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Circuit/System Testing

Secondary Air Injection Check Valve Malfunction

  1. Vehicle OFF, disconnect the KR26 secondary air injection solenoid valve relay. Vehicle in Service Mode.
  2. Verify a test lamp illuminates between the B+ circuit terminal 30 and ground.
    • If the test lamp does not illuminate and the circuit fuse is good 
    1. Vehicle OFF.
    2. Test for less than 2 Ω in the B+ circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, verify the fuse is not open and there is voltage at the fuse.
    • If the test lamp does not illuminate and the circuit fuse is open 
    1. Vehicle OFF
    2. Test for infinite resistance between the B+ circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Disconnect the harness connector at the Q29 secondary air injection solenoid valve.
    4. Test for infinite resistance between the control circuit terminal 5 and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    5. Test or replace the Q29 secondary air injection solenoid valve.
    • If the test lamp illuminates 
  3. Disconnect the harness connector at the Q29 secondary air injection solenoid valve.
  4. Vehicle OFF and all vehicle systems OFF, it may take up to 2 minutes for all vehicle systems to power down. Test for less than 10 Ω between the Q29 secondary air injection solenoid valve ground circuit terminal 4 and ground.
    • If 10 Ω or greater 
    1. Vehicle OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  5. Connect the harness connector at the Q29 secondary air injection solenoid valve.
  6. Connect a 20 A fused jumper wire between the KR26 secondary air injection solenoid valve relay B+ circuit terminal 30 and the control circuit terminal 87.
  7. Verify the Q29 secondary air injection solenoid valve is activated.
    • If the Q29 secondary air injection solenoid valve does not activate 
    1. Vehicle OFF, disconnect the harness connector at the Q29 secondary air injection solenoid valve.
    2. Test for less than 2 Ω in the control circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, test or replace the Q29 secondary air injection solenoid valve.
    • If the Q29 secondary air injection solenoid valve activates 
  8. Test or replace the KR26 secondary air injection solenoid valve relay.

Secondary Air Injection Pump Malfunction

  1. Vehicle OFF, disconnect the KR25 secondary air injection pump relay.
  2. Verify a test lamp illuminates between the B+ circuit terminal 87 and ground.
    • If the test lamp does not illuminate and the circuit fuse is good 
    1. Vehicle OFF
    2. Test for less than 2 Ω in the B+ circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, verify the fuse is not open and there is voltage at the fuse.
    • If the test lamp does not illuminate and the circuit fuse is open 
    1. Vehicle OFF
    2. Test for infinite resistance between the B+ circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Disconnect the harness connector at the G21 secondary air injection pump.
    4. Test for infinite resistance between the control circuit terminal 1 and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    5. Test or replace the G21 secondary air injection pump
    • If the test lamp illuminates 
  3. Disconnect the harness connector at the G21 secondary air injection pump.
  4. Vehicle OFF and all vehicle systems OFF, it may take up to 2 minutes for all vehicle systems to power down. Test for less than 10 Ω between the G21 secondary air injection pump ground circuit terminal 2 and ground.
    • If 10 Ω or greater 
    1. Vehicle OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  5. Connect the harness connector at the G21 secondary air injection pump.
  6. Connect a 40 A fused jumper wire between the B+ circuit terminal 87 and the control circuit terminal 30.
    7. NOTE:

    To prevent the secondary air injection pump from overheating, do not operate the pump consecutively for greater than 2 minutes. The pump is provided with a thermal protector that will automatically reset when allowed to cool.

  7. Verify the G21 secondary air injection pump is activated.
    • If the G21 secondary air injection pump does not activate 
    1. Vehicle OFF, disconnect the harness connector at the G21 secondary air injection pump.
    2. Test for less than 2 Ω in the control circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω,
    3. Test or replace the G21 secondary air injection pump.
    • If the G21 secondary air injection pump activates 
  8. Test or replace the KR25 secondary air injection pump relay.

Secondary Air Injection System Pressure Not In Range

  1. Verify the following conditions do not exist:
    • Hoses/pipes restricted or blocked
    • Hoses/pipes leaking or disconnected
    • Damaged secondary air injection check valve
    • Restricted or blocked cylinder head secondary air injection inlet ports and passages
    • If a condition is located 

      Repair or replace the affected component as necessary.

    • If all components test normal 
  2. Remove the Q29 secondary air injection solenoid valve.
  3. Connect the harness connector at the Q29 secondary air injection solenoid valve.
  4. Connect the secondary air injection pipe to the Q29 secondary air injection solenoid valve.
  5. Vehicle in Service Mode, command the Secondary Air Injection System to Active with a scan tool. Verify there is airflow through the Q29 secondary air injection solenoid valve.
    • If NO airflow 

      Replace the Q29 secondary air injection solenoid valve.

    • If airflow 
  6. Command the Secondary Air Injection Pump Relay ON with a scan tool. Verify there is NO airflow through the Q29 secondary air injection solenoid valve.
    • If airflow 

      Replace the Q29 secondary air injection solenoid valve.

    • If no airflow 
  7. Replace the G21 secondary air injection pump.
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