RM38T0EC _51 Engine / Hybrid System _144716 M20F-FXS, M20G-FXS COOLING _0602996 COOLING FAN SYSTEM J

M20F-FXS, M20G-FXS COOLING  COOLING FAN SYSTEM  Cooling Fan Circuit  


DESCRIPTION

The ECM turns on or off the fan relays using signals calculated from the engine coolant temperature, air conditioning switch (on/off), air conditioning refrigerant pressure, engine speed and vehicle speed signals.

The ECM switches the circuit of the cooling fan motors between series and parallel by turning on or off the fan relays in order to control the speed of the cooling fan motors in two steps.

WIRING DIAGRAM

A526956E05
0.49,7.781 1.49,8.208 1,0.427 10 false Auxiliary 3.281,7.667 5.135,7.917 1.854,0.25 10 false EFI-MAIN NO. 1 5.698,7.375 6.063,7.625 0.365,0.25 10 false 15 5.979,7.479 6.51,7.813 0.531,0.333 10 false MREL 6.229,8.146 6.76,8.479 0.531,0.333 10 false A47 6.198,8.302 6.729,8.635 0.531,0.333 10 false ECM 1.802,7.156 3.656,7.406 1.854,0.25 10 false EFI-MAIN NO. 1 0.656,7.167 2.51,7.417 1.854,0.25 10 false BATT MAIN 1.802,6.219 3.656,6.469 1.854,0.25 10 false EFI NO. 3 0.344,4.01 2.198,4.26 1.854,0.25 10 false DC/DC 2.542,2.667 4.396,2.917 1.854,0.25 10 false FAN NO. 1 4.344,4.792 4.917,4.979 0.573,0.188 10 false A188 4.333,4.958 5.083,5.458 0.75,0.5 10 false Cooling Fan Motor RH 3.979,4.667 5.833,4.917 1.854,0.25 10 false 2 3.969,5.146 5.823,5.396 1.854,0.25 10 false 1 5.979,4.385 6.51,4.719 0.531,0.333 10 false FANH 5.708,4.26 6.24,4.594 0.531,0.333 10 false 32 2.479,4.26 3.01,4.594 0.531,0.333 10 false 1 3.156,4.271 3.688,4.604 0.531,0.333 10 false 2 2.479,3.833 3.01,4.167 0.531,0.333 10 false 5 2.885,3.667 3.219,4 0.333,0.333 10 false 4 3.146,3.833 3.479,4.167 0.333,0.333 10 false 3 2.542,4.635 4.396,4.885 1.854,0.25 10 false FAN NO. 2 2.563,1 4.417,1.25 1.854,0.25 10 false FAN NO. 3 4.74,1.063 5.292,1.281 0.552,0.219 10 false A189 4.74,1.219 5.49,1.719 0.75,0.5 10 false Cooling Fan Motor LH 4.354,0.979 6.208,1.229 1.854,0.25 10 false 2 4.344,1.427 6.198,1.677 1.854,0.25 10 false 1 2.458,2.302 2.99,2.635 0.531,0.333 10 false 1 3.156,2.302 3.688,2.635 0.531,0.333 10 false 2 2.458,1.896 2.792,2.229 0.333,0.333 10 false 3 3.167,1.885 3.698,2.219 0.531,0.333 10 false 5 1.188,0.427 3.042,0.677 1.854,0.25 10 false FAN NO. 2 1.208,2.125 3.063,2.375 1.854,0.25 10 false FAN NO. 1 2.458,0.198 2.792,0.531 0.333,0.333 10 false 3 3.156,0.188 3.688,0.521 0.531,0.333 10 false 5 3.146,0.646 3.677,0.979 0.531,0.333 10 false 2 2.458,0.646 2.99,0.979 0.531,0.333 10 false 1 5.969,0.74 6.5,1.073 0.531,0.333 10 false FANL 5.708,0.625 6.24,0.958 0.531,0.333 10 false 33 0.49,7.927 1.49,8.354 1,0.427 10 false Battery 3.375,6.917 3.708,7.25 0.333,0.333 10 false 3 4.073,6.938 4.604,7.271 0.531,0.333 10 false 5 4.063,7.365 4.594,7.698 0.531,0.333 10 false 1 3.375,7.365 3.906,7.698 0.531,0.333 10 false 2

CAUTION / NOTICE / HINT

NOTICE:
·

Inspect the fuses for circuits related to this system before performing the following procedure.

·

Before replacing the ECM, refer to Service Bulletin.



PROCEDURE

1.PERFORM ACTIVE TEST USING GTS (CONTROL THE ENGINE COOLING FAN)
a.

Connect the GTS to the DLC3.


b.

Turn the ignition switch to ON (IG)


c.

Turn the GTS on.


d.

Enter the following menus: Powertrain / Engine / Active Test / Control the Engine Cooling Fan.

Powertrain > Engine > Active Test
Tester Display
Control the Engine Cooling Fan
50004 372 26

e.

Perform the Active Test according to the display on the GTS.

OK:
Active Tester Operation Fan Operation
HIGH Cooling fans high speed operate
LOW Cooling fans low speed operate
OFF Cooling fans stop



Result:
Proceed to
OK
NG



OK

NG

2.CHECK HARNESS AND CONNECTOR (FANL - FANH POWER SOURCE)
2.CHECK HARNESS AND CONNECTOR (FANL - FANH POWER SOURCE)
a.

Disconnect the A46 ECM connector.


b.

Turn the ignition switch to ON (IG)


c.
A526099C01
0.271,0.781 0.74,1.094 0.469,0.313 2.708,0.365 2.031,1.26 true 1.917,1.26 0.844,1.438 true 0.198,0.198 0.51,0.396 0.313,0.198 10 false *a 0.375,0.865 0.688,1.063 0.313,0.198 10 false A47 0.604,1.469 1.073,1.74 0.469,0.271 10 false FANH 2.656,0.167 3.125,0.438 0.469,0.271 10 false FANL
*a Front view of wire harness connector
(to ECM)


Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
A47-32 (FANH) - Body ground Ignition switch ON 11 to 14 V
A47-33 (FANL) - Body ground Ignition switch ON 11 to 14 V



Result:
Proceed to
OK
NG



OK

3.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY AND FAN NO. 3 RELAY POWER SOURCE CIRCUIT)

NG

12.INSPECT COOLING FAN RELAY (FAN NO. 1, FAN NO. 2 AND FAN NO. 3)
3.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY AND FAN NO. 3 RELAY POWER SOURCE CIRCUIT)
a.

Remove the FAN NO. 1 relay from the No. 2 relay block.


b.

Remove the FAN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

Measure the voltage according to the value(s) in the table below.

A526100C01
0.302,0.188 0.698,0.458 0.396,0.271 10 false *1 5.063,3.521 5.365,3.792 0.302,0.271 10 false *2 0.833,2.073 1.125,2.271 0.292,0.198 10 false *3
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 FAN NO. 1 Relay
*3 FAN NO. 3 Relay - -


Standard Voltage:
Tester Connection Condition Specified Condition
3 (FAN NO. 1 relay) - Body ground Always 11 to 14 V
3 (FAN NO. 3 relay) - Body ground Always 11 to 14 V



Result:
Proceed to
OK
NG



OK

4.INSPECT COOLING FAN RELAY (FAN NO. 1, FAN NO. 2 AND FAN NO. 3)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (FAN NO. 1 RELAY AND FAN NO. 3 RELAY POWER SOURCE CIRCUIT)

4.INSPECT COOLING FAN RELAY (FAN NO. 1, FAN NO. 2 AND FAN NO. 3)

Result:
Result Proceed to
OK A
NG (FAN NO. 1 relay) B
NG (FAN NO. 2 relay) C
NG (FAN NO. 3 relay) D



A

5.CHECK HARNESS AND CONNECTOR (FAN NO. 2 RELAY - BODY GROUND)

B

REPLACE FAN NO. 1 RELAY

C

REPLACE FAN NO. 2 RELAY

D

REPLACE FAN NO. 3 RELAY

5.CHECK HARNESS AND CONNECTOR (FAN NO. 2 RELAY - BODY GROUND)
a.
A435480C01
0.094,0.063 0.396,0.302 0.302,0.24 10 true *1 2.438,1.906 2.75,2.063 0.313,0.156 10 false *2
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly
*2 FAN NO. 2 Relay


Remove the FAN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
5 (FAN NO. 2 relay) - Body ground Always Below 1 Ω



Result:
Proceed to
OK
NG



OK

6.INSPECT FAN WITH MOTOR ASSEMBLY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (FAN NO. 2 RELAY - BODY GROUND)

6.INSPECT FAN WITH MOTOR ASSEMBLY
CAUTION:

To prevent injury due to contact with an operating cooling fan, keep your hands and clothing away from the cooling fans when inspecting the cooling fan system.


a.

Disconnect the cooling fan motor RH connector.


b.
A255569C23
1.427,0.406 1.927,0.656 0.5,0.25 1.906,1.406 2.531,1.406 true 0.844,1.406 1.469,1.406 true 0.115,0.073 0.427,0.229 0.313,0.156 10 false *a 2.594,1.302 3.052,1.5 0.458,0.198 10 false (-) 0.625,1.313 1.083,1.51 0.458,0.198 10 false (+) 1.521,0.448 2.135,0.646 0.615,0.198 10 false A188
*a Component without harness connected
(Cooling Fan Motor RH)


Check that the cooling fan motor RH operates smoothly when the auxiliary battery is connected to the cooling fan motor RH connector.


c.

Measure the current while the cooling fan motor RH is operating.

Standard Current:
Condition Specified Condition
Auxiliary battery voltage applied at 20°C (68°F) 6.8 to 12.7 A



Result:
Proceed to
OK
NG



OK

7.CHECK HARNESS AND CONNECTOR (COOLING FAN MOTOR RH - BODY GROUND)

NG

7.CHECK HARNESS AND CONNECTOR (COOLING FAN MOTOR RH - BODY GROUND)
a.

Disconnect the A188 cooling fan motor RH connector.


b.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A188-1 - Body ground Always Below 1 Ω



Result:
Proceed to
OK
NG



OK

8.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY AND FAN NO. 2 RELAY - COOLING FAN MOTOR RH)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (COOLING FAN MOTOR RH - BODY GROUND)

8.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY AND FAN NO. 2 RELAY - COOLING FAN MOTOR RH)
a.

Disconnect the A188 cooling fan motor RH connector.


b.

Remove the FAN NO. 1 relay from the No. 2 relay block.


c.

Remove the FAN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


d.

Measure the resistance according to the value(s) in the table below.

A526102C01
0.708,0.271 1.031,0.458 0.323,0.188 10 false *1 1.333,3.531 1.646,3.688 0.313,0.156 10 false *2 5.229,3.531 5.542,3.688 0.313,0.156 10 false *3
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 FAN NO. 1 Relay
*3 FAN NO. 2 Relay - -


Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A188-2 - 5 (FAN NO. 1 relay) Always Below 1 Ω
A188-2 - 4 (FAN NO. 2 relay) Always Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A188-2 or 5 (FAN NO. 1 relay) - Body ground Always 10 kΩ or higher
A188-2 or 4 (FAN NO. 2 relay) - Body ground Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

9.INSPECT FAN WITH MOTOR ASSEMBLY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (FAN NO. 1 RELAY AND FAN NO. 2 RELAY - COOLING FAN MOTOR RH)

9.INSPECT FAN WITH MOTOR ASSEMBLY
CAUTION:

To prevent injury due to contact with an operating cooling fan, keep your hands and clothing away from the cooling fans when inspecting the cooling fan system.


a.

Disconnect the cooling fan motor LH connector.


b.
A255569C24
1.448,0.469 1.948,0.719 0.5,0.25 1.906,1.406 2.531,1.406 true 0.844,1.406 1.469,1.406 true 0.115,0.073 0.427,0.229 0.313,0.156 10 false *a 2.594,1.302 3.052,1.5 0.458,0.198 10 false (-) 0.625,1.313 1.083,1.51 0.458,0.198 10 false (+) 1.542,0.5 2.156,0.698 0.615,0.198 10 false A189
*a Component without harness connected
(Cooling Fan Motor LH)


Check that the cooling fan motor LH operates smoothly when the auxiliary battery is connected to the cooling fan motor LH connector.


c.

Measure the current while the cooling fan motor LH is operating.

Standard Current:
Condition Specified Condition
Auxiliary battery voltage applied at 20°C (68°F) 6.8 to 12.7 A



Result:
Proceed to
OK
NG



OK

10.CHECK HARNESS AND CONNECTOR (FAN NO. 2 RELAY AND FAN NO. 3 RELAY - COOLING FAN MOTOR LH)

NG

10.CHECK HARNESS AND CONNECTOR (FAN NO. 2 RELAY AND FAN NO. 3 RELAY - COOLING FAN MOTOR LH)
a.

Disconnect the A189 cooling fan motor LH connector.


b.

Remove the FAN NO. 2 relay and FAN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

Measure the resistance according to the value(s) in the table below.

A526100C02
0.302,0.188 0.698,0.458 0.396,0.271 10 false *1 5.063,3.521 5.365,3.792 0.302,0.271 10 false *2 0.833,2.073 1.125,2.271 0.292,0.198 10 false *3
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 FAN NO. 1 Relay
*3 FAN NO. 3 Relay - -


Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A189-1 - 3 (FAN NO. 2 relay) Always Below 1 Ω
A189-2 - 5 (FAN NO. 3 relay) Always Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A189-1 or 3 (FAN NO. 2 relay) - Body ground Always 10 kΩ or higher
A189-2 or 5 (FAN NO. 3 relay) - Body ground Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

11.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY - FAN NO. 2 RELAY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (FAN NO. 2 RELAY AND FAN NO. 3 RELAY - COOLING FAN MOTOR LH)

11.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY - FAN NO. 2 RELAY)
a.

Remove the FAN NO. 1 relay from the No. 2 relay block.


b.

Remove the FAN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

Measure the resistance according to the value(s) in the table below.

A526102C02
0.708,0.271 1.031,0.458 0.323,0.188 10 false *1 1.333,3.531 1.646,3.688 0.313,0.156 10 false *2 5.229,3.531 5.542,3.688 0.313,0.156 10 false *3
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 FAN NO. 1 Relay
*3 FAN NO. 2 Relay - -


Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
1 (FAN NO. 1 relay) - 1 (FAN NO. 2 relay) Always Below 1 Ω
2 (FAN NO. 1 relay) - 1 (FAN NO. 2 relay) Always Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
1 (FAN NO. 1 relay) or 1 (FAN NO. 2 relay) - Body ground Always 10 kΩ or higher
2 (FAN NO. 1 relay) or 2 (FAN NO. 2 relay) - Body ground Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

NG

REPAIR OR REPLACE NO. 2 RELAY BLOCK

12.INSPECT COOLING FAN RELAY (FAN NO. 1, FAN NO. 2 AND FAN NO. 3)

Result:
Result Proceed to
OK A
NG (FAN NO. 1 relay) B
NG (FAN NO. 2 relay) C
NG (FAN NO. 3 relay) D



A

13.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY, FAN NO. 2 RELAY AND FAN NO. 3 RELAY POWER SOURCE CIRCUIT)

B

REPLACE FAN NO. 1 RELAY

C

REPLACE FAN NO. 2 RELAY

D

REPLACE FAN NO. 3 RELAY

13.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY, FAN NO. 2 RELAY AND FAN NO. 3 RELAY POWER SOURCE CIRCUIT)
a.

Remove the FAN NO. 1 relay from the No. 2 relay block.


b.

Remove the FAN NO. 2 relay and FAN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

Measure the voltage according to the value(s) in the table below.

A526105C01
0.542,0.198 0.854,0.354 0.313,0.156 10 false *1 1.385,3.531 1.698,3.688 0.313,0.156 10 false *2 5.042,3.531 5.354,3.688 0.313,0.156 10 false *3 0.854,2.063 1.167,2.219 0.313,0.156 10 false *4
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 FAN NO. 1 Relay
*3 FAN NO. 2 Relay *4 FAN NO. 3 Relay


Standard Voltage:
Tester Connection Condition Specified Condition
1 (FAN NO. 1 relay) - Body ground Always 11 to 14 V
1 (FAN NO. 2 relay) - Body ground Always 11 to 14 V
1 (FAN NO. 3 relay) - Body ground Always 11 to 14 V



Result:
Proceed to
OK
NG



OK

REPAIR OR REPLACE HARNESS OR CONNECTOR (FAN NO. 1 RELAY, FAN NO. 2 RELAY AND FAN NO. 3 RELAY - ECM)

NG

14.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY, FAN NO. 2 RELAY AND FAN NO. 3 RELAY - NO. 1 INTEGRATION RELAY)
14.CHECK HARNESS AND CONNECTOR (FAN NO. 1 RELAY, FAN NO. 2 RELAY AND FAN NO. 3 RELAY - NO. 1 INTEGRATION RELAY)
a.

Remove the FAN NO. 1 relay from the No. 2 relay block.


b.

Remove the FAN NO. 2 relay and FAN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

Remove the No. 1 integration relay from the No. 1 engine room relay block and No. 1 junction block assembly.


d.

Disconnect the 2B No. 1 integration relay connector.


e.

Measure the resistance according to the value(s) in the table below.

A526105C02
0.802,0.219 1.115,0.375 0.313,0.156 10 false *1 1.375,3.531 1.688,3.688 0.313,0.156 10 false *2 5.063,3.521 5.375,3.677 0.313,0.156 10 false *3 0.833,2.073 1.146,2.229 0.313,0.156 10 false *4
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 FAN NO. 1 Relay
*3 FAN NO. 2 Relay *4 FAN NO. 3 Relay


Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
1 (FAN NO. 1 relay) - 5 (EFI-MAIN NO. 1 relay) Always Below 1 Ω
1 (FAN NO. 2 relay) - 5 (EFI-MAIN NO. 1 relay) Always Below 1 Ω
1 (FAN NO. 3 relay) - 5 (EFI-MAIN NO. 1 relay) Always Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
1 (FAN NO. 1 relay) or 5 (EFI-MAIN NO. 1 relay) - Body ground Always 10 kΩ or higher
1 (FAN NO. 2 relay) or 5 (EFI-MAIN NO. 1 relay) - Body ground Always 10 kΩ or higher
1 (FAN NO. 3 relay) or 5 (EFI-MAIN NO. 1 relay) - Body ground Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

15.CHECK EFI-MAIN NO. 1 RELAY (NO. 1 INTEGRATION RELAY POWER SOURCE CIRCUIT)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (FAN NO. 1 RELAY, FAN NO. 2 RELAY AND FAN NO. 3 RELAY - EFI-MAIN NO. 1 RELAY)

15.CHECK EFI-MAIN NO. 1 RELAY (NO. 1 INTEGRATION RELAY POWER SOURCE CIRCUIT)
a.

Remove the EFI-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

Disconnect the EFI-MAIN NO. 1 relay connector.


c.

Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
3 (EFI-MAIN NO. 1 relay) - Body ground Always 11 to 14 V


A526106C01
0.219,0.135 0.531,0.333 0.313,0.198 10 false *1 1.146,0.313 1.458,0.51 0.313,0.198 10 false *2
*1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly *2 EFI-MAIN NO. 1 Relay



Result:
Proceed to
OK
NG



OK

16.CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 1 - EFI-MAIN NO. 1 RELAY)

NG

REPAIR OR REPLACE EFI-MAIN NO. 1 RELAY

16.CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 1 - EFI-MAIN NO. 1 RELAY)
a.

Remove the EFI-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

Disconnect the EFI-MAIN NO. 1 relay connector.


c.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
EFI-MAIN NO. 1-2 (EFI-MAIN NO. 1 relay) Always Below 1 Ω



Result:
Proceed to
OK
NG



OK

17.CHECK HARNESS AND CONNECTOR (ECM - EFI-MAIN NO. 1 RELAY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (EFI-MAIN NO. 1 RELAY - BODY GROUND)

17.CHECK HARNESS AND CONNECTOR (ECM - EFI-MAIN NO. 1 RELAY)
a.

Disconnect the A47 ECM connector.


b.

Disconnect the EFI-MAIN NO. 1 relay connector.


c.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A47-15 (MREL) - 1(EFI-MAIN NO. 1 relay) Always Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A47-15 (MREL) or 1(EFI-MAIN NO. 1 relay) - Body ground Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - EFI MAIN NO. 1 RELAY)