control circuit of the cooling fan relay and the battery positive voltage circuit of the cooling fan relay. Ignition OFF. Connect the ECT sensor. Clear the DTCs with a scan tool. Ignition ON, A/C OFF, if equipped. Engine temperature below 93°C (200°F). Observe that the lamp is OFF. Disconnect the ECT sensor connector. Observe that the lamp illuminates. Was the lamp OFF and then ON?	Go to Step 10	Go to Step 5
5	Does the test lamp remain illuminated with each command?	Go to Step 7	Go to Step 6
6	Test the control circuit of the cooling fan relay for a short to voltage or an open. Refer to Circuit Testing and Wiring Repairs. Did you find and correct the condition?	Go to Step 14	Go to Step 9
7	Test the control circuit of the cooling fan relay for a short to ground. Refer to Circuit Testing and Wiring Repairs. Did you find and correct the condition?	Go to Step 14	Go to Step 9
8	Test the battery positive voltage circuit of the cooling fan relay for a short to ground or an open. Refer to Circuit Testing and Wiring Repairs. Did you complete the repair?	Go to Step 14	Go to Step 11
9	Inspect for poor connections at the harness connector of the engine control module (ECM). Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs. Did you find and correct the condition?	Go to Step 14	Go to Step 13
10	Inspect for poor connections at the cooling fan relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs. Did you find and correct the condition?	Go to Step 14	Go to Step 12
11	Repair the cooling fan motor supply voltage circuit for a short to ground. Refer to Wiring Repairs. Did you complete the repair?	Go to Step 14	--
12	Replace the cooling fan relay. Did you complete the replacement?	Go to Step 14	--
13	Replace the engine control module (ECM). Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement?	Go to Step 13	--
14	Use the scan tool in order to clear the DTCs. Operate the vehicle within the Conditions for Running the DTC as specified in the supporting text. Does the DTC reset?	Go to Step 2	System OK

DTC P0480 or P0481 2.0 LSJ

Circuit Description

The powertrain control module (PCM) controls the low speed cooling fan operation by grounding the cool fan 1 relay control circuit with an internal solid state device called a driver. For high speed cooling fan operation, the PCM grounds the cool fan 2 and S/P relay control circuit at the same time the cool fan 1 control circuit is grounded. Battery positive voltage is supplied to the cool fan 1, cool fan 2 and S/P fan relays. When the PCM is commanding a fan relay ON, the voltage of the control circuit should be low, near 0 volts. When the PCM is commanding a fan relay OFF, the voltage potential of the control circuit should be high, near battery voltage. If the fault detection circuit senses a voltage other than what is expected, the DTC will set.

If the PCM detects an improper voltage level on the cool fan 1 or cool fan 2 speed driver circuits, then code P0480, P0481 or P0691 will set and the effected driver will be disabled.

DTC Descriptors

This diagnostic procedure supports the following DTCs:

•	P0480 Low Speed Relay 1 Cooling Fan Relay Control Circuit

•	P0481 High Speed Relay 2 Cooling Fan Relay Control Circuit

Conditions for Running the DTC

•	The ignition is ON.

•	System voltage is between 9-18 volts.

•	The relay control circuit is transitioned from OFF to ON or ON to OFF.

Conditions for Setting the DTC

•	The PCM detects an open, a short to ground, or a short to voltage on the cooling fan relay control circuit.

•	The above conditions are present for at least 30 seconds.

Action Taken When the DTC Sets

•	The PCM will illuminate the malfunction indicator lamp (MIL) during the second consecutive trip in which the diagnostic test has been run and failed.

•	The PCM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.

Conditions for Clearing the MIL/DTC

•	The PCM will turn OFF the MIL during the third consecutive trip in which the diagnostic has been run and passed.

•	The History DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.

•	The DTC can be cleared by using the scan tool.

Diagnostic Aids

•	If the condition is not present, refer to Testing for Intermittent Conditions and Poor Connections .

•	Review the Freeze Frame/Failure Records vehicle mileage since the diagnostic test last failed. This may help determine how often the condition that caused the DTC to be set occurs.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Listen for an audible click when the cool fan relay 1 operates. Command both the ON and OFF states. Repeat the commands as necessary.

Listen for an audible click when the S/P and cool fan 2 relays operate. Command both the ON and OFF states. Repeat the commands as necessary.

Step	Action	Yes	No
Schematic Reference: Engine Cooling Schematics Connector End View Reference: Cooling System Connector End Views
1	Did you perform the Diagnostic System Check - Vehicle?	Go to Step 2	Go to Diagnostic System Check - Vehicle
2	Install a scan tool. Start the engine. With a scan tool, monitor the engine coolant temperature (ECT) in the Inputs/Outputs scan tool data. Bring the vehicle up to normal operating temperature. At 106°C (223°F), the S/P and cool fan 2 relay should click ON and the low speed engine cooling fans should engage. Does the low speed cooling fans engage?	Go to Step 3	Go to Step 4
3	Important:: A 3 second delay occurs before the powertrain control module (PCM) changes the cooling fan speed. With a scan tool, monitor the ECT in the Inputs/Outputs scan tool data. At 110°C (230°F) the S/P and the cool fan 2 relays engage the high speed engine cooling fans. Are the S/P and the cool fan 2 relays turned ON?	Go to Diagnostic Aids	Go to Step 6
4	Turn the ignition OFF. Disconnect the cool fan 1 relay. Turn ON the ignition, with the engine OFF. Probe the battery voltage circuit of the cool fan 1 relay with a test lamp that is connected to a good ground. Does the test lamp illuminate?	Go to Step 5	Go to Step 16
5	Connect a test lamp between the control circuit of the cool fan 1 relay and the battery voltage circuit of the cool fan 1 relay. Ground the low speed cooling fan relay control circuit to the powertrain control module (PCM). Does the test lamp illuminate?	Go to Step 12	Go to Step 9
6	Turn the ignition OFF. Disconnect the cool fan 2 relay. Turn ON the ignition, with the engine OFF. Probe the battery voltage circuit of the cool fan 2 relay with a test lamp that is connected to a good ground. Does the test lamp illuminate?	Go to Step 7	Go to Step 16
7	Connect a test lamp between the control circuit of the cool fan 2 relay and the battery voltage circuit of the cool fan 2 relay. Ground the high speed cooling fan relay control circuit of the PCM. Is the test lamp illuminated?	Go to Step 14	Go to Step 8
8	Turn the ignition OFF. Disconnect the S/P fan relay. Turn ON the ignition, with the engine OFF. Connect a test lamp between the control circuit of the S/P fan relay and the battery voltage circuit of the S/P fan relay. Ground the high speed cooling fan relay control circuit to the PCM. Does the test lamp illuminate?	Go to Step 13	Go to Step 9
9	Intermittently ground then remove the ground on the high speed cooling fan relay control circuit to the PCM. Does the test lamp remain illuminated upon grounding the control circuit?	Go to Step 11	Go to Step 10
10	Test the control circuit of the appropriate relay for a short to voltage or an open. Refer to Testing for Intermittent Conditions and Poor Connections and Wiring Repairs . Did you find and correct the condition?	Go to Step 21	Go to Step 15
11	Test the control circuit of the appropriate relay for a short to ground. Refer to Testing for Intermittent Conditions and Poor Connections and Wiring Repairs . Did you find and correct the condition?	Go to Step 21	Go to Step 15
12	Inspect for poor connections at the cool fan 1 relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	Go to Step 21	Go to Step 17
13	Inspect for poor connections at the S/P fan relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	Go to Step 21	Go to Step 18
14	Inspect for poor connections at the cool fan 2 relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	Go to Step 21	Go to Step 19
15	Inspect for poor connections at the harness connector of the PCM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	Go to Step 21	Go to Step 20
16	Repair the battery voltage circuit for an open or high resistance. Refer to Wiring Repairs . Did you complete the repair?	Go to Step 21	--
17	Replace the cool fan 1 relay. Did you complete the repair?	Go to Step 21	--
18	Replace the S/P fan relay. Did you complete the repair?	Go to Step 21	--
19	Replace the cool fan 2 relay. Did you complete the repair?	Go to Step 21	--
20	Replace the PCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement?	Go to Step 21	--
21	Use the scan tool in order to clear the DTCs . Operate the vehicle within the Conditions for Running the DTC as specified in the supporting text. Does the DTC reset?	Go to Step 2	System OK

DTC P0480 or P0481 2.4L LE5

Circuit Description

The cooling fan has 2 windings in the motor, one winding is for low speed and the other winding is for high speed. The engine control module (ECM) controls the low speed fan operation by grounding the cool fan 1 relay control circuit. When the cooling fan 1 relay is energized, voltage is delivered to the cooling fan low speed winding. The ECM controls the high speed fan operation by grounding the cool fan 2 relay control circuit. When the cooling fan 2 relay is energized, voltage is delivered to the cooling fan high speed winding. The ECM controls the cooling fan relays by grounding the cooling fan relay control circuit through an internal solid state device called a driver. Each driver has a fault line which is monitored by the ECM. When the ECM is commanding a component ON, the voltage potential of the control circuit should be low, near 0 volts. When the ECM is commanding the control circuit to a component OFF, the voltage potential of the circuit should be high, near battery voltage. If the fault detection circuit senses a voltage other than what is expected, the DTC will set.

The ECM will monitor the control circuit for the following conditions:

•	A short to ground

•	A short to voltage

•	An open circuit

•	An open relay coil

•	An internally shorted or excessively low resistance relay coil.

When the ECM detects any of the above conditions, the DTC will set and the affected driver will be disabled.

DTC Descriptors

This diagnostic procedure supports the following DTCs:

•	P0480 Low Speed or Relay 1 Cooling Fan Relay Control Circuit

•	P0481 High Speed or Relay 2 Cooling Fan Relay Control Circuit

Conditions for Running the DTC

•	The ignition is ON.

•	The battery voltage is more than 9 volts.

Conditions for Setting the DTC

•	The ECM detects an open, a short to ground, or a short to voltage on the cooling fan relay control circuit.

•	The condition must be present for a minimum of 6 seconds.

Action Taken When the DTC Sets

•	The ECM will illuminate the malfunction indicator lamp (MIL) during the second consecutive trip in which the diagnostic test has been run and failed.

•	The ECM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.

Conditions for Clearing the MIL/DTC

•	The ECM will turn OFF the MIL during the third consecutive trip in which the diagnostic has been run and passed.

•	The History DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.

•	The DTC can be cleared by using the scan tool.

Diagnostic Aids

•	If the condition is not present, refer to Testing for Intermittent Conditions and Poor Connections .

•	Review the Freeze Frame/Failure Records vehicle mileage since the diagnostic test last failed. This may help determine how often the condition that caused the DTC to be set occurs.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Listen for an audible click when the cooling fan 1 relay operates. Command both the ON and OFF states. Repeat the commands as necessary.

Listen for an audible click when the cooling fan 2 relay operates. Command both the ON and OFF states. Repeat the commands as necessary.

This step tests for voltage at the coil side of the cooling fan relay. The cool fan 1 fuse supplies power to the cooling fan relay.

This step tests for voltage at the coil side of the cooling fan relay. The cool fan 2 fuse supplies power to the cooling fan relay.

This step verifies that the ECM is providing ground to the cooling fan 1 relay.

This step verifies that the ECM is providing ground to the cooling fan 2 relay.

This step tests if ground is constantly being applied to the cooling fan relay.

Step	Action	Yes	No
Schematic Reference: Engine Cooling Schematics Connector End View Reference: Cooling System Connector End Views
1	Did you perform the Diagnostic System Check - Vehicle?	Go to Step 2	Go to Diagnostic System Check - Vehicle
2	Install a scan tool. Turn ON the ignition, with the engine OFF. With a scan tool, command the Fan Relay ON and OFF. Does the cooling fan 1 relay turn ON and OFF with each command?	Go to Step 3	Go to Step 4
3	Install a scan tool. Turn ON the ignition, with the engine OFF. With a scan tool, command the Fan 2 Relay ON and OFF. Does the cooling fan 2 relay turn ON and OFF with each command?	Go to Diagnostic Aids	Go to Step 5
4	Turn OFF the ignition. Disconnect the cooling fan 1 relay. Turn ON the ignition, with the engine OFF. Probe the battery positive voltage circuit of the cooling fan 1 relay with a test lamp that is connected to a good ground. Does the test lamp illuminate?	Go to Step 5	Go to Step 8
5	Turn OFF the ignition. Disconnect the cooling fan 2 relay. Turn ON the ignition, with the engine OFF. Probe the battery positive voltage circuit of the cooling fan 1 relay with a test lamp that is connected to a good ground. Does the test lamp illuminate?	Go to Step 6	Go to Step 11
6	Connect a test lamp between the control circuit of the cooling fan 1 relay and the battery positive voltage circuit of the cooling fan 1 relay. With a scan tool, command the Fan Relay ON and OFF . Does the test lamp turn ON and OFF with each command?	Go to Step 13	Go to 7
7	Connect a test lamp between the control circuit of the cooling fan 2 relay and the battery positive voltage circuit of the cooling fan 2 relay. With a scan tool, command the Fan Relay 2 ON and OFF . Does the test lamp turn ON and OFF with each command?	Go to Step 13	Go to 8
8	Does the test lamp remain illuminated with each command?	Go to Step 10	Go to Step 9
9	Test the control circuit of the appropriate cooling fan relay for a short to voltage or an open. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition?	Go to Step 17	Go to Step 12
10	Test the control circuit of the appropriate cooling fan relay for a short to ground. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition?	Go to Step 17	Go to Step 12
11	Test the battery positive voltage circuit of the appropriate cooling fan relay for a short to ground or an open. Refer to Circuit Testing and Wiring Repairs . Did you complete the repair?	Go to Step 17	Go to Step 14
12	Inspect for poor connections at the harness connector of the engine control module (ECM). Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	Go to Step 17	Go to Step 16
13	Inspect for poor connections at the appropriate cooling fan relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	Go to Step 17	Go to Step 15
14	Repair the cooling fan motor supply voltage circuit for a short to ground. Refer to Wiring Repairs . Did you complete the repair?	Go to Step 17	--
15	Replace the appropriate cooling fan relay. Did you complete the replacement?	Go to Step 17	--
16	Replace the engine control module (ECM). Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement?	Go to Step 17	--
17	Use the scan tool in order to clear the DTCs . Operate the vehicle within the Conditions for Running the DTC as specified in the supporting text. Does the DTC reset?	Go to Step 2	System OK