HVAC System - Climate Control System-General Information: Diagnosis Ford Econoline E150

PINPOINT TEST C: THE AIR CONDITIONING (A/C) IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - GASOLINE ENGINES

Note. Before carrying out the following test, check that the A/C system pressure is above 290 kPa (42 psi), If the pressure is below 290 kPa (42 psi), refer to FLUORESCENT DYE LEAK DETECTION .

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PINPOINT TEST D: THE AIR CONDITIONING (A/C) IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - DIESEL ENGINE

Note. Before carrying out the following test, diagnose any PCM DTCs.

Note. Before carrying out the following test, check that the A/C system pressure is above 290 kPa (42 psi). If the pressure is below 290 kPa (42 psi), refer to FLUORESCENT DYE LEAK DETECTION .

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PINPOINT TEST F: THE AIR CONDITIONING (A/C) IS ALWAYS ON - DIESEL ENGINE

Note. Before carrying out the following test, diagnose any PCM DTCs.

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BLOWER MOTOR RESISTOR RESISTANCE

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AUXILIARY BLOWER MOTOR RESISTOR RESISTANCE

Heater Core - Pressure Test

Use the Radiator/Heater Core Pressure Tester to carry out the pressure test.

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1. Drain the coolant from the cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
2. Disconnect the heater hoses from the heater core. For additional information, refer to «HEATING & VENTILATION»(ref-210170) .
3. Install a short piece of heater hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater hose ends. Secure the heater hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 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 hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test.

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1. Remove the heater core from the vehicle. For additional information, refer to «HEATING & VENTILATION»(ref-210170) .
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/heater core pressure tester to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.

Evaporator/Condenser Core - On-Vehicle Leak Test

1. Discharge and recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-210167-S10740780802005121400000) .
2. Disconnect the suspect evaporator core or condenser core from the A/C system. For additional information, refer to «AIR CONDITIONING»(ref-210171) .
3. Clean the spring lock couplings. For additional information, refer to «SPRING LOCK COUPLING»(ref-210167-S21282093272005121400000) .
4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections.
5. Connect the red and blue hoses from the R134-a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and 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 evaporator core or condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and 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 open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new evaporator core or 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 (30 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 in 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 evaporator core or 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 evaporator core or condenser core does leak, as verified by the above procedure, install a new evaporator core or condenser core. For additional information, refer to «AIR CONDITIONING»(ref-210171) .

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 pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as 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 2 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 compressor shaft seal, the compressor front/rear head seal and the compressor rear head bolts.
7. If an external leak is found, install a new A/C compressor. Refer to «AIR CONDITIONING»(ref-210171) .
8. When the leak test is complete, recover the refrigerant from the compressor.

Visual Inspection

Diagnostic Table

1. Refer to the illustration below.

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1. Check the A/C clutch air gap at three equally spaced places between the clutch plate and the A/C clutch pulley.
2. Remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification.