Air Injection Pump Relay: Testing and Inspection

Diagnostic Procedures

Secondary Air Injection Pump Relay, Checking

Special tools, testers and auxiliary items required

• Multimeter.

• Wiring diagram.

• LED Test Lamp

Test requirements

• Secondary Air Injection (SAI) Pump Relay (-J299- ) fuse OK.

• Motronic Engine Control Module (ECM) Power Supply Relay (J271) fuse OK.

• Battery voltage at least 12.5 V.

• All electrical consumers switched off.

• A/C switched off.

• The ignition switched OFF.

Test procedure

- Perform a preliminary check to verify the customers complaint. Refer to => [ Preliminary Check ] Preliminary Check.

Start diagnosis

• The Secondary Air Injection system ONLY operates at initial start-up when the coolant temperature is near ambient temperature. The pump will operate for approximately 20 to 45 seconds and will NOT run again unless coolant temperature and ambient temperature are within 3 °C of each other.

- Remove the Secondary Air Injection (SAI) Pump Relay (-J299-).

Checking voltage

- Using a multimeter, check the Secondary Air Injection (SAI) Pump Relay (-J299-) socket 1 (relay 30) to Ground.

Specified value: Battery voltage.

If the specified value was Not obtained:

- Check the wiring connection from the Secondary Air Injection (SAI) Pump Relay (-J299-) socket 1 (relay 30) to the Battery Positive terminal for an open circuit or high resistance.

- Check the wiring connections for damage, corrosion, loose or broken terminals.

- If necessary, repair the faulty wiring connection.

If the specified value was obtained:

- Install a jumper between relay connector terminal 1 (relay 30) and 2 (relay 87).

- The Secondary Air Injection (SAI) Pump Motor ( -V101-) should turn ON.

If the motor did Not operate:

- Perform the Secondary Air Injection Pump Motor test.

If the motor did operate:

- Turn the Ignition switch ON.

- Connect an LED test lamp to battery ground.

- Connect the other end to relay connector terminal 4 (relay 85).

- Turn the Ignition switch OFF.

If the LED did Not turn ON:

- Locate the open, short or high resistance on the voltage supply circuit from the ECM relay, through fuse S130 to the Secondary Air Injection (SAI) Pump Relay (-J299-) terminal 4 (relay 85).

- Repair the circuit as necessary.

If the LED did turn ON:

• The Secondary Air Injection system ONLY operates at initial start-up when the coolant temperature is near ambient temperature. The pump will operate for approximately 20 to 45 seconds and will NOT run again unless coolant temperature and ambient temperature are within 3 °C of each other.

- Connect an LED test lamp to Battery Positive.

- Connect the other end to relay connector terminal 3 (relay 86).

- Start the engine.

If the LED was ON:

- Replace the Secondary Air Injection (SAI) Pump Relay (-J299-).

If the LED was Not ON:

Checking wiring

If the manufacturers test box is being used, perform the following step.

- Install the test box.

If the manufacturers test box is not being used, perform the following step.

- Remove the Motronic Engine Control Module (ECM) ( J220). Refer to the Repair Information.

- Using a multimeter, check the Secondary Air Injection (SAI) Pump Relay (-J299-) electrical harness connector terminal 3 (relay 86) to the Motronic Engine Control Module (ECM) ( J220) electrical harness connector T121 terminal 46 for an open circuit or high resistance.





Specified value: 1.5 ohms Max.

If the specified value was Not obtained:

- Check the wiring for an open, high resistance or short to voltage.

- Check the electrical harness connector for damage, corrosion, loose or broken terminals.

- If necessary, repair the faulty wiring or connection.

If no malfunction is detected in the wiring:

- Replace the Motronic Engine Control Module (ECM) (J220). Refer to the Repair Information.

Final procedures

After repair work, the following work steps must be performed in the following sequence:

1. Check the DTC memory. Refer to => [ Diagnostic Mode 03 - Read DTC Memory ] Diagnostic Modes 01 - 09.

2. If necessary, erase the DTC memory. Refer to => [ Diagnostic Mode 04 - Erase DTC Memory ] Diagnostic Modes 01 - 09.

3. If the DTC memory was erased, generate readiness code. Refer to => [ Readiness Code ] Monitors, Trips, Drive Cycles and Readiness Codes.