Manual A/c-Heater Systems Ford Econoline I

SPECIFICATIONS

SPECIFICATIONS

DESCRIPTION

MAIN SYSTEM

Main system is of a blend-air design. Evaporator and heater core assembly is mounted on right side of engine firewall, and air distribution plenum is mounted inside passenger compartment. The control panel is positioned on instrument panel, right of steering column.

The system uses a cycling clutch, fixed orifice tube refrigerant system and is designed to cycle compressor on and off to maintain desired cooling level and prevent evaporator freeze-up. Primary components are compressor, condenser, fixed orifice tube, evaporator core, suction accumulator-drier and control panel.

AUXILIARY SYSTEM

The auxiliary A/C-heater system is a recirculating-air type system. Auxiliary system is located on left side of vehicle, behind rear wheelwell. System components include blower motor, blower motor resistor, evaporator core, thermostatic expansion valve and heater core.

FIXED ORIFICE TUBE

Fixed orifice tube is a restriction between high and low pressure liquid refrigerant, and meters flow of liquid refrigerant into main system evaporator core. Fixed orifice tube is located in refrigerant line, near condenser. Filter screens are positioned on tube inlet and outlet ports. The "O" rings on tube body prevent liquid refrigerant from by-passing fixed orifice tube. Fixed orifice tube can be removed from A/C line and serviced.

EVAPORATOR CORE

Evaporator core is located in evaporator/blower unit. Liquid refrigerant from fixed orifice tube enters core and cools evaporator fins. Air from blower passes through fins and is cooled and dehumidified before flowing to passenger compartment.

Function Selector Control

This control knob actuates a function selector valve to control vacuum servomotors for floor/defrost door, panel/defrost door and outside/recirculated air door. When it is in OFF position, function selector knob stops blower motor operation. When in A/C position, function selector knob activates A/C compressor clutch.

Temperature Selector Control

Temperature selector knob is part of a temperature control module attached to control frame. The module contains a printed circuit board and a linear potentiometer. The knob is coupled to potentiometer wiper contact.

The temperature blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper contact is connected to the actuator output shaft and moves with the output shaft to indicate position of the temperature blend door.

Battery voltage is applied to the ends of each potentiometer. The voltage available at each wiper indicates position of the potentiometer. Actuator wiper voltage is sent to the control module and matched with wiper voltage of module potentiometer. The printed circuit board then drives actuator motor in direction necessary to make actuator wiper contact voltage agree with control module wiper voltage.

Blower Switch

A 4-speed blower switch is positioned on left side of control panel. A thermal limiter is part of the blower motor resistor circuit. If thermal limiter temperature reaches 250°F (121°C), circuit opens and blower motor becomes inoperative in all speeds except high speed. If thermal limiter is blown, replace blower motor resistor.

Front-Mounted Blower Switch

Switch is mounted on main control panel, under main blower switch. Switch has 4 blower speeds, a REAR CONTROL position and an OFF position.

Headliner-Mounted Blower Switch

Switch, mounted in the headliner, has 4 blower speeds and an OFF position. Switch operates only when front-mounted blower switch for auxiliary system (on main control panel) is in REAR CONTROL position.

MAX A/C

The outside/recirculated air door is in closed position (vacuum applied to door servomotor), allowing air to recirculate. Most air is discharged through instrument panel registers with some air going to floor. Compressor operation is dependent upon clutch cycling pressure switch. Temperature selector knob controls blend door to regulate airflow through heater core.

NORM A/C

The outside/recirculated air door is open to outside air entry (vacuum is not applied to door servomotor). Most air is discharged through instrument panel registers with some air going to floor. Compressor operation is dependent upon clutch cycling pressure switch. Temperature selector knob controls blend door to regulate airflow through heater core.

VENT

The outside/recirculated air door is open to outside air entry (vacuum is not applied to door servomotor). Most air is discharged through instrument panel registers with some air going to floor. Compressor does not operate. Temperature selector knob controls blend door, which regulates airflow through heater core.

FLOOR

The outside/recirculated air door is open to outside air entry (vacuum is not applied to door servomotor). Most air is discharged through floor outlets with some air going to defrost ducts. Compressor does not operate. Temperature selector knob controls blend door to regulate airflow through heater core.

MIX

The outside/recirculated air door is open to outside air entry (vacuum is not applied to door servomotor). Air is discharged through defrost and floor outlets. Temperature selector knob controls blend door to regulate airflow through heater core. Compressor operation is dependent upon clutch cycling pressure switch.

DEF

The outside/recirculated air door is open to outside air entry (vacuum is not applied to door servomotor). Air is discharged through defrost outlets to windshield with some air going to floor. Compressor operates to dehumidify air and prevent windshield fogging. Compressor operation depends on clutch cycling pressure switch. Temperature selector knob controls blend door to regulate airflow through heater core.

THERMOSTATIC EXPANSION VALVE (TXV)

TXV is used only in the auxiliary A/C-heater system. TXV is a restriction between high and low pressure liquid refrigerant. Valve meters flow of liquid refrigerant into auxiliary system evaporator core. Valve is mounted in refrigerant line adjacent to auxiliary system evaporator core.

TROUBLE SHOOTING

PRELIMINARY INSPECTION

1. Verify customer complaints by operating system in all available modes. Carefully check the following for possible cause of problems and repair as necessary: damaged vacuum hoses, system components, damaged compressor drive belt, open fuses, damaged/misrouted wiring circuits, and damaged/disconnected connectors.
2. Check for small leaks in vacuum circuit. Test vehicle with engine running and accelerate engine while checking airflow. During acceleration, all airflow will suddenly go to defrost outlets, indicating a small leak.
3. While checking vacuum hoses, DO NOT pinch hoses to stop vacuum flow. Instead, plug hoses with wooden golf tee for testing. Vacuum hose material will not withstand pinching.
4. If problem remains after preliminary inspection and any repairs have been made, go to «SYMPTOM DIAGNOSIS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__symptom-diagnosis) .

SYMPTOM DIAGNOSIS

1. Improper/Erratic Airflow From Outlets Go to «TEST A»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-a-impropererratic-direction-of-airflow) .
2. Insufficient, Erratic or No Heat Go to «TEST B»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-b-insufficient-erratic-or-no) .
3. A/C Does Not Operate/Does Not Operate Properly Go to «TEST C»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-c-ac-does-not-operate) .
4. Insufficient A/C Cooling For main system, go to «TEST D»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-d-insufficient-ac-cooling-main) . For auxiliary system, go to «TEST J»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-j-insufficient-ac-cooling-auxiliary) .
5. No Operation In All Temperature Settings Go to «TEST E»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-e-no-operation-in-all) .
6. Blower Motor Does Not Operate Go to «TEST F»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-f-blower-motor-does-not) .
7. Blower Motor Operates Only In High Go to «TEST G»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-g-blower-operates-continuously-in) .
8. No Operation In High Blower Setting Go to «TEST H»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-h-no-operation-in-high) .
9. Auxiliary Blower Motor Does Not Operate On models without rear auxiliary blower motor switch, go to «TEST K»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-k-auxiliary-blower-motor-does) . On models using rear auxiliary blower motor switch, go to «TEST L»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-l-auxiliary-blower-motor-does) .
10. Front Auxiliary Blower Motor Switch Operates Only In High Go to «TEST M»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-m-front-auxiliary-blower-motor) .
11. Rear Auxiliary Blower Motor Switch Operates Only In High Go to «TEST N»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-n-rear-auxiliary-blower-motor) .
12. Front Auxiliary Blower Motor Switch Does Not Operate In High Go to «TEST P»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-p-front-auxiliary-blower-motor) .
13. Rear Auxiliary Blower Motor Switch Does Not Operate In High Go to «TEST Q»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) .

TEST A: IMPROPER/ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS

1. Check System Airflow Start engine and run at idle. Set blower to HI speed. Turn function selector switch to each airflow position and check airflow at outlets during idle. If there is airflow only from defrost outlets at each switch position, go to next step. If airflow is incorrect under one or more conditions, go to step 14). If airflow is correct under all conditions, go to next step.
2. Check Vacuum Supply Hose Turn ignition off. Check that vacuum hose is connected. If it is disconnected, reconnect hose and go to step 13). If hose is connected, go to next step.
3. Check Vacuum Reservoir & Hoses Turn ignition off. Disconnect intake manifold vacuum hose and in-line vacuum harness. Plug vacuum hose at intake manifold. Connect vacuum tester to in-line vacuum harness and leak check vacuum reservoir, check valve and hoses. If a vacuum leak is found, go to next step. If no vacuum leak is found, go to step 9).
4. Leak Check Vacuum Supply Hose Remove evaporator core housing. Disconnect vacuum supply hose. Connect one end to vacuum tester and plug other end. Apply vacuum and check for leaks. If hose leaks, repair or replace hose and retest system. If hose does not leak, go to next step.
5. Inspect Vacuum Check Valve Turn ignition off. Disconnect vacuum check valve. Check for obstructions or improper operation. Airflow through check valve should be in direction of engine. If check valve is obstructed or plugged, replace check valve. Retest system. If check valve is okay, go to next step.
6. Leak Test Vacuum Check Valve Ensure ignition is off. Disconnect vacuum check valve. Attach vacuum tester with "T" fitting and two hoses to reservoir and control assembly vacuum ports. Apply 15 in. Hg of vacuum to check valve. If vacuum leak-down exceeds 1 in. Hg per minute, remove check valve, plug test hoses and check for leakage in hoses. If hoses are okay, but leak-down exceeded 1 in. Hg per minute, replace vacuum check valve. Retest system. If leak-down did not exceed 1 in. Hg per minute, restore vacuum check valve connections and go to next step.
7. Check Vacuum Reservoir Disconnect hose from vacuum reservoir. With vacuum tester, check for vacuum leaks in vacuum reservoir. If reservoir leaks, replace vacuum reservoir and bracket. Retest system. If vacuum reservoir does not leak, remove hose and go to next step.
8. Check Control Assembly Vacuum Supply Hose Disconnect vacuum supply hose from check valve and A/C-heater control panel. Connect vacuum tester to supply hose and check for vacuum leak. If supply hose leaks, repair or replace hose. Retest system. If no vacuum leak is present, reconnect hose and go to next step.
9. Check Function Selector Switch Vacuum Supply Hose Disconnect function selector switch vacuum supply hose. Connect vacuum tester to one end of supply hose and plug other end of hose. Connect vacuum tester to supply hose and check for vacuum leak. If supply hose leaks, repair or replace hose. Retest system. If no vacuum leak is present, reconnect hose and go to next step.
10. Check Control Assembly Vacuum Reconnect supply hose from function selector switch. Disconnect in-line vacuum harness connector. Connect vacuum tester to Black vacuum supply hose port. Plug other hose ports. As function selector switch is set to each position, apply 15 in. Hg vacuum and check for leak-down. If leak-down exceeds 1 in. Hg per minute, note switch position where leak-down occurred and go to next step. If leak-down does not exceed 1 in. Hg per minute, reconnect in-line vacuum harness connector and go to step 15).
11. Leak Test Control Assembly Disconnect vacuum harness from function selector switch. Connect vacuum tester to Black supply hose port on connector. Plug hose port with indicated vacuum leak in previous step. Apply 15 in. Hg of vacuum to control assembly. If vacuum drop exceeds 0.5 in. Hg per minute, replace function selector switch. Retest system. If vacuum drop does not exceed specified limits, reconnect function selector switch and go to next step.
12. Leak Test Jumper Vacuum Harness Disconnect suspect (leaking) vacuum hose. Plug one end of suspect hose and attach vacuum tester to other end. Apply 15 in. Hg of vacuum to hose. If vacuum leaks, repair or replace vacuum jumper harness. Retest system. If vacuum hose does not leak, check vacuum harness connections. Repair or replace vacuum hose(s) as necessary. Retest system.
13. Check System Airflow Start engine and run at idle. Set blower to HI speed. Turn function selector switch to each airflow position and check airflow at outlets during idle. If airflow is correct for each function position, go to next step. If airflow is incorrect under one or more conditions, go to step 15).
14. Isolate Leaking Vacuum Circuit Start engine and run at idle. Set blower switch to HI speed. Turn function selector switch to each airflow position and check airflow at outlets during acceleration. If there is airflow only from defrost outlets at each switch position, go to step 19). If airflow is correct under all conditions, go to next step.
15. Review Vehicle History Turn ignition off. If airflow system functioned properly prior to current complaint, go to step 18). If airflow system did not function properly in the past, go to next step.
16. Check Vacuum Harness Compare vacuum hose color in vacuum harness with each connector on function selector switch vacuum connector. (Scheme 4) If hose colors of vacuum harness and connector colors match, go to next step. If hose colors of vacuum harness do not match, replace vacuum harness. Retest system.
17. Check A/C Vacuum Circuit Check A/C vacuum circuit for pinched or kinked vacuum hose(s). If any hose is pinched or kinked, reposition or replace hose and retest system. If hoses are okay, go to next step.
18. Check Vacuum Circuit Connections Check each vacuum hose to ensure it is properly attached at all connections. If any vacuum hose is disconnected, reconnect hose and retest system. If hoses are properly connected, go to next step.
19. Check Vacuum Motor Hoses Disconnect each suspected vacuum hose from system. Connect vacuum tester to each hose and plug other end. Apply vacuum and check for leaks. Check each hose for restriction or blockage. Remove plug. Apply vacuum. If any hose is plugged, leaks or is restricted, replace vacuum hose and retest system. If hoses are okay, go to next step.
20. Check Vacuum Control Motor Disconnect hose from suspect vacuum control motor. Apply vacuum to suspect motor(s). If any motor leaks, replace vacuum control motor and retest system. If no leaks are found, go to next step. Reconnect vacuum control motor hose.
21. Check Vacuum Control Motor Installation Check attachment of vacuum control motor to damper door. If motor arm is properly attached to damper door, service damper door for binding and retest system. If motor arm is not properly attached to damper door, connect motor arm and retest system.

TEST B: INSUFFICIENT, ERRATIC OR NO HEAT

1. Check For Proper Coolant Level Check coolant level with engine cold. If coolant level is not okay, replace coolant and check for leaks. If coolant level is okay, go to next step.
2. Check For Hot Coolant To Heater Inlet Start and run engine to normal operating temperature. Check for hot coolant to heater core inlet hose by feeling heater hose at inlet tube to heater core. If hose is hot, go to next step. If hose is cool to touch, check cooling system and repair as needed.
3. Check For Cooling System Leaks Ensure coolant reservoir is filled to proper level. Perform cooling system pressure checks. If all components of cooling system hold pressure, go to next step. If leak is found, repair leak or replace component(s) as needed.
4. Check For Hot Coolant At Heater Outlet Ensure engine is running at normal operating temperature. Carefully feel heater core outlet hose at both main and auxiliary heater cores. If heater core outlet hose is cool or cold, test heater core for plugged or restricted condition. If outlet hose is hot, go to «TEST E»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-e-no-operation-in-all) .

TEST C: A/C DOES NOT OPERATE OR DOES NOT OPERATE PROPERLY

1. Check Compressor Operation Ensure outside temperature is above 50°F (10°C). Start and run engine to normal operating temperature. Place function selector switch in MAX A/C position. Set blower switch to HI position. If compressor engages, compressor circuit is functioning properly at this time. If compressor does not engage, go to next step.
2. Check A/C Cycling Switch Turn ignition off. Disconnect A/C cycling switch connector located on top of accumulator-drier. Install jumper wire between switch connector Red/Yellow wire and Violet wire terminals. Start engine. Set A/C switch to NORM A/C. Set blower switch to HI. If compressor clutch engages, go to next step. If compressor clutch does not engage, go to step 4) .
3. Check A/C Refrigerant Pressure Turn ignition off. Reconnect A/C cycling switch. Check pressure of refrigerant in A/C system. If refrigerant pressure is more than 50 psi (3.5 kg/cm 2 ), replace A/C cycling switch. Retest system. If pressure is less than 50 psi (3.5 kg/cm 2 ), check system for refrigerant leaks.
4. Check Voltage To A/C Cycling Switch Turn ignition off. Disconnect A/C cycling switch connector. Turn ignition to run position (engine off). Set A/C switch to MAX A/C position. With a voltmeter, measure voltage of Violet wire between A/C cycling switch connector and ground. If voltage is less than 10 volts, reconnect A/C cycling switch connector and go to step 11) . If voltage is 10 volts or more, go to next step.
5. Check Voltage To A/C Pressure Cutoff Switch Turn ignition off. Disconnect A/C pressure cutoff switch connector. Turn ignition to run position (engine off). Set A/C switch to MAX A/C position. With a voltmeter, measure voltage of Red/Yellow wire between A/C pressure cutoff switch connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open in Red/Yellow wire. Retest system.
6. Check A/C Pressure Switch For Open Turn ignition off. Disconnect A/C pressure cutoff switch connector. With an ohmmeter, measure resistance between Red/Yellow wire and Black/Yellow wire terminals of cutoff switch connector. If resistance is less than 5 ohms, reconnect switch and go to next step. If resistance is 5 ohms or more, replace pressure cutoff switch. Retest system.
7. Check Voltage To Compressor Clutch Turn ignition off. Disconnect compressor clutch connector. Turn ignition to run position (engine off). Set A/C switch to MAX A/C position. With a voltmeter, measure voltage of Black/Yellow wire between compressor clutch connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open in Black/Yellow wire. Retest system.
8. Check Black Wire Circuit For Open Turn ignition off. With an ohmmeter, measure resistance of Black wire between compressor clutch connector and ground. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace open in Black wire. Retest system.
9. Check Compressor Clutch Coil Resistance With an ohmmeter, measure resistance between compressor clutch terminals. If resistance is more than 6 ohms, replace compressor clutch coil. Retest system. If resistance is 6 ohms or less, go to next step.
10. Check Compress Clutch Coil Current Draw Turn ignition off. Connect jumper wire between Black/Yellow wire terminals of compressor clutch coil and clutch connector. Connect second jumper to Black wire terminal of compressor clutch. Connect an ammeter and measure current draw between Black wire and jumper. If current draw in between 2.5-4.5 amps, adjust compressor clutch air gap to .014-.033" (.36-.84 mm). Retest system. If current draw is not within specified range, replace compressor clutch. Retest system.
11. Check Voltage At Function Selector Switch Turn ignition off. Disconnect function selector switch connector. Turn ignition on. Using voltmeter, measure voltage between Pink/Black wire at switch connector and ground. If voltage is more than 10 volts, go to step 13) . If voltage is less than 10 volts, go to next step. Reconnect function switch connector.
12. Check Fuse No. 13 (15-Amp) Turn ignition off. Check fuse No. 13 (15-amp) in instrument panel fuse block. If fuse is okay, check for open or short in Pink/Black wire. Repair as necessary. Retest system. If fuse is blown, replace fuse. Retest system. If fuse blows again, check Pink/Black wire, Red/Yellow wire and Black/Yellow wire for short. Repair wire(s) as necessary. Retest system.
13. Check Voltage At Function Selector Switch Reconnect function selector switch connector. Turn ignition on. Using voltmeter, backprobe between function selector switch Violet wire and ground. If voltage is more than 10 volts, repair Violet wire. Retest system. If voltage is less than 10 volts, replace function selector switch and retest system.

TEST D: INSUFFICIENT A/C COOLING (MAIN SYSTEM)

1. Check Center Register Discharge Temperature Connect manifold gauge set. Start and run engine at 1500 RPM. Set A/C controls to MAX A/C. Set blower/fan on high speed and close doors and windows. Insert thermometer in center vent. Operate system for 10-15 minutes to allow system to stabilize. When vehicle has stabilized, check and record center register and ambient temperature. Compare readings with «AMBIENT/CENTER REGISTER TEMPERATURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are within specifications, system is functioning normally at this time. If readings are not within specifications, go to next step. AMBIENT/CENTER REGISTER TEMPERATURE SPECIFICATIONS Ambient Temp. °F (°C) Center Register Temp. °F (°C) 60 (16) 33-47 (0.6-8) 70 (21) 33-47 (0.6-8) 80 (27) 33-47 (0.6-8) 90 (32) 33-47 (0.6-8) 100 (38) 36-48 (2-9)
2. Check For Normal Discharge Pressure Check and record ambient temperature and compressor discharge (high) pressure. Compare readings with «AMBIENT TEMPERATURE/DISCHARGE PRESSURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are within specifications, go to next step. If readings are not within specifications, go to step 8) . AMBIENT TEMPERATURE/DISCHARGE PRESSURE SPECIFICATIONS Ambient Temp. °F (°C) Discharge Pressure psi (kg/cm 2 ) 60 (16) 75-175 (5-12) 70 (21) 100-200 (7-14) 80 (27) 125-225 (9-16) 90 (32) 150-250 (11-18) 100 (38) 175-350 (12-25)
3. Check For Low Pressure Performance Check and record ambient temperature and compressor suction (low) pressure. Compare readings with «AMBIENT TEMPERATURE/SUCTION PRESSURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are within specifications, go to next step. If readings are not within specifications, go to step 6) . AMBIENT TEMPERATURE/SUCTION PRESSURE SPECIFICATIONS Ambient Temp. °F (°C) Suction Pressure psi (kg/cm 2 ) 60 (16) 24-45 (2-3) 70 (21) 24-45 (2-3) 80 (27) 24-45 (2-3) 90 (32) 24-45 (2-3) 100 (38) 38-60 (3-4)
4. Check For Slow Or Continuous Run Clutch Cycle Rate Check and record ambient temperature and total compressor clutch cycle time (time on plus time off) in seconds. Compare readings with «AMBIENT TEMPERATURE/CLUTCH CYCLE TIME SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are above upper limit of specifications, go to next step. If readings are within specifications, repair evaporator core for partial restriction or plugged condition. Retest system. AMBIENT TEMPERATURE/CLUTCH CYCLE TIME SPECIFICATIONS Ambient Temp. °F (°C) Clutch Cycle Time (Seconds) 60 (16) 28-50 70 (21) 30-65 80 (27) 45-120 90 (32) 95-Continuous
5. Check For Long Or Continuous Clutch Off Time Check and record ambient temperature and total compressor off time in seconds. Compare readings with «AMBIENT TEMPERATURE/CLUTCH OFF TIME SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are above upper limit of specifications, repair system for excessive moisture or refrigerant oil. Retest system. If the readings are within specifications, go to step 7) . AMBIENT TEMPERATURE/CLUTCH OFF TIME SPECIFICATIONS Ambient Temp. °F (°C) Clutch Off Time (Seconds) 60 (16) 17-24 70 (21) 14-23 80 (27) 2-17 90 (32) 2-3
6. Check For High Suction Pressure If readings in step 3) are above upper limit of specifications, repair evaporator core orifice for missing or damaged (leaking) "O" rings. Retest system. If readings in step 3) are below lower limit of specifications, replace A/C cycling switch for low cut-out condition. Retest system.
7. Check Ambient Temperature Refer to readings obtained in step 5) . If ambient temperature is above 80°F (27°C), this is normal operation for refrigerant system in high humidity conditions. If ambient temperature is not above 80°F (27°C), repair system for overcharge condition. Retest system.
8. Check For High Discharge Pressure Refer to readings obtained in step 2) . If reading is above upper limit of specification, go to next step. If reading is not above upper limit of specification, go to step 11) .
9. Check For Normal Low Pressure Check and record ambient temperature and compressor suction (low) pressure. Compare readings with «AMBIENT TEMPERATURE/SUCTION PRESSURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are within specifications, repair engine for overheating condition. Retest system. If readings are not within specifications, go to next step.
10. Check For Normal-To-Low Suction Pressure Refer to readings obtained in step 9) . If reading is below lower limit of specification, repair evaporator core orifice for partially restricted or plugged condition. Retest system. If reading is not below lower limit of specification, repair condenser core for partially blocked or inadequate air flow condition. Retest system.
11. Check For Normal Suction Pressure Check and record ambient temperature and compressor suction (low) pressure. Compare readings with «AMBIENT TEMPERATURE/SUCTION PRESSURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are within specifications, go to next step. If readings are not within specification, go to step 15) .
12. Check For Slow Clutch Cycle Rate Check and record ambient temperature and total compressor clutch cycle time (time on plus time off) in seconds. Compare readings with «AMBIENT TEMPERATURE/CLUTCH CYCLE TIME SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If readings are above upper limit of specification, repair evaporator-to-compressor suction line for partially restricted or plugged condition. Retest system. If readings are within specification, go to next step.
13. Check For Normal Clutch Off Time Check and record ambient temperature and total compressor off time in seconds. Compare readings with «AMBIENT TEMPERATURE/CLUTCH OFF TIME SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If reading is within specifications, repair evaporator core for low or restricted air flow. Retest system. If readings are not within specifications, go to next step.
14. Check For Long Clutch Off Time Refer to readings obtained in step 13) . If reading is above upper limit of specification, repair condenser core for partially or plugged condition. Retest system. If reading is not above upper limit of specification, repair system for low refrigerant condition.
15. Check For Missing Evaporator Core Orifice Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove condenser-to-evaporator tube. Check for presence of fixed orifice tube. If fixed orifice tube is missing, install new orifice tube. Retest system. If fixed orifice tube is not missing, replace A/C compressor. Retest system.

TEST E: NO OPERATION IN ALL TEMPERATURE SETTINGS

1. Check Electronic Blend Door Actuator Motor Start engine and allow it to reach normal operating temperature. Place function selector switch in MAX A/C position. Adjust blend door potentiometer (temperature knob) to full COOL position. Check for cool air discharge. Adjust blend door potentiometer (temperature knob) to full WARM position. Check for warm air discharge. Vary blend door actuator control from full WARM to full COOL. If air temperature changed, system is okay. If air temperature did not change, go to next step.
2. Check Fuse No. 13 (15-Amp) Turn ignition off. Check fuse No. 13 (15-amp) in instrument panel fuse block. If fuse is okay, go to next step. If fuse is blown, replace fuse. Retest system. If fuse blows again, check Pink/Black wire for short. Repair circuit as necessary. Retest system.
3. Check Voltage To Electronic Blend Door Actuator Motor Turn ignition off. Disconnect electronic blend door actuator motor connector. Turn ignition to run position (engine off). With a voltmeter, measure voltage between electronic blend door actuator motor connector Pink/Black wire and Black wire terminals. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open circuit in Pink/Black wire and/or Black wire. Retest system.
4. Check Control Potentiometer Voltage Turn ignition off. Reconnect electronic blend door actuator motor connector. Disconnect A/C temperature control switch connector. Turn ignition on. Using voltmeter, measure voltage between temperature control switch connector Red/Light Green wire and Red/White wire terminals. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, go to step 6).
5. Check Control Potentiometer Resistance Turn ignition off. Using ohmmeter, measure resistance between A/C temperature control switch Red/White wire and Yellow/Light Green wire terminals. If resistance is less than 100 ohms with switch at full COOL position, and approximately 10,000 ohms with switch at full WARM position, replace electronic blend door actuator motor. Retest system. If resistance is not as specified, replace temperature control switch. Retest system.
6. Check Red/Light Green Wire Circuit For Open Turn ignition off. Disconnect electronic blend door actuator control connector. With temperature control switch connector disconnected, measure resistance of Red/Light Green wire between blend door actuator control connector and temperature control switch connector. (Scheme 1) If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair Red/Light Green wire. Retest system.
7. Check Yellow/Light Green Wire Circuit For Open With ignition off and blend door actuator control and temperature control switch connectors still disconnected, measure resistance of Yellow/Light Green wire between blend door actuator control connector and temperature control switch connector. (Scheme 1) If resistance is less than 5 ohms, replace electronic blend door actuator. If resistance is more than 5 ohms, repair Yellow/Light Green wire. Retest system.

Scheme 1

TEST F: BLOWER MOTOR DOES NOT OPERATE

1. Check Fuse No. 13 (15-Amp) Turn ignition off. Check instrument panel fuse block fuse No. 13 (15-amp). If fuse is okay, go to next step. If fuse is blown, go to step 14) .
2. Check Fuse No. 13 (50-Amp) Turn ignition off. Check engine compartment fuse block fuse No. 13 (50-amp). If fuse is okay, go to next step. If fuse is blown, go to step 11) .
3. Check Voltage To Blower Motor Disconnect blower motor connector. Turn ignition to run position (engine off). Set function selector switch to FLOOR position. With a voltmeter, measure voltage of Orange/Red wire between blower motor connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, go to step 5) .
4. Check Blower Motor Ground Disconnect blower motor connector. Turn ignition to run position (engine off). With a voltmeter, measure voltage between Orange/Red wire and Black wire terminals of blower motor connector. If voltage is more than 4 volts, replace blower motor. Retest system. If voltage is less than 4 volts, repair open Orange/Black wire. Retest system.
5. Check Yellow Wire Circuit Voltage Turn ignition off. Disconnect blower motor relay, located in engine compartment fuse block. With a voltmeter, measure voltage of Yellow wire between blower motor relay cavity (in fuse block) and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open Yellow wire. Retest system.
6. Check Yellow/Red Wire Circuit Voltage Turn ignition to run position (engine off). Set function selector switch to FLOOR position. With a voltmeter, measure voltage of Yellow/Red wire between blower motor relay cavity (in fuse block) and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, go to step 9) .
7. Check Black Wire Circuit Resistance Turn ignition off. Using ohmmeter, measure resistance of Black wire between blower motor relay cavity (in fuse block) and ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair Black wire. Retest system.
8. Check Orange/Red Wire Circuit Resistance With ignition off, disconnect blower motor connector. Using ohmmeter, measure resistance of Orange/Red wire between blower motor relay cavity (in fuse block) and blower motor connector. If resistance is less than 5 ohms, replace blower motor relay. If resistance is more than 5 ohms, repair Orange/Red wire. Retest system.
9. Check Voltage To Function Selector Switch Turn ignition off. Disconnect function selector switch connector. Turn ignition to run position (engine off). With a voltmeter, measure voltage of Pink/Black wire between function selector switch connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair Pink/Black wire. Retest system.
10. Check Yellow/Red Wire Circuit Resistance Turn ignition off. Disconnect blower motor relay. Using ohmmeter, measure resistance of Yellow/Red wire between blower motor relay terminal in fuse block and function selector switch. If resistance is less than 5 ohms, replace function selector switch. Retest system. If resistance is more than 5 ohms, repair open in Yellow/Red wire. Retest system.
11. Check Blower Motor For Short Disconnect blower motor connector. Turn ignition to run position (engine off). Set function selector switch to FLOOR position. Measure resistance of Orange/Red wire between blower motor connector and ground. If resistance is more than 10,000 ohms, replace blower motor. Retest system. If resistance is less than 10,000 ohms, go to next step.
12. Check Orange/Red Wire Circuit For Short To Ground Turn ignition off. Disconnect blower motor relay connector. Measure resistance of Orange/Red wire between blower motor connector and ground. If resistance is more than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, repair short to ground in Orange/Red wire. Retest system.
13. Check Yellow Wire Circuit For Short To Ground Turn ignition off. Disconnect blower motor relay connector. Measure resistance of Yellow wire between blower motor relay terminal in fuse block and ground. If resistance is more than 10,000 ohms, replace blower motor relay. Retest system. If resistance is less than 10,000 ohms, repair short to ground in Yellow wire. Retest system.
14. Check Yellow/Red Wire Circuit For Short Turn ignition off. Disconnect blower motor relay connector and function selector switch connector. Measure resistance of Yellow/Red wire between function selector switch connector and ground. If resistance is more than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, repair short in Yellow/Red wire. Retest system.
15. Check Pink/Black Wire Circuit For Short To Ground Disconnect electronic blend door actuator connector. Measure resistance of Pink/Black wire between function selector switch connector and ground. If resistance is more than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, repair short to ground in Pink/Black wire. Retest system.
16. Check Electronic Blend Door Actuator Replace fuse No. 13 (15-amp) in instrument panel fuse block. Reconnect electronic blend door actuator connector. Turn ignition on. Check fuse No. 13. If fuse is okay, go to next step. If fuse is blown, replace electronic blend door actuator.
17. Check Function Selector Switch Turn ignition off. Reconnect function selector switch connector. Turn ignition on. Turn function selector switch to all positions. Check fuse No. 13. If fuse is okay, replace blower motor relay. If fuse is blown, go to «TEST C»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems__test-c-ac-does-not-operate) .

TEST G: BLOWER OPERATES CONTINUOUSLY IN HIGH SPEED

1. Check Orange/Black Wire Circuit For Short To Ground Turn ignition off. Disconnect blower motor connector. Disconnect blower motor resistor connector located on heater case in engine compartment. Set blower motor switch to LOW position. Using ohmmeter, measure resistance of Orange/Black wire between blower motor connector and ground. If resistance is more than 10,000 ohms, replace blower motor resistor. If resistance is less than 10,000 ohms, go to next step.
2. Check Blower Motor Switch Turn ignition off. Disconnect blower motor switch connector. Measure resistance of Orange/Black wire between blower motor switch connector and ground. If resistance is more than 10,000 ohms, replace blower motor switch. Retest system. If resistance is less than 10,000 ohms, repair short to ground in Orange/Black wire. Retest system.

TEST H: NO OPERATION IN HIGH BLOWER SETTING

1. Check Blower Motor Speed Turn ignition to run position (engine off). Place function selector switch in FLOOR position and place blower motor switch in HI position. If blower motor operates in HI position, check for intermittent problem. Retest system. If blower motor does not operate in HI, go to next step.
2. Check Blower Motor Switch Resistance Turn ignition off. Disconnect blower motor switch connector. With an ohmmeter, measure resistance between blower motor switch terminals. See «BLOWER MOTOR SWITCH RESISTANCE CHECK»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. If resistance is less than 5 ohms, repair open in Orange/Black wire. If resistance is more than 5 ohms, replace blower motor switch. Retest system.

BLOWER MOTOR SWITCH RESISTANCE CHECK

TEST J: INSUFFICIENT A/C COOLING (AUXILIARY A/C SYSTEM)

1. Check Mode Door Operation Turn ignition off. Remove rear lower body inside trim panel to access auxiliary A/C system. Start engine. Cycle function selector switch between FLOOR, NORM A/C and MAX A/C. Check mode door operation between heater core and evaporator core positions. If mode door operates properly, check A/C thermal expansion valve for proper operation. Replace valve if necessary. Retest system. If mode door does not operate properly, go to next step.
2. Check Vacuum Source Turn ignition off. Disconnect auxiliary vacuum control motor. Connect vacuum tester to supply hose. Start engine. Cycle function selector switch between FLOOR, NORM A/C and MAX A/C. Measure vacuum. If vacuum is between 12-18 in. Hg, go to next step. If vacuum is less than 12 in. Hg, or more than 18 in. Hg, locate and repair vacuum hose restriction or leak. Retest system.
3. Check Vacuum Control Motor Turn ignition off. Connect vacuum tester to auxiliary vacuum control motor. Apply 12-18 in. Hg of vacuum to motor. Check for vacuum drop. If vacuum drops, replace vacuum control motor. Retest system. If vacuum holds, check for a sticking mode door and repair as necessary. Retest system.

TEST K: AUXILIARY BLOWER MOTOR DOES NOT OPERATE (WITHOUT REAR AUXILIARY BLOWER MOTOR SWITCH)

1. Check Fuse No. 16 (50-Amp) Check fuse No. 16 (50-amp), in power distribution box, in engine compartment. If fuse is okay, go to next step. If fuse is blown, go to step 14) .
2. Check Voltage To Auxiliary Blower Motor Turn ignition off. Disconnect auxiliary blower motor connector. Turn ignition to run position (engine off). Set function selector switch to FLOOR position. Set auxiliary blower motor switch to HI position. With a voltmeter, measure voltage of Pink/White wire between auxiliary blower motor connector and ground. If voltage is more than 10 volts, go to step 7) . If voltage is less than 10 volts, go to next step.
3. Check Voltage To Auxiliary Blower Motor Relay Turn ignition off. Disconnect auxiliary blower motor relay. Turn ignition to run position (engine off). Measure voltage of Yellow/Black wire between auxiliary blower motor relay connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open Yellow/Black wire. Retest system.
4. Check Pink/White Wire Circuit Turn ignition off. Using ohmmeter, measure resistance of Pink/White wire between auxiliary blower motor relay connector and auxiliary blower motor connector. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Pink/White wire. Retest system.
5. Check Yellow/Red Wire Circuit Turn ignition on. Set function selector switch to FLOOR position. Using voltmeter, measure voltage of Yellow/Red wire between auxiliary blower motor relay connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open Yellow/Red wire. Retest system.
6. Check Black Wire Of Blower Relay Circuit For Open Turn ignition off. Measure resistance of Black wire between auxiliary blower motor relay connector and ground. If resistance is less than 5 ohms, replace auxiliary blower motor relay. Retest system. If resistance is more than 5 ohms, repair open in Black wire. Retest system.
7. Check Auxiliary Blower Motor Ground Turn ignition on. Using voltmeter, measure voltage between Pink/White wire and Orange/Black wire terminals at blower motor connector. If voltage is more than 4 volts, replace blower motor. Retest system. If voltage is less than 4 volts, go to next step.
8. Check Black Wire Circuit Turn ignition off. Disconnect auxiliary high blower motor relay. Using ohmmeter, measure resistance of Black wire between auxiliary blower motor relay connector and ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Black wire. Retest system.
9. Check Orange/Black Wire Circuit Measure resistance of Orange/Black wire between auxiliary blower motor connector and auxiliary high blower motor relay connector. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Orange/Black wire. Retest system.
10. Check Yellow/Red Wire Circuit Turn ignition on. Set function selector switch to FLOOR position. Using voltmeter, measure voltage of Yellow/Red wire between auxiliary high blower motor relay connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open Yellow/Red wire. Retest system.
11. Check Red/White Wire Circuit Turn ignition off. Set auxiliary blower motor switch to HI position. Using ohmmeter, measure resistance of Red/White wire between auxiliary high blower motor relay connector and ground. If resistance is less than 5 ohms, replace auxiliary high blower motor relay. Retest system. If resistance is more than 5 ohms, go to next step.
12. Check Black Circuit From Auxiliary Blower Motor Switch Disconnect auxiliary blower motor switch. Measure resistance of Black wire between auxiliary blower motor switch connector and ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Black wire. Retest system.
13. Check Red/White Wire Circuit For Open Measure resistance of Red/White wire between auxiliary high blower motor relay connector and auxiliary blower motor switch connector. If resistance is less than 5 ohms, replace auxiliary blower motor switch. If resistance is more than 5 ohms, repair open Red/White wire. Retest system.
14. Check Auxiliary Blower Motor For Short Disconnect auxiliary blower motor connector. Turn ignition on. Set function selector switch to FLOOR position. Measure resistance of Pink/White wire between auxiliary blower motor connector and ground. If resistance is less than 10,000 ohms, go to next step. If resistance is more than 10,000 ohms, replace blower motor. Retest system.
15. Check Pink/White Wire Circuit For Short To Ground Turn ignition off. Disconnect auxiliary blower motor relay. Measure resistance of Pink/White wire between auxiliary blower motor connector and ground. If resistance is more than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, repair short to ground in Pink/White wire. Retest system.
16. Check Yellow/Black Wire Circuit For Short To Ground If equipped, disconnect remote keyless entry module connector (located in trim panel, behind front door). With an ohmmeter, measure resistance of Yellow/Black wire between auxiliary blower motor relay connector and ground. If resistance is more than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, repair Yellow/Black wire. Retest system.
17. Check Remote Keyless Entry Module (If Equipped) Reconnect remote keyless entry module. Turn ignition on. Replace fuse No. 16 (50-amp) in power distribution center. If fuse blows, replace remote keyless entry module. If fuse does not blow, replace auxiliary blower motor relay. Retest system.

TEST L: AUXILIARY BLOWER MOTOR DOES NOT OPERATE (WITH REAR AUXILIARY BLOWER MOTOR SWITCH)

1. Check Rear Auxiliary Heater Blower Motor Switch Turn ignition off. Disconnect rear auxiliary blower motor switch connector. Turn front auxiliary blower motor switch to REAR CTRL position. With an ohmmeter, measure resistance of Light Green/White wire between rear auxiliary blower motor switch connector and ground. If resistance is more than 5 ohms, go to next step. If resistance is less than 5 ohms, replace rear auxiliary heater blower motor switch. Retest system.
2. Check Front Auxiliary Blower Motor Switch Measure resistance of Light Green/White wire between front auxiliary blower motor switch connector and rear auxiliary blower motor switch connector. If resistance is less than 5 ohms, replace front auxiliary blower motor switch. Retest system. If resistance is more than 5 ohms, repair open Light Green/White wire. Retest system.

TEST M: FRONT AUXILIARY BLOWER MOTOR SWITCH OPERATES ONLY IN HIGH

1. Check Auxiliary High Speed Blower Motor Relay Turn ignition off. Remove rear lower body inside trim panel to access auxiliary A/C system. Disconnect auxiliary high speed blower motor relay. Turn front auxiliary heater blower motor switch to medium-high position. Using ohmmeter, measure resistance of Orange/Red wire between auxiliary high speed blower motor relay and ground. If resistance is more than 5 ohms, go to next step. If resistance is less than 5 ohms, replace auxiliary high speed blower motor relay.
2. Check Orange/Red Wire Circuit Disconnect auxiliary heater blower motor switch resistor connector. Using ohmmeter, measure resistance of Orange/Red wire between blower motor switch resistor connector and auxiliary blower motor relay connector. If resistance is less than 5 ohms, replace blower motor switch resistor. Retest system. If resistance is more than 5 ohms, repair open Orange/Red wire. Retest system.

TEST N: REAR AUXILIARY BLOWER MOTOR SWITCH OPERATES ONLY IN HIGH

1. Check Auxiliary High Speed Blower Motor Relay Turn ignition off. Remove rear lower body inside trim panel to access auxiliary A/C system. Disconnect auxiliary high speed blower motor relay connector. Turn front auxiliary heater blower motor switch to REAR CTRL position. Turn rear auxiliary blower motor switch to medium-low position. Using ohmmeter, measure resistance of Orange/Red wire between auxiliary high speed blower motor relay and ground. If resistance is more than 5 ohms, go to next step. If resistance is less than 5 ohms, replace auxiliary high speed blower motor relay. Retest system.
2. Check Orange/Red Wire Circuit Disconnect auxiliary heater blower switch resistor connector. Measure resistance of Orange/Red wire between auxiliary blower motor switch resistor connector and high speed blower motor relay connector. If resistance is less than 5 ohms, replace blower motor switch resistor. Retest system. If resistance is more than 5 ohms, repair open Orange/Red wire. Retest system.

TEST P: FRONT AUXILIARY BLOWER MOTOR SWITCH DOES NOT OPERATE IN HIGH

1. Check Yellow/Red Wire Circuit Turn ignition off. Remove rear lower body inside trim panel to access auxiliary A/C system. Disconnect auxiliary high speed blower motor relay connector. Set function selector switch to FLOOR position. Using voltmeter, measure voltage of Yellow/Red wire between auxiliary high speed blower motor relay connector and ground. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open Yellow/Red wire. Retest system.
2. Check Black Wire Circuit Turn ignition off. Measure resistance of Black wire between auxiliary high speed blower motor relay connector and ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Black wire. Retest system.
3. Check Auxiliary High Speed Blower Motor Relay Turn front auxiliary blower motor switch to HI position. Measure resistance of Red/White wire between auxiliary high speed blower motor relay connector and ground. If resistance is less than 5 ohms, replace auxiliary high speed blower motor relay. If resistance is more than 5 ohms, go to next step.
4. Check Red/White Wire Circuit Disconnect front auxiliary heater blower motor switch connector. Measure resistance of Red/White wire between front auxiliary heater blower motor switch connector and auxiliary high speed blower motor relay connector. If resistance is less than 5 ohms, replace front auxiliary heater blower motor switch. If resistance is more than 5 ohms, repair open Red/White wire. Retest system.

Check Rear Auxiliary Heater Blower Motor Switch

Turn ignition off. Disconnect rear auxiliary heater blower motor switch connector. Disconnect auxiliary high speed blower motor relay connector. Using ohmmeter, measure resistance of Red/White wire between auxiliary heater blower motor switch connector and auxiliary high speed blower motor relay connector. If resistance is less than 5 ohms, replace auxiliary heater blower motor switch. Retest system. If resistance is more than 5 ohms, repair open Red/White wire between splice (located along left "B" pillar, near roof) and rear auxiliary blower motor switch connector. Retest system.

TESTING

A/C SYSTEM PERFORMANCE

1. Park vehicle in shade. Connect manifold gauge set. Start engine and run at 1500 RPM. Set A/C controls to MAX A/C position and temperature control at full cold.
2. Set blower/fan on high speed, and close doors and windows. Insert thermometer in center vent. Operate system for 10-15 minutes to allow system to stabilize. Measure temperature at center vent.
3. Temperature must be 33-47°F (0.6-8°C) at center vent, with high side and low side pressures within specification. See «A/C SYSTEM HIGH SIDE PRESSURE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) table. Low side pressure remains constant at 25-45 psi (1.8-3.2 kg/cm 2 ) throughout normal operating range.

A/C SYSTEM HIGH SIDE PRESSURE SPECIFICATIONS

AUXILIARY BLOWER MOTOR SWITCH

Remove control switch from overhead console. See REAR (AUXILIARY) CONTROL PANEL under REMOVAL & INSTALLATION. Check for continuity in all switch positions. See AUXILIARY BLOWER MOTOR SWITCH CONTINUITY table. If continuity is not as specified, replace auxiliary blower motor switch.

AUXILIARY BLOWER MOTOR SWITCH CONTINUITY

REMOVAL & INSTALLATION

Note. For removal and installation procedures not covered in this article, see HEATER SYSTEMS - "E" SERIES article.

Disconnect A/C cycling switch connector at top of accumulator-drier. Remove switch from accumulator-drier. To install, reverse removal procedure. Use new "O" ring coated with clean refrigerant oil.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove battery and battery tray. Disconnect pressure switch connector. Disconnect refrigerant lines from accumulator-drier. Remove retaining screws and accumulator-drier. Cap all openings.
2. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Evacuate, charge, and leak test A/C system.

1. Remove third, fourth and fifth bench seats (if equipped). Drain cooling system. Disconnect heater hoses located under left side of body. Remove trim. Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Disconnect refrigerant lines. (Scheme 2) Disconnect rear A/C-heater assembly harness connectors. Remove mounting bolts, and lift assembly off locating dowel pin. Remove heater assembly while guiding heater hoses through from underbody. To install, reverse removal procedure.

Scheme 2

Removal & Installation (Main System)

Disconnect negative battery cable. Remove battery and battery tray, if necessary. Remove accumulator-drier. See ACCUMULATOR-DRIER . Disconnect electrical leads from blower motor. Remove 4 blower mounting plate-to-evaporator case screws. Remove blower motor and wheel assembly from evaporator case. To install, reverse removal procedure.

Removal & Installation (Auxiliary System)

1. Disconnect negative battery cable. Remove third, fourth and fifth bench seats (if equipped). Remove trim panels as necessary to access auxiliary A/C-heater assembly.
2. Disconnect electrical leads from blower motor. Remove 4 blower mounting plate-to-evaporator case screws. Remove blower motor and wheel assembly from evaporator case. To install, reverse removal procedure.

Pull wiring harness connector from resistor assembly (located on evaporator case, in engine compartment). Remove 2 resistor attaching screws, and remove resistor from evaporator case. To install, reverse removal procedure.

1. Remove third, fourth and fifth bench seats (if equipped). Remove auxiliary A/C-heater cover attaching screws, and remove cover. Disconnect wiring harness from resistor. Remove retaining bolts from resistor assembly.
2. To install, reverse removal procedure. DO NOT touch resistor coils when installing assembly. Ensure cover seal is positioned correctly to prevent air leakage.

CONDENSER

Note. If condenser leak is suspected, leak test condenser before removing condenser.

1. Condenser is mounted forward of radiator, attached to radiator support. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect compressor-to-condenser discharge line and condenser-to-evaporator tube from condenser core. Cap all openings.
2. Remove air deflector. On models with 4.2L engine, remove discharge line isolator mounting screw. Position isolator aside.
3. On all models, remove right and left side top radiator mounting bracket bolts. Loosen bottom right and left side radiator bracket bolts. Carefully push top part of radiator rearward.
4. Remove bolts retaining top of condenser core to radiator upper support. Lift condenser from vehicle. Remove both seals from condenser. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system.

1. Disconnect negative battery cable. Remove trim plate. Remove control panel mounting bracket. Carefully pull control panel from mounting bracket. Disconnect connectors from blower switches, function selector valve and illumination bulb. Remove push-on retaining clips from function selector valve harness.
2. Disconnect vacuum harness from function selector valve. Using needle nose pliers to compress retainer ears, disconnect bullet-type selector cable retainer from bracket. To install, reverse removal procedure. Use new vacuum harness push-on clips during installation.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove auxiliary battery (if equipped). Loosen oil filler tube support bracket bolt and move tube aside. Remove windshield washer reservoir. On models with 4.2L engine, remove discharge line isolator mounting screw. Position isolator aside.
2. On all models, disconnect refrigerant line from accumulator-drier. Disconnect refrigerant line from evaporator inlet. Cap all openings. Remove evaporator support bracket. Remove evaporator cover. Remove evaporator and seal assembly.
3. To install, reverse removal procedure. Use new "O" rings as required. Ensure proper length screws go into respective evaporator support bracket holes. Evacuate, charge, and leak test A/C system.

1. Remove third, fourth and fifth bench seats (if equipped). Remove auxiliary A/C-heater cover. Discharge A/C system using approved refrigerant recovery/recycling equipment.
2. Disconnect suction line from evaporator core and refrigerant line from expansion valve, and cap openings. Position heater core heater hoses aside. Remove evaporator cover.
3. Remove evaporator core mounting bracket screws from auxiliary case assembly. Remove expansion valve and mounting bracket from evaporator core. Remove evaporator core and mounting bracket from case assembly.
4. To install, reverse removal procedure. Use new "O" rings lubricated with clean refrigerant oil. Evacuate, charge, and leak test A/C system. Ensure cover seal is positioned correctly to prevent air leakage.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove auxiliary battery (if equipped). Disconnect liquid line from evaporator core. Squirt a small amount of clean refrigerant oil into evaporator core to lubricate fixed orifice tube.
2. Using Fixed Orifice Tube Remover/Replacer (T83L-19990-A), remove fixed orifice tube from evaporator core. DO NOT break tube.
3. Install fixed orifice tube using fixed orifice tube remover/replacer. Install refrigerant line retaining nuts and bolts. Evacuate, charge, and leak test A/C system.

Disconnect negative battery cable. Remove center instrument trim panel. Remove 2 screws attaching A/C control panel and remove control panel. Remove function selector switch control knob. From rear of control panel, disconnect function selector switch electrical connector. Remove function selector switch attaching screw and remove switch. To install, reverse removal procedure.

1. Drain cooling system. Remove coolant hoses from heater core in engine compartment, and plug hoses. Remove trim panel from lower edge of dash.
2. Remove 7 screws from heater core covers. Remove heater core and seal from case. (Scheme 3) To install, reverse removal procedure. Fill cooling system.

1. Remove third, fourth and fifth bench seats (if equipped). Remove auxiliary heater cover attaching screws, and remove cover assembly. Remove strap retaining heater core in auxiliary heater case.
2. Drain coolant from radiator. Disconnect heater hoses from auxiliary heater core. Plug openings. Disengage wire assembly from auxiliary heater core seal. Slide heater core and seal assembly out of case. To install, reverse removal procedure.

Scheme 3

Carefully pry control panel away from overhead console. Disconnect light and blower motor switch connectors from switch. Remove control knob. Remove screw and blower motor switch. To install, reverse removal procedure.

1. Remove third, fourth and fifth bench seats (if equipped). Remove auxiliary A/C-heater cover assembly. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove evaporator core. See «EVAPORATOR CORE»(/ford/econoline/i-1985-2013/remont/manual-hvac-system/#manual-ac-heater-systems) . Remove insulating tape from thermocouple. Remove thermocouple.
2. Using 2 wrenches, disconnect refrigerant lines from expansion valve. Using 2 wrenches, remove expansion valve from evaporator core inlet tube. Cap all openings.
3. To install, reverse removal procedure. Use new "O" rings lubricated with clean refrigerant oil. Evacuate, charge, and leak test A/C system. Ensure cover seal is positioned correctly to prevent air leakage.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 4

Manual A/C-Heater System Wiring Diagram ("E" Series - 1 Of 2). Scheme 5

Manual A/C-Heater System Wiring Diagram ("E" Series - 2 Of 2). Scheme 6

See also:
• SYMPTOM DIAGNOSIS
• TEST A
• TEST B
• TEST C
• TEST D
• TEST J
• TEST E
• TEST F
• TEST G
• TEST H
• TEST K
• TEST L
• TEST M
• TEST N
• TEST P
• TEST Q