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July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

DTC P0645: A/C Clutch Relay Circuit: Testing

  1. Turn ignition on. Using scan tool, actuate A/C clutch relay. Listen for clicking sound at A/C clutch relay. The A/C clutch relay is located in IPM. IPM is located on left side of engine compartment, next to battery. If clicking sound is heard at A/C clutch relay, go to next step. If clicking sound is not heard at A/C clutch relay, go to step  4.
  2. Ensure ignition is still on and A/C clutch relay is still actuated. Wiggle wiring harness and connectors between A/C clutch relay and PCM while A/C clutch relay is still actuated. PCM is located on left side of engine compartment, in front of battery. If clicking sound at A/C clutch relay was not interrupted while wiggling wiring harness and connectors, go to next step. If clicking sound at A/C clutch relay was interrupted while wiggling wiring harness and connectors, repair wiring or connectors as necessary.
  3. At this time, conditions for DTC to set do not exist or fault is an intermittent problem. Start engine and allow it to idle. Ensure engine is at normal operating temperature. Using scan tool, monitor parameters related to DTC while wiggling connectors and wiring harness. If value changes while wiggling connectors and wiring harness, repair connectors and wiring harness where wiggling caused value to change. If value does not change, review Freeze Frame data using scan tool. Attempt to duplicate condition that caused DTC to set. Check for any related technical service bulletins that may apply. Visually inspect related connectors and wiring harness. Repair connectors and wiring harness as necessary. See WIRING DIAGRAMS article. If no problems are indicated, test is complete.
  4. Turn ignition off. Remove A/C clutch relay from IPM. IPM is located on left side of engine compartment, next to battery. Turn ignition on. Using a test light connected to ground, probe terminal No. 86 at A/C clutch relay socket in IPM. If test light illuminates, go to next step. If test light does not illuminate, go to step  10.
  5. Turn ignition off. Disconnect test light. Using test light connected to positive battery voltage, probe terminal No. 85 at A/C clutch relay socket in IPM. Turn ignition on. Using scan tool, actuate A/C clutch relay. If test light does not flash on and off, stop A/C relay activation and go to next step. If test light flashes on and off, replace A/C clutch relay.
  6. Turn ignition off. Disconnect IPM C3 connector. Turn ignition on. Using a test light connected to positive battery voltage, probe terminal No. 9 (Light Blue/Orange wire) at IPM C3 harness connector. Using scan tool, actuate A/C clutch relay. If test light does not flash on and off, go to next step. If test light flashes on and off, replace IPM.
  7. Turn ignition off. Disconnect PCM connectors. PCM is located on left side of engine compartment, in front of battery. Measure resistance of Light Blue/Orange wire between terminals No. 64 at PCM C2 harness connector and No. 9 at IPM C3 harness connector. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Light Blue/Orange wire.
  8. Measure resistance between ground and terminal No. 9 (Light Blue/Orange wire) at IPM C3 harness connector. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in Light Blue/Orange wire between PCM and IPM. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Light Blue/Orange wire.
  9. At this time, PCM is assumed to be defective. Replace PCM. Program the new PCM. See PROGRAMMING .
  10. Turn ignition off. Disconnect IPM C3 connector. Turn ignition on. Using a test light connected to ground, probe terminal No. 19 (Pink/Gray wire) at IPM C3 harness connector. If test light illuminates, replace IPM. If test light does not illuminate, repair open in fused uniting switch output circuit to A/C clutch relay. See WIRING DIAGRAMS article.
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