HVAC Control System - General Information: Diagnosis Ford Escape I рестайлинг

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical A/C compressor A/C compressor drive belt A/C clutch Vacuum lines Vacuum control motor Refrigerant lines Coolant level Heater hoses Radiator Condenser Suction accumulator Battery junction box (BJB) fuses: 14 (15A) 18 (40A) Smart junction box (SJB) fuse 26 (5A) Engine cooling fans Blower motor Circuitry
3. As pinpoint tests and measurements are being carried out, be sure to inspect for any disconnected, loose-fitting, or incorrectly installed component, module, or in-line electrical connectors and pins.
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
5. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position.
6. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
7. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: CAN or ISO circuit fault; all electronic control units no response/not equipped, refer to «MODULE COMMUNICATIONS NETWORK»(ref-232245) . No response/not equipped for the PCM, refer to «MODULE COMMUNICATIONS NETWORK»(ref-232245) . System passed; retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the PCM.
8. If the DTCs retrieved are related to the concern, go to the «POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-232279-S10082640172006051600000) .
9. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(ref-232279-S38743027192006051600000) .

POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX

Symptom Chart

SYMPTOM CHART

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PINPOINT TEST A: INCORRECT/ERRATIC DIRECTION OF AIR FLOW FROM OUTLET(S)

Note. Because of the materials used in construction of the vacuum hoses, never pinch off the vacuum hoses to locate a leak during diagnosis. A golf tee can be used as a plug when it is necessary to plug one end of a vacuum hose for leak test purposes.

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1. A1 CHECK THE SYSTEM AIRFLOW Key in ON position. With the engine running, set the blower motor speed to maximum. Check for correct airflow in each function selector position at engine idle. Is there airflow only from the defroster outlets in each function switch position? Yes : GO to A2. No : GO to A13 .
2. A2 CHECK THE VACUUM SUPPLY HOSE CONNECTIONS Key in OFF position. Check for a disconnected vacuum supply hose between the engine intake manifold and the A/C vacuum reservoir. Is the hose disconnected? Yes : CONNECT the hose. TEST the system for normal operation. No : GO to A3.
3. A3 CHECK THE SUPPLY HOSE FOR BLOCKAGE Disconnect: Vacuum Reservoir. Connect a vacuum pump to the reservoir side of the supply hose and try to pull a vacuum. If the pump can pull a vacuum, the hose is plugged. If the pump pulls a partial vacuum, the hose is restricted. Is the hose plugged or restricted? Yes : INSTALL a new supply hose. TEST the system for normal operation. No : CONNECT the vacuum hose. GO to A4.
4. A4 LEAK CHECK THE VACUUM SUPPLY HOSE Disconnect: Vacuum Supply Hose. Plug the intake manifold end of the supply hose and connect the vacuum pump to the reservoir side of the supply hose. Apply a vacuum to the hose while checking for leaks. Does the hose leak? Yes : INSTALL a new vacuum hose. TEST the system for normal operation. No : CONNECT the vacuum supply hose to the intake manifold. GO to A5.
5. A5 CHECK THE VACUUM CHECK VALVE START the vehicle. Check the A/C vacuum check valve for blockage by removing the reservoir hose from the A/C vacuum check valve. Check for vacuum. Is vacuum available at the check valve port? Yes : GO to A6. No : INSTALL a new A/C vacuum check valve. TEST the system for normal operation.
6. A6 LEAK TEST THE VACUUM CHECK VALVE Key in OFF position. Disconnect: A/C Vacuum Check Valve. Connect the A/C vacuum check valve to a vacuum pump. Pump 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 valve from the pump and plug the vacuum hose. Pull a vacuum with the pump to be certain that the hose and pump are not the cause of the leak. Does the A/C vacuum check valve 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 : CONNECT the A/C vacuum check valve. GO to A7.
7. A7 CHECK THE VACUUM RESERVOIR Disconnect: A/C Vacuum Reservoir Tank. 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 : GO to A8.
8. A8 CHECK THE VACUUM SUPPLY HOSE FOR LEAKS Disconnect: Function Selector Switch Vacuum Harness. Plug the vacuum supply hose at the supply connection. Use a vacuum pump to leak test the vacuum harness supply hose. Does the vacuum harness supply hose leak? Yes : REPAIR or INSTALL a new vacuum harness. TEST the system for normal operation. No : CONNECT the vacuum harness. GO to A9.
9. A9 CHECK THE FUNCTION SELECTOR SWITCH Disconnect: In-Line Vacuum Harness. Disconnect: In-Line Vacuum Supply Harness. Plug the four vacuum ports in the function selector switch side of the in-line vacuum harness. Connect a vacuum pump to the black hose of the in-line supply harness, function selector switch side. At each function selector switch position, apply 51 kPa (15 in-Hg) of vacuum and check for vacuum leakage. Does the vacuum leakage exceed 3.37 kPa (1 in-Hg) per minute? Yes : NOTE the function selector switch position(s) where the vacuum leaks occurred and GO to A11 . No : CONNECT the in-line vacuum harness connectors. GO to A10.
10. A10 CHECK THE VACUUM SUPPLY HOSE FOR BLOCKAGE Disconnect: Function Selector Switch Vacuum Harness. Connect a vacuum pump to the function selector switch supply hose and try to pull a vacuum. If the pump can pull a vacuum, the hose is plugged. If the pump pulls a partial vacuum, the hose is restricted. Is the hose plugged or restricted? Yes : INSTALL a new vacuum harness. TEST the system for normal operation. No : CONNECT the function selector switch vacuum harness. GO to A15 .
11. A11 LEAK TEST THE FUNCTION SELECTOR SWITCH Disconnect: Function Selector Switch Vacuum Harness. Connect a vacuum pump to the function selector switch vacuum supply port and plug the control port that indicated a leak in Step A9 . Does the vacuum drop exceed 1.68 kPa (0.5 in-Hg) per minute? Yes : INSTALL a new function selector switch. REFER to «CONTROL COMPONENTS»(ref-232280) . TEST the system for normal operation. No : GO to A12.
12. A12 LEAK TEST THE JUMPER VACUUM HARNESS 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. Is there vacuum leakage? Yes : REPAIR or INSTALL a new vacuum jumper harness. TEST the system for normal operation. No : INSTALL a new function selector switch. REFER to «CONTROL COMPONENTS»(ref-232280) . TEST the system for normal operation.
13. A13 EVALUATE THE SYSTEM AIRFLOW Evaluate the system airflow; refer to «PRINCIPLES OF OPERATION»(ref-232279-S04561579052006051600000) , «SYSTEM AIR FLOW DESCRIPTION»(ref-232279-S30137361152006051600000) . Is the airflow in Step A1 correct for each function selector switch position? Yes : GO to A14. No : GO to A15 .
14. A14 ISOLATE THE LEAKING VACUUM CIRCUIT(S) Check for correct airflow in each function selector switch position during engine acceleration. Does the airflow go to the defroster outlets during acceleration in all function selector switch positions? Yes : GO to A15. No : The system is OK.
15. A15 CHECK THE VACUUM HARNESS Compare the vacuum hose color in each vacuum harness to the Function Selector Switch Vacuum Connector end view. Does the hose color agree with the chart? Yes : GO to A16. No : INSTALL a new vacuum harness. TEST the system for normal operation.
16. A16 CHECK THE A/C VACUUM CIRCUIT(S) Check the A/C vacuum circuit for a pinched or kinked vacuum hose. Is the hose pinched or kinked? Yes : REPOSITION the vacuum hose. TEST the system for normal operation. No : GO to A17.
17. A17 CHECK THE VACUUM CIRCUIT CONNECTIONS Check each vacuum hose connection to determine if it is partially connected or disconnected. Is a vacuum hose disconnected or partially connected? Yes : CONNECT the hose. TEST the system for normal operation. No : GO to A18.
18. A18 CHECK THE VACUUM HOSE Disconnect: Function Selector Switch Vacuum Harness. Disconnect the suspect hose at the respective vacuum motor. Plug one end of the hose and attach a vacuum pump to the other end. Check for a leak in the hose. Does the vacuum hose leak? Yes : REPAIR or INSTALL a new hose. TEST the system for normal operation. No : GO to A19.
19. A19 CHECK THE VACUUM CONTROL MOTOR Disconnect: Vacuum Control Motor. Connect a vacuum pump to the vacuum control motor. Apply 51 kPa (15 in-Hg) of vacuum. Does the vacuum drop exceed 1.68 kPa (0.5 in-Hg) per minute? Yes : INSTALL a new vacuum control motor. REFER to «CONTROL COMPONENTS»(ref-232280) . TEST the system for normal operation. No : GO to A20.
20. A20 CHECK THE VACUUM CONTROL MOTOR INSTALLATION Check the attachment of the vacuum control motor arm to the damper door. Is the vacuum control motor arm attached to the door or the door crank arm? Yes : REPAIR the damper door. TEST the system for normal operation. No : CONNECT the vacuum control motor arm to the door crank arm. TEST the system for normal operation.

Heater Core - Pressure Test

Use the pressure tester to carry out the pressure test.

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1. Clamp off the heater hoses.
2. Disconnect the heater water hoses from the heater core.
3. Install a short piece of heater water hose approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the pressure tester in the heater water hose ends. Secure the heater water hoses, the plug, and the adapter with hose clamps.
5. Attach the pump and gauge assembly from the 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 3 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.

Scheme 99

1. Remove the heater core from the vehicle. For additional information, refer to «HEATING AND VENTILATION»(ref-232228) .
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 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.

A/C Evaporator/Condenser Core - On Vehicle Leak Test

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-232279-S03696491132006051600000) .
2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. For additional information, refer to «HVAC SYSTEM - AIR CONDITIONING»(ref-232213) .
3. Clean the spring lock couplings. For additional information, refer to «SPRING LOCK COUPLING»(ref-232279-S08244578212006051600000) .
4. Connect the appropriate test fittings from the A/C Fittings Set to the evaporator or condenser tube connections.
5. Connect the red and blue hoses from the R-134a gauge 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 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 A/C evaporator core or A/C 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 A/C evaporator core 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 (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 the 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 check for a loss of vacuum. If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for a vacuum loss.
9. If the A/C evaporator core or A/C condenser core leaks, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. For additional information, refer to «HVAC SYSTEM - AIR CONDITIONING»(ref-232213) .

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 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 the entire A/C compressor for leaks.
7. If an external leak is found, install a new A/C compressor. For additional information, refer to «HVAC SYSTEM - AIR CONDITIONING»(ref-232213) .
8. When the leak test is complete, recover the refrigerant from the compressor.

Diagnostic Table

1. Proceed to the diagnostic table.

REFRIGERANT SYSTEM DIAGNOSTIC TABLE

Scheme 100

1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley.
2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification.