Campaign - AIR Relay Module

WORK INSTRUCTIONS

Group: 14

Date: April 1994

Number: 317

SUBJECT:
MODEL 202.028
REPLACEMENT OF SECONDARY AIR INJECTION (AIR) RELAY MODULE (K17)

In vehicles within the Effective Serial Number Range below, the secondary air injection (AIR) relay module must be replaced if the production date stamped on the relay modules prior to 21.10.93.





This procedure should be performed during the vehicles next scheduled maintenance or repair.





1. Remove previous version (prior to 21.10.93 production) secondary air injection relay module (K17, Figure 1) from fuse box.

2. Check amperage draw of secondary air injection pump and AIR pump circuit using a multimeter.

^ Multimeter with inductive pickup:

Using a 10 AWG (4 sq.mm) jumper wire, jump circuit 30 (pin 3) to circuit 87 (pin 1) at the relay module harness connector then clamp on inductive pickup around jumper wire.

^ Multimeter without inductive pickup:

Connect one lead of multimeter to circuit 30 (pin 3) and the other lead to circuit 87 (pin 1) at the relay module harness connector.

Test results:

Nominal value: 22 amps minimum (at 11-13 volts) after approx. 4 seconds.
Amperage draw < 22 amps, replace AIR pump (see procedure below).
Amperage draw = "0", check voltage Supply starting with fuse 17 in fuse box 2.

3. Install new version relay module (stamped w/ production date 21.10.93) and mark with white paint for identification purposes.

Replacement of pump (M33)

Procedure

1. Disconnect battery ground cable.

2. Remove (plastic) front engine cover.

3. Unplug secondary air injection pump electrical connector and unbolt air pump ground wire.

4. Loosen poly-V-belt and slide off generator pulley.

5. Remove generator bolt securing secondary air injection pump harness clamp.

6. Lift vehicle

7. Remove lower encapsulation panel.

8. Remove secondary air injection pump hose at pump.




9. Replace secondary air injection pump (M33, Figure 2) with modified version.

10. Mark the new version pump with a white paint dot for identification purposes.

11. Connect electrical connector to harness and reinstall bolt previously mentioned in step 3 (which bolted the ground wire to the front of the cylinder head).

Note:
The ground wire for the new version air pump is located inside the pumps electrical connector and is no longer separately bolted to front of the cylinder head.

12. Further installation is in reverse order of removal.

13. Erase engine codes using Hand-Held Tester (HHT).

14. Actuate secondary air injection pump with HHT and check readings according to HHT display





Parts Information:





Warranty Claim Submission Information

Operation: Check production date of secondary air injection relay module (Repair Code 10).

Check production date of secondary air injection relay module, perform test and replace relay module (Repair Code 11).

Check production date of secondary air injection relay module. perform test and replace relay module and secondary air injection pump (Repair Code 12).