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Vacuum Schematic
—
Manual A/C
SECTION 412-00: Clim ate Control System - G eneral Information 2001 F-150 Worksho p Manual
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DIAGNOSIS AND TES TING
Procedure revision date: 08/05/2002
Climate Control System
Refer to Wiring Diagrams Ce ll 54, Air Conditioner/Heater for sc hematic and connector informa tion.
Special Tool(s)
Alternator, Regulator, Battery and Starter Tester (ARBST)
010-00735 or equivalent
Worldwide Diagnostic System (W DS)
418-F224,
New Generation STAR (NGS) Tester
418-F052, or equivalent scan tool
Fluke 77 III Automotive Meter
105-R0056 or equivalent
R-134a Manifold Gauge Set
176-R032A or equivalent
Connector, Refrigerant Pressure Line
412-093 (T94P-19623-E)
Set, A/C Fittings
412-DS028 (014-00333, D93L-19703-B) or equivalent
Refrigerant Leak Detector
216-00001 or equivalent
Pressure Test Kit
014-R1072 or equivalent
Breakout Box, EEC V Control S ystem
418-049 (014-00950, T94L-50-EEC-V)
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Item Part Number Description
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1 18A318 Vacuum control motor, panel/defrost door
2 18A478 Panel/defrost door (full vacuum position)
3 — Defrost airflow
4 — Side window demister airflow
5 18B545 Temperature blend door (full heat position)
6 19860 A/C evaporator core
7 19A813 Air inlet duct door (full vacuum position)
8 — Outside air inlet
9 18A318 Vacuum control motor, air inlet duct door
10 — Recirculated air inlet
11 19805 Blower motor
12 — Vacuum to emission control
13 — Vacuum from the engine intake manifold
14 19A563 A/C vacuum check valve
15 19A566 A/C vacuum reservoir tank and bracket
16 19B888 A/C-heater function selector swi tch
17 18476 Heater core
18 18A559 Floor/panel door (full vacuum position)
19 — Floor airflow
20 18A318 Vacuum control motor, floor/panel door
21 — Panel vent airflow
Vacuum Connector End View — Manual A/C
Port Hose Color Function
1 White Air inlet duct door
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2 Yellow Floor/panel door
Loose, missing or damaged A/C compressor drive belt.
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3 Black Vacuum source
4 — Not us ed
5 Blue Floor/panel door
6 Red Panel/defrost door
VACUUM APPLICATION CH ART—MANUAL A/C
Switch Port Color Function
1 White Recirc/fresh V NV NV V NV NV NV NV
2 Yellow Floor/panel NV NV NV V NV V NV NV
3 Black Va cuum source V V V V V V V V
5 Blue Full floor NV NV NV V V V V NV
6 Red Panel/defrost V V V NV V NV NV NV
V = Vacuum
NV = No Vacuum
Inspection and Verification
1. Verify the customer's concern by operating the climate control system to duplicate the condition.
2. Inspect to determine if one of the following mechanical or elect rical concerns apply:
Visual Inspection Chart
Loose or disconnected A/C clutch.
Loose, misrouted or damaged vacuum lines.
Broken or leaking vacuum control motor.a
Broken or leaking refrigerant lines.
a
a
A leak in the vacuum control circuit may occur during acceleration (slow leak), may exist at all times (large leak), and may exist only when specific functions are selected (indicating
a leak in that portion of the circuit). The vacuum hoses used i n the passenger compartment co ntrol circuit are constructed from PVC plastic material. The vacu um hoses used in the
engine compartment are const ructed of Hytrel®. Because of the materials used, never pinch the vacuum hoses off during diagnosis to locate a leak. A wood golf tee can be used as
a plug when it is necessary to plug one end of the vacuum hose for leak test purposes.
3. If the inspection reveals obvious concern(s) that can be readi ly identified, repair as required.
4. If the concern remains after the inspection, connect a scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the
scan tool menu. If the vehicle selection cannot be entered:
check that the program card is correctly installed.
check the connections to the vehicle.
check the ignition switch position.
If the scan tool still does not a llow the vehicle selection to be entered, refer to the scan tool users manual.
5. Perform the DATA LINK DIAGN OSTIC TEST using the scan tool. If the scan tool responds w ith:
CKT 914 and CKT 915 = ALL MODULE NO RESPONSE/NOT EQUIPPED, go to Communication System Diagnostics in Sect ion 418-00 to diagnose netwo rk concern.
If the powertrain control module (PCM) is not listed for a communication concern, turn the A/C function selector switch to OF F and execute self-test diagnostics for the PCM.
6. If any PCM DTCs are retrieve d, and are related to the concern, go to the Powertrain Control Module Diagnostic Trouble Cod e (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, go to the Symptom Chart to continue diagnostics.
Powertrain Control Module Diagnostic Trouble Code (DTC) Index
DTC Description Action
P1460 Wide Open Throttle A/C Primary Circuit Malfunction REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
P1464 A/C Demand Out Of Self-Test Range REFER to the Powertrain Control/Emissions Diagnosis (PC/ED ) manual.
P1469 Low A/C Cycling Period REFER to the Powertrain Control/Emissions Diagnosis (PC/ED ) manual.
Symptom Chart
SYMPTOM CHART
Improper/erratic direction of airflow from outlet
MAX A/C A/C PNL/ VENT OFF FLR/ PNL FLOOR FLR/ DEF DEF
Mechanical Electrical
Condition Possible Sources Action
Function Selector Switch Posi tion
Open fuses.
Blower motor inoperative.
A/C compressor inoperative.
Circuitry open/shorted.
Disconnected electrical connectors.
Function selector switch.
A/C vacuum check valve.
Vacuum hose.
A/C vacuum reservoir tank and bracket.
Vacuum control motor.
Vacuum actuator arm.
GO to Pinpoint Test A.
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Insufficient, erratic, or no heat
The A/C does not operate/does not operate correctly
No operation in all the temperature settings
The blower motor does not operate
The blower motor does not operate correctly
No operation in high blower setting
Low engine coolant level.
Engine overheating.
Plugged or partially plugged heater core.
Temperature blend door binding/stuck.
A/C electronic blend door actuator.
Fuse.
Circuitry short/open.
A/C cycling switch.
A/C system.
Function selector switch.
A/C refrigerant.
Temperature blend door actuator control.
Temperature blend door.
A/C electronic blend door actuator motor.
Circuitry open/shorted.
Fuse.
Circuitry open/shorted.
A/C blower motor switch.
A/C blower motor resistor.
A/C blower motor.
Circuitry short/open.
A/C blower motor resistor.
A/C blower motor switch.
A/C blower motor resistor.
A/C blower motor switch.
Pinpoint Tests
PINPOINT TEST A: IMPROP ER/ERRATIC DIRECTION OF AIRFLOW FROM OUTLET
CONDITIONS DETAILS/RESULTS/ACTIO NS
A1 CHECK THE SYSTEM AIR FLOW
GO to Pinpoint Test B.
GO to Pinpoint Test C.
GO to Pinpoint Test D.
GO to Pinpoint Test E.
GO to Pinpoint Test F.
GO to Pinpoint Test G.
A2 CHECK THE VACUUM SUPPLY HOSE
Place the heater blower motor switch in the HI position.
Check for correct airflow from each function selector switch position at engine idle and during engine speed
acceleration.
Is there airflow from defroste r outlets under all conditions?
Yes
GO to A2.
No
If the airflow is from defroster outlets in all switch positions only under engine speed acceleration, GO to A19 .
If the airflow is incorrect under one or more conditions, GO t o A13 .
If the airflow is correct under all conditions, RETURN to the Symptom Chart.
Verify the vacuum supply hose is connected between the engine manifold and the A/C vacuum check valve.
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A3 LEAK CHECK THE VACUUM SUPPLY HOSE
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Vacuum Supply Hose
A4 CHECK THE VACUUM CH ECK VALVE
Is the hose connected?
Yes
GO to A3.
No
RECONNECT the hose. TEST the system for normal operation.
Plug one end of the hose and connect the vacuum pump to the other end. Apply vacuum and observe the gauge
reading.
Does the hose leak?
Yes
REPAIR or INSTALL a new vacuum hose. TEST the system for normal operation.
No
GO to A4.
A5 INSPECT THE VACUUM CHECK VALVE
A/C Vacuum Check Valve
Check the A/C vacuum check valve (19A563) for correct ins tallation by removing (one at a t ime) the reservoir
hose and the control assembly s ource hose from the A/C vacuum check valve. Check for vacuum.
Is vacuum available at both check valve ports?
Yes
GO to A6.
No
GO to A5.
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A6 LEAK TEST THE VACUU M CHECK VALVE
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A/C Vacuum Check Valve
Inspect the A/C vacuum chec k valve for an obstruction and/or correct operation. Airflow thro ugh the A/C vacuum
check valve should be in the direction toward the engine (engine connection site is marked "VAC") .
Is the A/C vacuum check valve plugged or obstructed?
Yes
INSTALL a new A/C vacuum check valve. TEST the system for normal operation.
No
GO to A6.
Connect the A/C vacuum check valve to a vacuum pump wit h two hoses and a tee fitting.
Apply 51 kPa (15 in-Hg) vacuum on the A/C vacuum check valve and observe the gauge reading.
If the vacuum loss exceeds 3. 37 kPa (1 in-Hg) per minute, remove the A/C vacuum check v alve from the pump
and plug the vacuum hoses. Apply 51 kPa (15 in-Hg) of vacuum with the pump to be certain hoses and tester are
not the cause of the leak.
Does the A/C vacuum check va lve lose more than 3.37 kPa (1 in-Hg) of vacuum in one minute?
Yes
INSTALL a new A/C vacuum check valve. TEST the system for normal operation.
No
A7 CHECK THE VACUUM RESERVOIR
A/C Vacuum Reservoir Tank
A8 CHECK THE SUPPLY HO SE
Function Selector Switch Supply Hose
Use a vacuum pump to leak test the function selector switch supply hose.
RECONNECT the A/C vacuum check valve. GO to A7 .
Use a vacuum pump to leak test the A/C vacuum reservoir tank.
Does the reservoir leak?
Yes
INSTALL a new A/C vacuum reservoir tank. TEST the system for normal operation.
No
RECONNECT the A/C vacuum reservoir tank. GO to A8 .
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A9 CHECK THE CONTROL ASSEMBLY
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Inline Vacuum Harness
Does the function selector sw itch supply hose leak?
Yes
REPAIR or INSTALL a new function selector switch supply hose. TEST the system for normal operation.
No
RECONNECT the function selector switch supply hose. GO to A9 .
Connect a vacuum tester to the black hose and plug the other hoses.
A10 LEAK TEST THE CONTRO L ASSEMBLY
Function Selector Switch Vacuum
At each function selector switch position, apply 51 kPa (15 in-Hg) of vacuum and check for a vacuum drop.
Does the vacuum drop exceed 3.37 kPa (1 in-Hg) per minute?
Yes
NOTE the function selector switch position where the vacuum drops. GO to A10 .
No
RECONNECT the inline vacuum harness connector. GO to A11 .
Connect a vacuum pump to the function selector switch supp ly port and plug the control port that indicated a leak
in Step A9.
Select the function selector switch position that indicated a lea k in Step A9 and then apply 51 kPa (15 in-Hg) of
vacuum.
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A11 CHECK THE SUPPLY HO SE FOR OBSTRUCTIONS
A/C Damper Door Switch Supply Hose
A12 LEAK TEST THE JUMPER VACUUM HARNESS
Does the vacuum drop exceed 1.68 kPa (1/2 in-Hg) per minute?
Yes
INSTALL a new function sel ector switch. TEST the system for normal operation.
No
RECONNECT the function selector switch vacuum connector. GO to A12 .
Connect a vacuum pump to the supply hose and try to apply vacuum. If the vacuum pump can pull vacuum, the
hose is plugged. If the vacuum pump pulls partial vacuum, the hose is restricted.
Is the hose plugged or restricted?
Yes
INSTALL a new supply hose. TEST the system for normal o peration.
No
RECONNECT the A/C dampe r door switch supply hose. GO to A15 .
Disconnect the suspect hose.
Plug one end of the suspect hose and attach a vacuum pump to the other end. Apply 51 kPa ( 15 in-Hg) of
vacuum to the hose.
Does the vacuum drop?
Yes
REPAIR or INSTALL a new vacuum jumper harness. TEST the system for normal operation.
No
A13 REVIEW THE VEHICLE'S HISTORY
REPAIR or INSTALL a new function selector switch. TEST the system for normal operation .
Review the vehicle's history.
Did the climate control system function correctly prior to th is concern?
Yes
GO to A16.
No
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A14 CHECK THE VACUUM H OSES TO DAMPER DOORS
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A15 CHECK THE VACUUM H ARNESS
A16 CHECK THE A/C VACUUM CIRCUIT
GO to A14.
Connect a vacuum pump to each hose and try to pull a vacuum. If the vacuum pump can pull a vacuum, the hose
is plugged. If the vacuum pump pulls a partial vacuum, the hose is restricted.
Is a hose plugged or restricted?
Yes
INSTALL a new vacuum ho se. TEST the system for normal operation.
No
GO to A15.
Compare the vacuum hose color in each vacuum harness to the vacuum schematic.
Does the hose color agree wi th the schematics?
Yes
GO to A16.
No
INSTALL a new vacuum ha rness. TEST the system for normal operation.
Check the A/C vacuum circuit for a pinched or kinked vacuu m hose.
Is the hose pinched or kinked?
Yes
REPAIR or INSTALL a new vacuum hose. TEST the system for normal operation.
No
A17 CHECK THE VACUUM C IRCUIT CONNECTIONS
A18 CHECK THE VACUUM H OSE
Plug one end of the hose and attach a vacuum pump to the ot her end. Apply vacuum and obse rve the gauge
GO to A17.
Check each vacuum hose connection to determine if it is partially connected or disconnected.
Is a vacuum hose disconnected or partially connected?
Yes
RECONNECT the hose. TEST the system for normal operation.
No
GO to A18.
Disconnect the suspect hose.
reading.
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A19 CHECK THE VACUUM C ONTROL MOTOR
Vacuum Control Motor
A20 CHECK THE VACUUM C ONTROL MOTOR INSTALLAT ION
Does the vacuum hose leak?
Yes
REPAIR or INSTALL a new hose. TEST the system for normal operation.
No
GO to A19.
Check the vacuum control mot or for leaks with a vacuum pump.
Does the vacuum control motor hold a vacuum?
Yes
GO to A20.
No
INSTALL a new vacuum control motor. TEST the system for normal operation.
Check the attachment of the vacuum control motor arm to th e damper door.
Is the vacuum control motor arm attached to the door or do or crank arm?
Yes
REPAIR or INSTALL a new damper door. TEST the system for normal operation.
No
CONNECT the vacuum control motor arm to the door and/or crank arm and check operation. TEST the system for
PINPOINT TEST B: INSUFFIC IENT, ERRATIC, OR NO HEAT
B1 CHECK FOR PROPER ENG INE COOLANT LEVEL
Check the engine coolant lev el when hot and cold.
CONDITIONS DETAILS/RESULTS/ACTIO NS
normal operation.
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Is the engine coolant at the co rrect level (hot/cold) as indicated on the engine coolant rec overy
reservoir?
Yes
GO to B2.
No
B2 CHECK FOR HOT WATE R TO THE HEATER CORE INLET HOSE
WARNING: The heater core inlet hose will become too hot to handle and may cause seri ous burns if the system is working correctly.
NOTE: Be sure that the inlet hose flow restrictor is in place and is undamaged.
B3 CHECK THE ENGINE COO LING SYSTEM INCLUDING RA DIATOR CAP FOR LEAKS
GO to B3.
Allow the engine to reach normal operating temperature.
Feel the heater core inlet hose.
Is the heater core inlet hose t oo hot to handle?
Yes
GO to B4.
No
GO to Section 303-03A.
Fill the engine cooling system to specified level.
Pressure check the engine cooling system. For additional information, refer to Section 303-0 3A. It is not
necessary to check the components separately at this time.
Does the engine cooling system , including the radiator cap , hold pressure?
Yes
GO to B4.
No
B4 CHECK THE HEATER COR E OUTLET HOSE FOR HOT WATER
Feel the heater core outlet hose.
PRESSURE TEST the heater core.
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Is the heater core outlet hose cool or cold?
Yes
TEST the heater core for a p lugged or partially plugged condition.
No
PINPOINT TEST C: THE A/C DOES NOT OPERATE OR DOES NOT OPERATE CORRECTLY
C1 CHECK THE PID ACCS WI TH THE A/C OFF
CONDITIONS DETAILS/RESULTS/ACTIO NS
GO to Pinpoint Test D.
PCM PID ACCS
C2 CHECK THE PID WAC WIT H THE A/C OFF
PCM PID WAC
C3 CHECK THE PID ACCS WI TH THE A/C ON
NOTE: The outside temperature must be over 10° C (50° F).
PCM PID ACCS
C4 CHECK THE PID WAC WIT H THE A/C ON
NOTE: The outside temperature must be over 10° C (50° F).
Place the function selector switch in the OFF position.
Does the PCM PID ACCS read ON?
Yes
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
No
GO to C2.
Does the PCM PID WAC read O N?
Yes
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
No
GO to C3.
Place the function selector switch in the MAX A/C position.
Does the PCM PID ACCS read ON?
Yes
GO to C4.
No
GO to C5.
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PCM PID WAC
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C5 CHECK THE A/C CYCLING SWITCH VOLTAGE
A/C Cycling Switch C139
Does the PCM PID WAC read O N?
Yes
GO to C13.
No
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Measure the voltage between the A/C cycling switch C139 p in 1, circuit 441 (RD/YE) and grou nd.
C6 CHECK THE A/C CYCLING SWITCH
NOTE: The outside temperature must be over 10° C (50° F).
C7 CHECK THE A/C SYSTEM PRESSURE
Is the voltage greater than 10 volts?
Yes
GO to C6.
No
GO to C9.
Connect a fused jumper lead between the A/C cycling switch C139 pin 1, circuit 441 (RD/YE ) and pin 4, circuit
347 (BK/YE).
Does the A/C compressor clu tch engage?
Yes
GO to C7.
No
GO to C8.
Connect the manifold gauge set. Refer to Manifold Gauge Set Connection in this section.
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C8 CHECK CIRCUIT 347 (BK/Y E)
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Is the pressure reading between 345 kPa (50 psi) and 1724 kPa (250 psi)?
Yes
INSTALL a new A/C cycling switch. TEST the system for normal operation.
No
CHECK for refrigerant leaks. REFER to Electronic Leak Detection or Tracer Dye Leak Detec tion in this section.
A/C Cycling Switch C139
PCM C174
C9 CHECK THE A/C PRESSU RE CUTOFF SWITCH VOLTAG E
Remove the fused jumper lead from the A/C cycling switch C139.
Connect the EEC-V 104-Pin Breakout Box to the PCM C174. Do not connect the breakout box to the PCM.
Measure the voltage between the breakout box pin 41 and ground.
Is the voltage greater than 10 volts?
Yes
INSTALL a new PCM. REFER to Section 303-14. TEST the system for normal operation.
No
REPAIR Circuit 347 (BK/YE) . TEST the system for normal operation.
A/C Pressure Cutoff Switch C170
Measure the voltage between the A/C pressure cutoff switch C170 pin 3, circuit 348 (VT) and ground.
Is the voltage reading greater than 10 volts?
Yes
GO to C10.
No
GO to C11.
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C10 CHECK THE A/C PRES SURE CUTOFF SWITCH
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C11 CHECK CIRCUIT 348 (V T)
Connect a fused jumper lead between the A/C pressure cuto ff switch C170 pin 1, circuit 441 (RD/YE) and pin 3,
circuit 348 (VT).
Measure the voltage between the A/C cycling switch C139 p in 1, circuit 441 (RD/YE) and grou nd.
Is the voltage reading greater than 10 volts?
Yes
INSTALL a new A/C pressure cutoff switch. TEST the syste m for normal operation.
No
REPAIR Circuit 441 (RD/YE). TEST the system for normal operation.
Function Selector Switch C217
C12 CHECK CIRCUIT 295 (LB /PK)
Measure the voltage between the function selector switch C2 17 pin 1, circuit 295 (LB/PK) and ground.
Measure the resistance between the A/C pressure cutoff sw itch C170 pin 3, circuit 348 (VT) and the function
selector switch C217 pin 2, circ uit 348 (VT).
Is the resistance less than 5 ohms?
Yes
GO to C12.
No
REPAIR circuit 348 (VT). TEST the system for normal operation.
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Is the voltage greater than 10 volts?
Yes
INSTALL a new function sel ector switch. TEST the system for normal operation.
No
C13 CHECK THE VOLTAGE AT THE A/C COMPRESSOR CLUTCH FIELD COIL
A/C Compressor Clutch Field Coil C106
REPAIR circuit 295 (LB/PK). TEST the system for normal operation.
Measure the voltage between the A/C compressor clutch fie ld coil C106, circuit 321 (GY/WH) and ground.
Is the voltage reading greater than 10 volts?
Yes
GO to C14.
No
C14 CHECK FOR GROUND AT THE A/C COMPRESSOR CLUTCH FIELD COIL
C15 CHECK CIRCUIT 321 (GY/ WH)
GO to C15.
Measure the resistance between the A/C compressor clutch field coil C106, circuit 57 (BK) and ground.
Is the resistance less than 5 ohms?
Yes
GO to C19.
No
REPAIR circuit 57 (BK). TEST the system for normal operation.
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A/C Clutch Relay
C16 CHECK CIRCUIT 883 (P K/LB)
Measure the resistance between the A/C clutch relay socket pin 5, circuit 321 (GY/WH) and the A/C compressor
clutch field coil C106, circuit 321 (GY/WH).
Is the resistance less than 5 ohms?
Yes
GO to C16.
No
REPAIR Circuit 321(GY/WH). TEST the system for normal op eration.
Measure the voltage between the A/C clutch relay socket pin 3, circuit 883 (PK/LB) and ground.
C17 CHECK WAC OUTPUT F ROM THE PCM
C18 CHECK CIRCUIT 331 (P K/YE)
Is the voltage greater than 10 volts?
Yes
GO to C17.
No
REPAIR circuit 883 (PK/LB). TEST the system for normal operation.
Measure the resistance between the A/C clutch relay socket pin 2, circuit 331 (PK/YE) and ground.
Is the resistance less than 5 ohms?
Yes
INSTALL a new A/C clutch relay. TEST the system for normal operation.
No
GO to C18.
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PCM C174
C19 CHECK THE A/C COMPR ESSOR CLUTCH GAP
Connect the EEC-V 104-Pin Breakout Box to the PCM C174. Do not connect the breakout box to the PCM.
Measure the resistance between the A/C clutch relay socket pin 2, circuit 331 (PK/YE) and the breakout box pin
69.
Is the resistance less than 5 ohms?
Yes
INSTALL a new PCM. REFER to Section 303-14. TEST the system for normal operation.
No
REPAIR circuit 331 (PK/YE). TEST the system for normal operation.
Measure the A/C compressor clutch gap at three equally spac ed locations between the clutch hub and the A/C
compressor clutch pulley.
Is the A/C compressor clutch gap greater than 0.75 mm (0.030 in)?
Yes
ADJUST the A/C compressor clutch air gap. REFER to Air Conditioning (A/C) Clutch Air Gap Adjustment in this
section. TEST the system for normal operation.
No
INSTALL a new A/C compress or clutch field coil. REFER to Section 412-03. TEST the system for normal
PINPOINT TEST D: NO OPER ATION IN ALL THE TEMPERATURE SETTINGS
D1 CHECK THE A/C ELECTR ONIC BLEND DOOR ACTUATOR MOTOR SYSTEM
D2 CHECK FUSE 5 (15A)
CONDITIONS DETAILS/RESULTS/ACTIO NS
operation.
Allow the engine to reach normal operating temperature.
Set the function selector switch to the MAX A/C position. Adjust the blend door potentiometer to full COOL (left)
and check for cool air discharge.
Adjust the blend door potentiometer to full WARM (right) and check for warm air discharge.
Vary the blend door actuator control from full WARM to full CO OL.
Did the air temperature change?
Yes
The system is OK.
No
GO to D2.
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D3 CHECK CIRCUIT 295 (LB /PK) FOR A SHORT TO GROUND
A/C Electronic Blend Door Actuator Motor C229
Fuse 5 (15A)
Function Selector Switch C217
Fuse Junction Panel C242
Is the fuse OK?
Yes
GO to D4.
No
REPLACE Fuse 5 (15A). TEST the system for normal operation. If the fuse opens again, GO to D3 .
Measure the resistance between fuse junction panel C242-1 5, Circuit 295 (LB/PK), and ground.
Is the resistance greater than 10,000 ohms?
Yes
INSTALL a new fuse junctio n panel. TEST the system for n ormal operation.
No
D4 CHECK THE VOLTAGE TO THE A/C ELECTRONIC BLE ND DOOR ACTUATOR MOTOR
A/C Electronic Blend Door Actuator Motor C229
REPAIR Circuit 295 (LB/PK). TEST the system for normal operation.
Measure the voltage between the A/C electronic blend door actuator motor C229-7, Circuit 295 (LB/PK), and
ground.
Is the voltage greater than 10 volts?
Yes
GO to D5.
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D5 CHECK CIRCUITS 436 (R /LG), 437 (Y/LG) AND 438 (R/W )
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Blend Door Actuator Control C220
D6 CHECK THE A/C CONTROL POTENTIOMETER
No
REPAIR Circuit 295 (LB/PK). TEST the system for normal operation.
Measure the resistance between the following pins:
Blend Door Actuator Control C220 A/C Electronic Blend Door Actuator Motor C229 Circuit
Are the resistances less than 5 ohms?
Yes
GO to D6.
No
REPAIR the circuit(s) in question. TEST the system for norm al operation.
Measure the resistance between the blend door actuator cont rol terminal 2 Circuit 437 (Y/LG ) and terminal 3
Circuit 436 (R/LG).
Pin 3 Pin 4 436 (R/LG)
Pin 2 Pin 3 437 (Y/LG)
Pin 1 Pin 6 438 (R/W)
Yes
GO to D7.
No
D7 CHECK CIRCUIT 57 (BK)
PINPOINT TEST E: THE BLOW ER MOTOR DOES NOT OPE RATE
CONDITIONS DETAILS/RESULTS/ACTIO NS
INSTALL a new blend door actuator control. TEST the system for normal operation.
Measure the resistance between the A/C electronic blend doo r actuator motor C229-8, Circ uit 57 (BK), and
ground.
Yes
INSTALL a new A/C electronic blend door actuator motor. TEST the system for normal opera tion.
No
REPAIR Circuit 57 (BK). TES T the system for normal operat ion.
Is the blend door actuator control at full WARM greater than 3,000 ohms and at full COOL less than 300
ohms? Is there a linear variation in the resistance between COOL and WARM?
Is the resistance less than 5 ohms?
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E1 CHECK FUSE 22 (10 A)
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Fuse 22 (10A)
E2 CHECK CIRCUIT 181 (BR/O) FOR A SHORT TO GRO UND
A/C Blower Motor Relay
Function Selector Switch C217
Is the fuse OK?
Yes
GO to E3.
No
GO to E2.
Measure the resistance between function selector switch C2 17-1, Circuit 181 (BR/O), and g round.
Is the resistance greater than 10,000 ohms?
Yes
REPAIR Circuit 296 (W/P) for a short. TEST the system for normal operation.
No
E3 CHECK FUSE 105 (4 0A)
Fuse 105 (40A)
E4 CHECK THE BLOWER MOTOR SUPPLY FOR A SHORT TO GROUND
A/C Blower Motor C190
Measure the resistance between the A/C blower motor C190 -2, Circuit 399 (BR/Y) and groun d while selecting
REPAIR Circuit 181 (BR/O) for a short. TEST the system for normal operation.
Is the fuse OK?
Yes
GO to E7.
No
GO to E4.
each mode on the function select or switch.
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E5 CHECK CIRCUIT 399 (BR/Y) FOR A SHORT TO GR OUND
A/C Blower Motor Relay
E6 CHECK CIRCUIT 364 (BK/LG) FOR A SHORT TO GROUND
Is the resistance greater than 10,000 ohms in all function selector switch positions except OFF?
Yes
INSTALL a new A/C blower motor. TEST the system for normal operation.
No
GO to E5.
Measure the resistance between the A/C blower motor C190 -2, Circuit 399 (BR/Y), and ground.
Is the resistance greater than 10,000 ohms?
Yes
GO to E6.
No
REPAIR Circuit 399 (BR/Y) for a short. TEST the system for normal operation.
Measure the resistance between the power distribution box Fuse 105 (40A) Pin 2, Circuit 364 (BK/LG) and
ground.
Is the resistance greater than 10,000 ohms?
Yes
INSTALL a new A/C blower motor relay. TEST the system for normal operation.
No
E7 CHECK THE VOLTAGE TO THE A/C BLOWER MOTOR
A/C Blower Motor C190
REPAIR Circuit 364 (BK/LG) for a short. TEST the system for normal operation.
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1 and ground. TEST the system for
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E8 CHECK THE BLOWER MOTOR GROUND
Measure the voltage between A/C blower motor C190-2, Circuit 399 (BR/Y), and ground whil e selecting each
mode on the function selector switch.
Is the voltage greater than 10 volts in all function selector sw itch positions except OFF?
Yes
GO to E8.
No
GO to E10.
Turn the blower motor switch to the HI position.
E9 CHECK CIRCUIT 261 (O/BK)
A/C Blower Motor Resistor C191
Measure the resistance between the A/C blower motor C190 -1, Circuit 261 (O/BK) and grou nd.
Is the resistance less than 10 ohms?
Yes
INSTALL a new A/C blower motor. TEST the system for normal operation.
No
GO to E9.
Measure the resistance between the A/C blower motor C190 -1, Circuit 261 (O/BK), and the A/C blower motor
resistor C191-2, Circuit 261 (O/BK).
Is the resistance less than 5 ohms?
Yes
REPAIR Circuit 57 (BK) for an open between the function s elector switch C218-
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normal operation.
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No
E10 CHECK CIRCUIT 364 (BK/ LG) FOR AN OPEN
A/C Blower Motor Relay
E11 CHECK THE VOLTAGE TO THE A/C BLOWER MOTOR RELAY
REPAIR Circuit 261 (O/BK) for an open. TEST the system for normal operation.
Measure the voltage between A/C blower motor relay connector Pin 87, Circuit 364 (BK/LG ) and ground.
Yes
GO to E11.
No
REPAIR Circuit 364 (BK/LG) for an open. TEST the system for normal operation.
Is the voltage 10 volts or greater?
E12 CHECK THE VOLTAGE TO THE FUNCTION SELECTOR SWITCH
Function Selector Switch C217
Measure the voltage between function selector switch C217-2 , Circuit 296 (W/P), and ground .
Measure the voltage between A/C blower motor relay connector Pin 86, Circuit 181 (BR/O), and ground while
selecting each mode on the funct ion selector switch.
Is the voltage 10 volts or greater in all positions except OFF?
Yes
GO to E14.
No
GO to E12.
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E13 CHECK CIRCUIT 181 (BR /O)
E14 CHECK THE A/C BLOW ER MOTOR RELAY GROUND
Is the voltage 10 volts or greater?
Yes
GO to E13.
No
REPAIR Circuit 296 (W/P) for an open. TEST the system for normal operation.
Measure the resistance between function selector switch C2 17-1, Circuit 181 (BR/O), and A/C blower motor relay
connector Pin 86, Circuit 181 (BR/O).
Is the resistance less than 5 ohms?
Yes
INSTALL a new function sel ector switch. TEST the system for normal operation.
No
REPAIR Circuit 181 (BR/O) for an open. TEST the system for normal operation.
E15 CHECK FOR AN OPEN IN THE A/C BLOWER MOTOR FEED CIRCUIT
Blower Motor C190
Measure the resistance between A/C blower motor relay connector Pin 30, Circuit 399 (BR/Y), and blower motor
Measure the resistance between A/C blower motor relay connector Pin 85, Circuit 57 (BK), and ground.
Is the resistance less than 5 ohms?
Yes
GO to E15.
No
REPAIR Circuit 57 (BK) for an open. TEST the system for normal operation.
C190, Circuit 181 (BR/O).
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Is the resistance less than 5 ohms?
Yes
INSTALL a new A/C blower motor relay (19E703). TEST the system for normal operation.
No
PINPOINT TEST F: THE BLO WER MOTOR DOES NOT OPERATE CORRECTLY
F1 CHECK THE A/C BLOWER MOTOR OPERATION
CONDITIONS DETAILS/RESULTS/ACTIO NS
REPAIR Circuit 399 (BR/Y) for an open. TEST the system for normal operation.
F2 CHECK THE BLOWER MOT OR SWITCH POSITIONS
F3 CHECK THE GROUND CIRCUIT
A/C Blower Motor Resistor
Turn the function selector switch to the FLOOR position and the blower motor switch to the L O position.
Does the A/C blower motor op erate correctly?
Yes
GO to F5.
No
GO to F2.
Turn the function selector switch to the FLOOR position and slowly rotate the blower motor sw itch from the LO
position to the HI position.
Does the A/C blower motor op erate in any position except HI?
Yes
GO to F4.
No
GO to F3.
Measure the resistance between A/C blower motor resistor C191-3, Circuit 57 (BK), and ground.
Is the resistance less than 5 ohms?
Yes
INSTALL a new A/C blower motor resistor. RETEST the syst em for normal operation.
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F4 CHECK THE CIRCUIT RESI STANCE
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A/C Blower Motor Resistor
A/C Blower Motor
F5 CHECK THE BLOWER MOT OR SWITCH
F6 CHECK THE BLOWER MOT OR SWITCH RESISTANCE
No
REPAIR Circuit 57 (BK). TES T the system for normal operat ion.
Measure the resistance between A/C blower motor resistor C191-2, Circuit 261 (O/BK), and the A/C blower motor
C190-1, Circuit 261 (O/BK).
Is the resistance less than 5 ohms?
Yes
INSTALL a new A/C blower motor resistor. RETEST the syst em for normal operation.
No
REPAIR Circuit 261 (O/BK). TEST the system for normal operation.
Turn the function selector switch to the FLOOR position and slowly rotate the blower motor sw itch from the LO
position to the HI position and back several times.
Does the A/C blower motor op erate in all switch positions without interruption?
Yes
CHECK the system operations in all function selector switch positions and A/C blower motor speeds. If OK,
ADVISE the customer on correct operation of the system.
No
GO to F6.
Blower Motor Switch
Measure the resistance between the blower motor switch terminals in each switch position.
Switch Position Continuity Betwe en Terminals
LO None
Low medium 2 and 3
High medium 2, 3 and 4
HI 1, 2 and 4
Is the resistance between the specified terminals less than 5 ohms?
Yes
CHECK for opens and shorts; REPAIR as required Circuits 752 (Y/R) or 754 (LG/W). RETEST the system for
normal operation.
No
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PINPOINT TEST G: NO OPERATION IN HIGH BLOWER SETTING
G1 CHECK THE A/C BLOWER MOTOR OPERATION
CONDITIONS DETAILS/RESULTS/ACTIO NS
INSTALL a new blower motor switch. TEST the system for normal operation.
G2 CHECK THE A/C BLOWER MOTOR SPEED
G3 CHECK THE BLOWER MOT OR SWITCH
Blower Motor Switch
Turn the function selector switch to the FLOOR position and the blower motor switch to the p osition next to the HI
position.
Does the A/C blower motor op erate?
Yes
GO to G2.
No
GO to G4.
Turn the function selector switch to the FLOOR position and the blower motor switch to the H I position.
Does the A/C blower motor op erate?
Yes
CYCLE the blower motor switch from HI to LO several times. If the blower operates each time, ADVISE the
customer of correct system operation. If the blower does no t operate correctly, INSTALL a new blower motor
switch. TEST the system for normal operation.
No
GO to G3.
Measure the resistance between the blower motor switch terminals in each switch position.
Switch Position Continuity Betwe en Terminals
LO None
Low medium 2 and 3
High medium 2, 3 and 4
HI 1, 2 and 4
Is the resistance between the specified terminals less than 5 ohms?
Yes
REPAIR Circuit 57 (BK). RETEST the system for normal operation.
No
G4 CHECK THE OTHER A/C B LOWER MOTOR SPEEDS
G5 CHECK THE BLOWER MOT OR SWITCH CONNECTOR
INSTALL a new blower motor switch. RETEST the system for normal operation.
Turn the function selector switch to the FLOOR position and the blower motor switch to the L O position and then
to the next position.
Does the A/C blower motor op erate in both positions?
Yes
INSPECT the harness connector at the blower motor switch. INSTALL a new harness conn ector if damaged. If
OK, INSTALL a new blower motor switch.
No
If the blower doesn't work in LO, INSTALL a new A/C blower motor resistor.
If the blower works in LO, G O to G5 .
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Heater Core
— Bench Test
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Component Tests
Heater Core
WARNING: Carbon monoxide is colorless, odorless and d angerous. If it is necessary to o perate the engine with the vehicle in a closed area such a s a garage, always use
an exhaust collector to vent the exhaust gases outside the closed area.
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are go od and did not require replacement. If a heater core leak is suspected, the heater core
must be tested by following the plugged heater core compone nt test before the heater core pressure test. Perform a system inspection by checking the hea ter system thoroughly as
follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater wat er hose could follow the heater core tube to the heater
core and appear as a leak in t he heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps c an cause leakage at the heater water hose connection and
damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core — Plugged
WARNING: The heater core i nlet hose will become too hot to handle if the system is wo rking correctly.
1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on th e heater.
3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot.
If it is not hot:
the heater core may have an air pocket
the heater core may be plugged, or
the thermostat is not working correctly.
Heater Core — Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system.
2. Disconnect the heater water hoses from the heater core. For additional information, refer to Se ction 412-02.
3. Install a short piece of heater water hose, approximately 101 m m (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and in stall Plug BT-7422-B and adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose
ends. Secure the heater water hoses, plug and adapter with hose clamps.
Check to ensure the connector is correctly and securely connected to the blower motor swi tch.
Is the connector correctly atta ched to the blower motor s witch?
Yes
INSTALL a new blower motor switch. RETEST the system for normal operation.
No
RECONNECT and CHECK t he A/C blower motor operation.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the ad apter.
6. Close the bleed valve at the b ase of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core.
7. Observe the pressure gauge for a minimum of three minutes.
8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform
the bench test.
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1. Remove the heater core from the vehicle. For additional information, refer to Section 412-02.
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2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes . Then connect the Radiator/Hea ter Core Pressure Tester to the adapter.
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Subm erge the heater core in water.
5. If a leak is observed, replace the heater core.
A/C Evaporator/Condenser Core — On Vehicle Leak Test
1. Discharge and recover the ref rigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging.
2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier (19C836) attached to the core tubes.
Disconnect the suspect A/C evaporator core or A/C condense r core from the A/C system. Fo r additional information, refer to Section 412-03.
3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling.
4. Connect the appropriate test f ittings from the R-12/R-134a Air Conditioning Test Fitting Set to t he evaporator or condenser tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hos es do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off
valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shu t-off valve does not
open.
Connect the red and blue hose s from the R-134a Manifold G auge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good
vacuum pump.
6. Open both gauge set valves an d start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa
(30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C co ndenser core. If the refrigerant is not completely
removed from the oil, outgassing will degrade the vacuum an d appear as a refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in -Hg) when the valves on the gauge and manifold set are ope n and the vacuum pump is operating, close the gauge
set valves and observe the low pressure gauge. If the pressu re rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gaug e set connections before
replacing the A/C evaporator c ore or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (3 0 in-Hg) mark.
If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position i n 10 minutes, a leak is indicated.
If a very small leak is suspected , wait 30 minutes and observe the vacuum gauge.
If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C
evaporator core or A/C condenser core. Then recheck for loss of vacuum.
If a very small leak is suspected , allow the system to set overnight with vacuum applied and check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. For additional information,
refer to Section 412-03.
A/C Compressor — External Leak Test
1. Install the A/C Pressure Test Adapter on the rear head of the A /C compressor using the existing manifold retaining bolt.
2. Connect the high and low pres sure lines of a manifold gauge set or a refrigerant recovery/recycling station such as the R-134a A/C Service Center to the corresponding fittings on the
A/C Pressure Test Adapter
3. Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position.
4. Hand-rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/ C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the co mpressor shaft seal and the compressor center seal.
7. If a shaft seal leak is found, ins tall a new shaft seal. For addit ional information, refer to Section 412-03. If an external leak is found at the center joint of the A/C compressor, install a
new A/C compressor.
8. When the leak test is complete, recover the refrigerant from the compressor.
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