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DTC P0645: A/C Clutch Relay CKT: Testing

  1. Turn ignition on. Using scan tool, actuate A/C clutch relay. Locate A/C clutch relay in Power Distribution Center (PDC). PDC is located in engine compartment, behind air cleaner. See Figure . If A/C clutch relay is clicking, go to next step. If A/C clutch relay is not clicking, go to step  4 .
  2. Turn ignition off. Visually inspect wiring related harness and connectors. If a problem is found, repair as necessary. If no problems are found, go to next step.
  3. Turn ignition on. Using scan tool, actuate A/C clutch relay. Wiggle wiring harness between A/C clutch relay and PCM. If A/C clutch relay does not stop clicking, go to next step. If A/C clutch relay stops clicking, repair wiring harness as necessary where wiggling caused A/C clutch relay to stop clicking.
  4. Turn ignition off. Remove A/C clutch relay from PDC. Inspect connectors for damage or poor connections. Repair connectors as necessary. If connectors are okay, turn ignition on. Measure voltage between ground and fused ignition switch output circuit (Light Green/Black wire) at A/C clutch relay harness connector terminal No. 4. See Figure . If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open or short in fused ignition switch output circuit.
  5. Measure resistance between A/C clutch relay terminals No. 2 and 4 (component side). If resistance is 50-90 ohms, go to next step. If resistance is not 50-90 ohms, replace A/C clutch relay.
  6. Ensure ignition is off. Disconnect PCM harness connectors. See Figure . Inspect connectors for damage or poor connections. Repair connectors as necessary. If connectors are okay, measure resistance of A/C clutch relay control circuit (Dark Blue/Orange wire) between A/C clutch relay harness connector terminal No. 2 and terminal No. 64 at PCM C2 harness connector. See Figure . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Blue/Orange wire.
  7. Measure resistance between ground and A/C clutch relay control circuit (Dark Blue/Orange wire) at A/C clutch relay harness connector terminal No. 2. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in Dark Blue/Orange wire between A/C clutch relay and PCM.
  8. If no other possible causes are remaining, replace PCM.
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