HVAC System - General Information and Diagnostics Ford Explorer Sport Trac II

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

a Manifold gauge set pressures may vary slightly depending on the distance between the service gauge port valve and the A/C pressure relief valve, the A/C cycling switch and the pressure cutoff switch location.

Climate Control System

Note. To avoid damaging the vehicle or air conditioning (A/C) components, the following precautions must be observed. The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging. Failure to do so can contaminate the shop bulk refrigerant and other vehicles. Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These 2 types of refrigerant must never be mixed. Doing so can damage the A/C system. Charge the A/C system with the engine running only at the low-pressure side to prevent refrigerant slugging from damaging the A/C compressor. Use only R-134a refrigerant. Due to environmental concerns, when the A/C system is drained, the refrigerant must be collected using refrigerant recovery/recycling equipment. Federal, State/Provincial and/or local laws REQUIRE that R-134a be recovered into appropriate recovery equipment and the process be conducted by qualified technicians who have been certified by an approved organization, such as ASE or Mobile Air Conditioning Society (MACS). Use of a recovery machine dedicated to R-134a is necessary to reduce the possibility of oil and refrigerant incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the A/C system. Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other purpose above atmospheric pressure. R-134a is combustible when mixed with high concentrations of air and higher pressures. A number of manufacturers are producing refrigerant products that are described as direct substitutes for Refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely damage the A/C components. If repair is required, use only new or recycled Refrigerant R-134a.

Note. To avoid contamination of the air conditioning (A/C) system: Never open or loosen a connection before recovering the refrigerant. When loosening a connection, if any residual pressure is evident, allow it to leak out before opening the fitting. Evacuate a system that has been opened to install a new component or one that has discharged through leakage before charging. Seal open fittings with a cap or plug immediately after disconnecting a component from the system. Clean the outside of the fittings thoroughly before disconnecting a component from the system. Do not remove the sealing caps from a new component until ready to install. Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil container until ready to use and install the cap immediately after using. Store the oil in a clean, moisture-free container. Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with mineral oil before connecting. When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any sharp edges that can chafe the line. Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the refrigerant system will not tolerate overtightening. When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the refrigerant lines or tubes. Do not open a refrigerant system or uncap a new component unless it is as close as possible to room temperature. This will prevent condensation from forming inside a component that is cooler than the surrounding air.

The manual climate control system heats or cools the vehicle depending on the function selector switch position and the temperature selected.

1. The function selector switch position determines heating or cooling, air distribution and enables blower motor operation.
2. The temperature control setting determines the air temperature.
3. The blower motor switch varies the blower motor speed.

The Dual Automatic Temperature Control (DATC) system maintains the selected vehicle interior temperature by heating and/or cooling the air.

1. During A/C operation the system also reduces the relative humidity of the air.
2. The driver may override the automatic mode of operation.
3. The driver side and passenger side temperature settings can be individually controlled.

The system components are the following

1. A/C compressor
2. A/C compressor clutch assembly
3. A/C condenser core
4. A/C evaporator core
5. Suction accumulator
6. Connecting refrigerant lines
7. A/C evaporator core orifice
8. A/C cycling switch
9. A/C pressure transducer
10. Heater core and evaporator core housing
11. HVAC module - DATC
12. Manual climate control assembly
13. Blower switch (manual system)
14. Temperature blend door actuator(s)
15. Blower motor resistor or speed control module
16. Blower motor
17. Ambient temperature sensor
18. In-vehicle temperature sensor
19. Solar radiation sensor
20. Auxiliary connecting refrigerant lines
21. Auxiliary heater core and evaporator core housing
22. Auxiliary A/C evaporator core
23. Auxiliary climate control assembly
24. Auxiliary blower motor
25. Auxiliary blower motor resistor

Manual Climate Control System

The manual climate control system operation is determined by the settings on the climate control assembly. The climate control assembly includes a serviceable function selector switch and blower motor switch. The temperature control switch, A/C request switch and rear window defrost switch are integral to the climate control assembly and are serviced as an assembly.

The blower motor switch

1. sets the front blower motor speed.
2. directs the blower motor path to ground through the blower motor resistor to allow blower motor operation in LO, MED-LO and MED-HI.
3. actuates the high speed blower motor relay, giving the blower motor a direct path to ground which allows the blower motor to operate in HI.

The temperature control switch

1. is a potentiometer that outputs a variable voltage to the temperature blend door actuator to set the position of the temperature blend door.
2. initiates closing of the heater control valve. When set to full COOL, a lever on the temperature blend door pivot shaft depresses the pintle of the heater control valve vacuum switch. The heater control valve vacuum switch then applies vacuum to the heater control valve, closing off engine coolant flow to the heater core.
3. is serviced only with the climate control assembly.

The function selector switch setting

1. determines where the system airflow is directed.
2. enables blower motor operation.
3. enables auxiliary blower motor operation, if equipped, by supplying voltage to the auxiliary blower motor relay.
4. commands A/C compressor operation in MAX A/C, FLOOR/DEFROST and DEFROST.

The A/C request switch

1. can command the A/C compressor on when the function selector switch is in PANEL, FLOOR/PANEL and FLOOR when the A/C request switch is pressed.
2. is inoperative in MAX A/C, OFF, FLOOR/DEFROST and DEFROST.
3. indicator illuminates when the function selector switch is in MAX A/C and cannot be toggled.
4. indicator does not illuminate in OFF and cannot be toggled.
5. indicator does not illuminate in FLOOR/DEFROST and DEFROST and cannot be toggled. The A/C compressor will not operate if the outside air temperature is below -1°C (30°F). The A/C compressor will resume operation when the outside air temperature rises above 2°C (35°F).
6. is serviced only with the climate control assembly.

Dual Automatic Temperature Control (DATC) System

The DATC system maintains the selected vehicle interior temperature by heating and/or cooling the air.

1. During A/C operation the system also reduces the relative humidity of the air.
2. The driver may override the automatic mode of operation.
3. The temperature control setting determines the desired air temperature.
4. The blower motor control override buttons vary the blower motor speed.
5. The driver side and passenger side temperature settings can be individually controlled.

The DATC system operation is determined by the settings on the HVAC module - DATC. The DATC system automatically maintains a selected temperature for vehicle interior comfort, including capabilities to maintain separate temperature settings for the driver and front passenger. The electronic temperature control capabilities are achieved by splitting the air distribution system internally and utilizing 2 individually operated temperature blend doors. The DATC system is composed of the HVAC module - DATC, solenoid and manifold assembly, blower motor speed control, 4 vacuum control motors, 2 temperature blend door actuators, in-car temperature sensor, ambient air temperature sensor and solar radiation sensor to control the various functions.

When the HVAC module - DATC is set to AUTO

1. the air distribution direction, heater control valve operation and blower motor speed are automatically controlled based on the temperature(s) selected.

The HVAC module - DATC manual override settings

1. allow the air distribution direction to be manually selected.
2. allow the blower motor speed to be manually selected.
3. allow RECIRCULATION mode to be manually selected except in FLOOR/DEFROST and DEFROST. The A/C request can be cancelled by pressing the A/C request switch, turning the indicator off.
4. allow A/C compressor operation to be manually selected except in FLOOR/DEFROST and DEFROST.

The HVAC module - DATC also includes

1. an EXT button to monitor ambient (outside) air temperature. By pressing the EXT button the ambient temperature will be displayed on the HVAC module - DATC display until the EXT button is pressed again.
2. a F°/C° temperature conversion button to toggle the temperature being displayed from Fahrenheit and Celsius.
3. a rear window defrost button (Explorer only). Refer to «GLASS, FRAMES AND MECHANISMS»(/ford/explorer-sport-trac/ii-2006-2010/remont/heated-glassdefoggers/#windows-and-glass) article.

Dual temperature control can be enabled in AUTO or in all manual override settings. When the HVAC module - DATC is set to DUAL

1. the DATC system enables varying temperatures to be selected by the driver and the front passenger. Dual temperature control is indicated by the presence of 2 temperature settings on the HVAC module - DATC display. To return to single temperature control press the DUAL button, turning the DUAL button indicator off and the front passenger temperature display off.
2. the air distribution direction and the blower motor speed cannot be varied between the driver and front passenger. Only the temperature settings can be varied.
3. the system will favor the driver temperature setting if the driver and front passenger temperature set points vary greatly.

External Temperature Display

The external temperature is displayed when the EXT button is pressed. While the actual external temperature can vary continuously, the value that is displayed will update at a specific rate depending on whether or not the engine is "hot" and whether or not the vehicle is moving.

When the external temperature is rising, the display will update slowly.

Updates (when the actual external temperature is higher than currently displayed value) will be limited to 0.6°C (1°F) every 20 seconds while the vehicle is moving at greater than 40 km/h (25 mph) for more than 90 seconds OR 0.6°C (1°F) every 20 minutes if the vehicle is not moving at this speed. This is to prevent the heat from the engine compartment from affecting the accuracy of the display.

When the external temperature is dropping, the display will update quickly.

Updates (when the actual external temperature is lower than currently displayed value) will only be limited to 0.6°C (1°F) every 2 seconds (regardless of vehicle speed). Consequently the display will essentially follow the drop experienced by the external temperature thermistor.

Auxiliary Climate Control System

Note. Auxiliary climate control system not available on Sport TRAC model.

An auxiliary climate control system is available as optional equipment. The auxiliary climate control system operation is determined by the settings on the front auxiliary climate control assembly. The auxiliary climate control assemblies include a blower motor switch, temperature control switch and air distribution mode switch, none of which can be individually serviced.

On vehicles with manual climate control the auxiliary blower motor operation is enabled when the function selector switch is in any position except OFF. The auxiliary system air can be cooled below ambient temperature only when A/C compressor operation has been requested by the settings of the climate control assembly of the base (front) system. The auxiliary system air can be heated at any time, the heater control valve does not affect the auxiliary climate control system operation.

On vehicles with DATC the auxiliary blower motor is operational regardless of the DATC system setting. The auxiliary system air can be cooled below ambient temperature only when A/C compressor operation has been requested by the settings of the HVAC module - DATC. The auxiliary system air can be heated at any time, the heater control valve operation does not affect the auxiliary climate control system.

The front auxiliary climate control assembly

1. blower motor switch controls the auxiliary blower motor speed. The blower motor speed can be set to OFF, MED-LO, MED-HI or HI.
2. air distribution mode switch toggles airflow between the overhead vents and the floor vent by outputting signals to the auxiliary airflow mode door actuator which positions the auxiliary airflow mode door in all blower motor switch positions. Back-lit icons on the front climate control display indicate the source of the auxiliary system airflow.
3. temperature control switch is a potentiometer that outputs a variable voltage to the auxiliary temperature blend door actuator to set the position of the auxiliary temperature blend door in all blower motor switch positions. The temperature of the auxiliary system air may be affected by the manual climate control assembly or HVAC module - DATC settings (as equipped). When A/C compressor operation has not been initiated (A/C compressor commanded on) by the manual climate control assembly or the HVAC module - DATC (as equipped), the auxiliary climate control system cannot cool the air below that of the ambient temperature.

MAX A/C

When MAX A/C is selected

1. the air inlet door vacuum control motor is at full vacuum, closing off outside air and admitting only recirculated air.
2. the panel door vacuum control motor is at full vacuum and the defrost door and floor door vacuum control motors are at no vacuum, directing airflow to the instrument panel A/C registers. A small amount of airflow from the floor duct, defroster duct and side window demisters will be present.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core. Otherwise, blended air temperature is available.
4. air will be drawn from the recirculated air inlet by the blower motor. When the temperature selection is in the full COOL position, the airflow will be diverted past the heater core and then into the passenger compartment through the instrument panel A/C registers.
5. the A/C request switch will be illuminated and will be disabled.
6. The A/C compressor will not operate if the outside air temperature is below -1°C (30°F). The A/C compressor will resume operation when the outside air temperature rises above 2°C (35°F).
7. the blower motor is ON.
8. the auxiliary blower motor is enabled, if equipped.

PANEL

When PANEL is selected

1. the air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the panel door vacuum control motor is at full vacuum and the defrost door and floor door vacuum control motors are at no vacuum, directing airflow to the instrument panel A/C registers. A small amount of airflow from the floor duct, defroster duct and side window demisters will be present.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core. Otherwise, blended air temperature is available.
4. the A/C request switch will be enabled. The A/C compressor can operate and the indicator will be illuminated if the A/C request switch is selected and if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
5. the blower motor is ON.
6. the auxiliary blower motor is enabled, if equipped.

PANEL/FLOOR

When PANEL/FLOOR is selected

1. the air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the panel door and floor door vacuum control motors are at full vacuum and the defrost door vacuum control motor is at no vacuum, directing airflow to the floor duct and the instrument panel A/C registers. A small amount of airflow from the defroster duct and side window demisters will be present.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core. Otherwise, blended air temperature is available.
4. the A/C request switch will be enabled. The A/C compressor can operate and the indicator will be illuminated if the A/C request switch is selected and if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
5. the blower motor is ON.
6. the auxiliary blower motor is enabled, if equipped.

OFF

When OFF is selected

1. the air inlet door vacuum control motor is at full vacuum, closing off outside air from entering the passenger compartment.
2. the defrost door vacuum control motor is at full vacuum and the panel door and floor door vacuum control motors are at no vacuum, closing off airflow to the passenger compartment outlets.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core.
4. the A/C request switch is disabled.
5. the blower motor is OFF.
6. the auxiliary blower motor is disabled, if equipped.

FLOOR

When FLOOR is selected

1. the air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the floor door and defrost door vacuum control motors are at full vacuum and the panel door vacuum control motors are at no vacuum, directing airflow to the floor duct and the defroster duct. A small amount of airflow from the instrument panel A/C registers, defroster duct and side window demisters will be present.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core. Otherwise, blended air temperature is available.
4. the A/C request switch will be enabled. The A/C compressor can operate and the indicator will be illuminated if the A/C request switch is selected and if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
5. the blower motor is ON.
6. the auxiliary blower motor is enabled, if equipped.

FLOOR/DEFROST

When FLOOR/DEFROST is selected

1. the air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the floor door vacuum control motor is at full vacuum and the defrost door and panel door vacuum control motors are at no vacuum, directing airflow to the floor duct, the defroster duct and the side window demisters. A small amount of airflow from the instrument panel A/C registers will be present.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core. Otherwise, blended air temperature is available.
4. the A/C request switch will not illuminate and will be disabled. To reduce fogging, the A/C compressor will operate automatically if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
5. the blower motor is ON.
6. the auxiliary blower motor is enabled, if equipped.

DEFROST

When DEFROST is selected

1. the air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the floor door, panel door and defrost door vacuum control motors are at no vacuum, directing airflow to the defroster duct and the side window demisters. A small amount of airflow from the instrument panel A/C registers and floor duct will be present.
3. the heater control valve is at full vacuum when the temperature selection is in the full COOL position, preventing the flow of hot coolant to the heater core. Otherwise, blended air temperature is available.
4. the A/C request switch will not illuminate and will be disabled. To reduce fogging, the A/C compressor will operate automatically if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
5. the blower motor is ON.
6. the auxiliary blower motor is enabled, if equipped.

AUTO

When AUTO is selected

1. the temperature control setting(s) is/are manually set to the desired setting(s).
2. the air inlet door vacuum control motor is controlled by the HVAC module - DATC, based on the temperature settings.
3. the mode door vacuum control motors are controlled by the HVAC module - DATC, based on the temperature settings.
4. the heater control valve is by the HVAC module - DATC based on the temperature settings.
5. the A/C request is controlled by the HVAC module - DATC based on the temperature settings. The A/C compressor will not operate if the outside air temperature is below -1°C (30°F). The A/C compressor will resume operation when the outside air temperature rises above 2°C (35°F).
6. the A/C request switch or the RECIRC button, if pressed, will transfer the system to manual operation.
7. the blower motor is ON. The blower motor speed is automatically controlled by the HVAC module - DATC based on the temperature settings, but can be manually overridden.

When OFF is selected

1. the air inlet door vacuum control motor is at full vacuum, closing off outside air to the passenger compartment.
2. the defrost door vacuum control motor is at full vacuum and the floor door and panel door vacuum control motors are at no vacuum, closing off airflow to the passenger compartment outlets.
3. the heater control valve is at full vacuum, preventing the flow of hot coolant to the heater core.
4. the blower motor is OFF.

When PANEL is selected

1. the RECIRC button is enabled. If the RECIRC button is pressed (indicator ON) the air inlet door vacuum control motor is at full vacuum, closing off outside air to the passenger compartment. If the RECIRC button is not selected (indicator OFF), the air inlet door vacuum control motor will be at no vacuum, admitting only outside air into the passenger compartment.
2. the defrost door and panel door vacuum control motors are at full vacuum and the floor door vacuum control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small amount of airflow from the floor duct, defroster duct and side window demisters will be present.
3. the heater control valve is controlled by the HVAC module - DATC based on the temperature settings.
4. temperature control can be adjusted by directing the airflow through and around the heater core. Only when A/C compressor operation has been selected by pressing the A/C request switch (indicator ON) can the airflow temperature be cooled below that of the ambient (outside) air temperature.
5. the A/C request switch is enabled. When the A/C request switch is pressed (indicator ON), the A/C compressor can operate if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
6. the blower motor is ON.

When PANEL/FLOOR is selected

1. the RECIRC button is enabled. If the RECIRC button is pressed (indicator ON), the air inlet door vacuum control motor is at full vacuum, closing off outside air to the passenger compartment. If the RECIRC button is not selected (indicator OFF) the air inlet door vacuum control motor will be at no vacuum, admitting only outside air into the passenger compartment.
2. the defrost door, panel door and floor door vacuum control motors are at full vacuum, directing airflow to the instrument panel A/C registers and to the floor duct. A small amount of airflow from the defroster duct and side window demisters will be present.
3. the heater control valve is controlled by the HVAC module - DATC based on the temperature settings.
4. temperature control can be adjusted by directing the airflow through and around the heater core. Only when A/C compressor operation has been selected by pressing the A/C request switch (indicator ON) can the airflow temperature be cooled below that of the ambient (outside) air temperature.
5. the A/C request switch is enabled. When the A/C request switch is pressed (indicator ON), the A/C compressor can operate if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
6. the blower motor is ON.

When FLOOR is selected

1. the RECIRC button is enabled. If the RECIRC button is pressed (indicator ON), the air inlet door vacuum control motor is at full vacuum, closing off outside air to the passenger compartment. A RECIRC door time-out strategy will be used to prevent fogging and the RECIRC function will automatically be turned off after approximately 4 minutes. If the RECIRC button is not selected (indicator OFF), the air inlet door vacuum control motor will be at no vacuum, admitting only outside air into the passenger compartment.
2. the defrost door and floor door vacuum control motors are at full vacuum and the panel door vacuum control motor is at no vacuum, directing airflow to the floor duct. A small amount of airflow from the instrument panel A/C registers, defroster duct and side window demisters will be present.
3. the heater control valve is controlled by the HVAC module - DATC based on the temperature settings.
4. temperature control can be adjusted by directing the airflow through and around the heater core. Only when A/C compressor operation has been selected by pressing the A/C request switch (indicator ON) can the airflow temperature be cooled below that of the ambient (outside) air temperature.
5. the A/C request switch is enabled. When the A/C request switch is pressed (indicator ON), the A/C compressor can operate if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
6. the blower motor is ON.

When FLOOR/DEFROST is selected

1. the RECIRC button is disabled. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the floor door vacuum control motor is at full vacuum and the defrost door and panel door vacuum control motors are at no vacuum, directing airflow to the floor duct, defroster duct and side window demisters. A small amount of airflow from the instrument panel A/C registers will be present.
3. the heater control valve is controlled by the HVAC module - DATC based on the temperature settings.
4. temperature control can be adjusted by directing the airflow through and around the heater core.
5. the A/C request switch will be disabled and will not illuminate. The A/C compressor will operate automatically if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
6. the blower motor is ON.

When DEFROST is selected

1. the RECIRC button is disabled. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. the floor door, defrost door and panel door vacuum control motors are at no vacuum, directing airflow to the defroster duct and side window demisters. A small amount of airflow from the instrument panel A/C registers and the floor duct will be present.
3. the heater control valve is controlled by the HVAC module - DATC based on the temperature settings.
4. temperature control can be adjusted by directing the airflow through and around the heater core.
5. the A/C request switch will be disabled and will not illuminate. The A/C compressor will operate automatically if the outside air temperature is not below -1°C (30°F). If the outside air temperature has gone below -1°C (30°F), A/C compressor operation will resume when the outside air temperature rises above 2°C (35°F).
6. the blower motor is ON.

Special Tools Illustration Tool Name Tool Number A/C Flush Adapter Kit 219-00074 or equivalent Flex Probe Kit 105-R025B or equivalent Fluke 77 III Automotive Meter 105-R0056 or equivalent Pressure Test Kit 014-R1072 or equivalent R-134a Manifold Gauge Set 176-R032A or equivalent Refrigerant Leak Detector 216-00001 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 1

Scheme 2

Principles of Operation

There are 4 main principles involved with the basic theory of operation

1. Heat transfer
2. Latent heat of vaporization
3. Relative humidity
4. Effects of pressure

Heat Transfer

If 2 substances of different temperature are placed near each other, the heat in the warmer substance will transfer to the colder substance.

Latent Heat of Vaporization

When a liquid boils (converts to gas) it absorbs heat without raising the temperature of the resulting gas. When the gas condenses (converts back to a liquid), it gives off heat without lowering the temperature of the resulting liquid.

Relative Humidity

The amount of moisture (water vapor content) that the air can hold is directly related to the air temperature. The more heat there is in the air, the more moisture the air can hold. The lower the moisture content in the air, the more comfortable you feel. Removing the moisture from the air lowers its relative humidity and improves personal comfort.

Effects of Pressure on Boiling or Condensation

As the pressure is increased on a liquid, the temperature at which the liquid boils (converts to gas) also increases. Conversely, when the pressure on a liquid is reduced, its boiling point is also reduced. When in the gas state, an increase in pressure causes an increase in temperature, while a decrease in pressure will decrease the temperature of the gas.

Compressor Anti-Slugging Strategy (CASS)

Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate damage to the A/C compressor, CASS is utilized.

CASS is initiated only under specific conditions

1. The ignition is off for more than 8 hours
2. The ambient temperature is above -4°C (25°F)
3. Battery voltage is above 8.5 volts during engine cranking

When these conditions are present, the PCM will activate the A/C control relay prior to cranking of the engine. The A/C control relay engages the A/C compressor for approximately 4-15 A/C compressor revolutions or a maximum of 2 seconds (depending upon vehicle application), allowing the liquid refrigerant to be pushed from the A/C compressor. CASS is initiated by the PCM regardless of the climate system settings.

The Refrigerant Cycle

During stabilized conditions (A/C system shutdown), the refrigerant is in a vaporized state and pressures are equal throughout the system. When the A/C compressor is in operation, it increases pressure on the refrigerant vapor, raising its temperature. The high-pressure and high-temperature vapor is then released into the top of the condenser core.

The condenser core, being close to ambient temperature, causes the refrigerant vapor to condense into a liquid when heat is removed from the refrigerant by ambient air passing over the fins and tubing. The liquid refrigerant, still at high pressure, exits from the bottom of the condenser core and enters the inlet side of the evaporator core orifice.

The evaporator core orifice is the restriction in the refrigerant system that creates the low pressure drop in the evaporator core and separates the high- and low-pressure sides of the A/C system. As the liquid refrigerant leaves this restriction, its pressure and boiling point are reduced.

The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the evaporator core, it absorbs heat from the passenger compartment airflow passing over the plate/fin sections of the evaporator core. This addition of heat causes the refrigerant to boil (convert to gas). The now cooler passenger compartment air can no longer support the same humidity level of the warmer air and this excess moisture condenses on the exterior of the evaporator coils and fins and drains outside the vehicle.

The suction accumulator is designed to remove moisture from the refrigerant and to prevent any liquid refrigerant that may not have been vaporized in the evaporator core from reaching the A/C compressor. The A/C compressor is designed to pump refrigerant vapor only, as liquid refrigerant will not compress and can damage the A/C compressor.

The refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and temperature of the refrigerant.

The A/C cycling switch interrupts compressor operation before the external temperature of the evaporator core gets low enough to cause the condensed water vapor (excess humidity) to turn to ice. It does this by monitoring low side line pressure. It is known that a refrigerant pressure of approximately 210 kPa (30 psi) will yield an operating temperature of 0°C (32°F). The A/C cycling switch controls system operation in an effort to maintain this temperature.

The high side line pressure is also monitored so that A/C compressor operation can be interrupted if system pressure becomes too high.

The A/C pressure relief valve will open and vent refrigerant to relieve unusually high system pressure.

Scheme 3

Scheme 4

Scheme 5

VACUUM APPLICATION CHART - MANUAL CLIMATE CONTROL

a Vacuum port 3 is not currently used and is sealed by the vacuum harness connector when connected to the function selector switch.

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VACUUM APPLICATION CHART - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL

a The dual automatic temperature control (DATC) system may be manually set to enable or disable the recirculation of cabin air by pressing the RECIRCULATION manual override button in all manual override modes except OFF, DEFROST and FLOOR/DEFROST.

b The automatic temperature control solenoid and manifold will supply vacuum and close the heater control valve depending on the HVAC module - DATC settings and ambient conditions in any setting except OFF.

Inspection and Verification

1. Verify the customer concern by operating the climate control system to duplicate the condition.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Loose, missing or damaged A/C compressor drive belt A/C compressor inoperative Loose, misrouted or damaged vacuum lines a Broken or leaking vacuum control motor a Discharged A/C system Broken or leaking refrigerant lines Smart Junction Box (SJB) fuse: 20 (10A) 28 (10A) 18 (10A) Battery Junction Box (BJB) fuse: 16 (40A) 18 (30A) 35 (10A) 40 (15A) Blower motor Loose or disconnected A/C clutch connector Circuitry open/shorted Disconnected, loose fitting or incorrectly installed electrical connectors and pins 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 in the passenger compartment control circuit are constructed from PVC plastic material. The vacuum hoses used in the engine compartment are constructed of Hytrel®. Because of the materials used, never pinch the vacuum hoses off during diagnosis to locate a leak. A 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. As pinpoint tests and measurements are being carried out, be sure to inspect for any disconnected, loose-fitting or incorrectly installed component, module and inline electrical connectors and pins.
4. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
5. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
6. If the scan tool does not communicate with the VCM: check the VCM connection to the vehicle. check the scan tool connection to the VCM. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article, No Power To The Scan Tool, to diagnose no power to the scan tool.
7. If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article to diagnose no response from the PCM or HVAC module - Dual Automatic Temperature Control (DATC).
8. Carry out the network test. If the scan tool responds with no communication from one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article. If the network test passes, retrieve and record the continuous memory DTCs.
9. Carry out the self-test diagnostics from the PCM or HVAC module - DATC.
10. If any of the DATC DTCs retrieved are related to the concern, go to the HVAC Module - Dual Automatic Temperature Control (DATC) DTC Chart. If the PCM DTCs retrieved are related to the concern, go to the PCM DTC Chart. For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#multifunction-electronic-modules) article.
11. If no DTCs related to the concern are retrieved, go to the Go to «Symptom Chart - Climate Control Systems»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) or Go to «Symptom Chart - NVH»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) .

Alternate Diagnostic Methods - HVAC Module - Dual Automatic Temperature Control (DATC)

The DATC system must be diagnosed by first retrieving any DTCs, if present.

1. An on-demand (hard fault) DTC indicates that the fault is currently present. An on-demand DTC suggests a wiring fault, disconnected connector or component failure.
2. A continuous (intermittent) DTC alone (corresponding on-demand DTC is not present) indicates that the fault is an intermittent condition and may not be currently present. A continuous only DTC suggests a poor wiring connection, loose pin or terminal or intermittent component failure.

On-demand (hard fault) or continuous (intermittent fault) DTCs can be retrieved using a scan tool. If using a scan tool, refer to the scan tool operating manual.

On-demand DTCs can also be retrieved by carrying out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self Test. To retrieve and/or clear continuous DTCs carry out the HVAC Module - Dual Automatic Temperature Control (DATC) - Retrieve Continuous DTCs procedure. Always retrieve both on-demand and continuous DTCs before proceeding with diagnosis and/or repair.

If no DTCs are present, go to the Go to Symptom Chart - Climate Control Systems or Go to Symptom Chart - NVH for the appropriate diagnostic action.

HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test - The HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test will retrieve on-demand (hard fault) DTCs only, it will not retrieve continuous DTCs. Continuous DTCs can be cleared when exiting the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Make sure to retrieve continuous DTCs by carrying out the HVAC Module - Dual Automatic Temperature Control (DATC) - Retrieve Continuous DTCs procedure before clearing any DTCs.

1. The HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test will not detect concerns associated with data link messages like engine coolant temperature or vehicle speed signals. A scan tool must be used to retrieve these concerns.
2. The HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test will detect concerns in the system control functions and will display on-demand (hard fault) DTCs for concerns that are present during the self-test. The vehicle interior temperature should be between 4°-38°C (40°-100°F) when performing the self-test. If the temperatures are not within the specified ranges, false DTCs may be displayed.
3. The self-test can be initiated after cycling the ignition switch from OFF to ON. Normal operation of the climate control system stops when the self-test is activated.
4. To enter the self-test, press the OFF and DEFROST buttons simultaneously and release, then press the AUTO button within 2 seconds. The display will show a flashing blower icon for 20 seconds, after which all vacuum fluorescent segments will be displayed if there are no on-demand DTCs present. If DTCs are present the HVAC module - DATC will display "00 00" and then on-demand DTCs. Record all DTCs displayed.
5. If any DTCs appear during the self-test, carry out the diagnostic procedure. Refer to the HVAC Module - Dual Automatic Temperature Control (DATC) DTC Chart and follow the ACTION for each DTC given.
6. To exit the self-test and retain all continuous DTCs, press any button except DEFROST. The HVAC module - DATC will exit the self-test and retain all DTCs.
7. Always exit the self-test before powering the system down (system turned OFF). Once the self-test is exited the ignition switch must remain ON for at least 30 seconds to allow the temperature blend door actuators to automatically recalibrate.
8. If a condition exists but no DTCs appear during the self-test, go to the Go to «Symptom Chart - Climate Control Systems»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) or Go to «Symptom Chart - NVH»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) .

HVAC Module - Dual Automatic Temperature Control (DATC) - Retrieve Continuous DTCs - The HVAC module - DATC will retrieve only continuous (intermittent) DTCs when carrying out this procedure.

1. Retrieval of continuous DTCs can be initiated after cycling the ignition switch from OFF to ON. Normal operation of the climate control system stops when retrieving continuous DTCs.
2. To retrieve continuous DTCs, press the OFF and PANEL buttons simultaneously and release, then press the AUTO button within 2 seconds. All vacuum fluorescent segments will be displayed if there are no continuous DTCs present. Continuous DTCs are indicated by the presence of the degrees Celsius symbol (°C) on the HVAC module - DATC display. Record all DTCs displayed.
3. If any DTCs appear, carry out the diagnostic procedure. Refer to the HVAC Module - Dual Automatic Temperature Control (DATC) DTC Chart and follow the ACTION for each DTC given.
4. If a condition exists but no DTCs appear, go to the Go to «Symptom Chart - Climate Control Systems»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) or Go to «Symptom Chart - NVH»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) .
5. To exit and retain all continuous DTCs, press any button except DEFROST. The HVAC module - DATC will exit the retrieve continuous DTCs mode and retain all continuous DTCs.
6. To exit and clear all continuous DTCs, press the DEFROST button. The HVAC module - DATC will exit the retrieve continuous DTCs mode and all continuous DTCs will be cleared.
7. Always exit the procedure before powering the system down (system turned OFF). Once the procedure is exited the ignition switch must remain ON for at least 30 seconds to allow the temperature blend door actuators to automatically recalibrate.
8. Continuous DTCs will be deleted after 80 ignition switch ON cycles after the intermittent fault occurs.

HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process - The purpose of the cold boot process is to allow the HVAC module - DATC to re-initialize and calibrate the actuators. To carry out the cold boot process, follow the steps below.

1. Turn the ignition switch to the OFF position.
2. Disconnect the HVAC module - DATC electrical connectors.
3. Wait one minute.
4. Connect the HVAC module - DATC electrical connectors.
5. Turn the ignition switch to the ON position.
6. Select any position except OFF on the HVAC module - DATC.

DTC Charts

PCM DTC CHART

a PCM DTC P1464 will set if the function selector is in PANEL with A/C button pressed, DEFROST or MAX A/C mode when the on-demand self test is being run.

Note. Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose those first. Refer to the PCM DTC Chart.

HVAC MODULE - DUAL AUTOMATIC TEMPERATURE CONTROL (DATC) DTC CHART

Symptom Chart - Climate Control Systems

Symptom Chart - Climate Control Systems

Symptom Chart - NVH

Note. NVH symptoms will be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to NOISE, VIBRATION AND HARSHNESS article. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to NOISE, VIBRATION AND HARSHNESS article for the next likely system and continue diagnosis.

Symptom Chart - NVH

Pinpoint Tests

Note. As pinpoint tests and measurements are being carried out, be sure to inspect for any disconnected, loose-fitting or incorrectly installed component, module and inline electrical connectors and pins.

Pinpoint Test A: DTC P0532 or P0533

Refer to SYSTEM WIRING DIAGRAMS for schematic and connector information.

Refer to SYSTEM WIRING DIAGRAMS for schematic and connector information.

Normal Operation

Under normal operation, the A/C pressure transducer receives a ground from the PCM through circuit RE407 (YE/VT). A 5-volt reference voltage is supplied to the A/C pressure transducer from the PCM through circuit LE423 (GN/VT). The A/C pressure transducer sends a voltage to the PCM through circuit VH433 (VT/OG) to indicate the A/C pressure.

1. DTC P0532 A/C Pressure Refrigerant Sensor A Circuit Low - The A/C pressure transducer inputs a voltage to the PCM. If the voltage is below the calibrated level, this DTC sets.
2. DTC P0533 A/C Pressure Refrigerant Sensor A Circuit High - The A/C pressure transducer inputs a voltage to the PCM. If the voltage is above the calibrated level, this DTC sets.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. A/C pressure transducer
3. PCM

Note. When disconnecting and reconnecting the pressure transducer electrical connector, make sure that the connector-locking device is in place and that the locking device and connector are correctly and fully seated.

Scheme 9

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Scheme 17

1. A1 CHECK THE PCM OUTPUT VOLTAGE Key in OFF position. Disconnect: A/C Pressure Transducer C1078 Key in ON position. Measure the voltage between ground and A/C pressure transducer C1078-2, circuit LE423 (GN/VT), harness side. Is the voltage between 4.7 and 5.1 volts? YES : Go to A2 . NO : REPAIR circuit LE423 (GN/VT) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. A2 CHECK THE PCM SENSOR GROUND Measure the voltage between A/C pressure transducer C1078-1, circuit RE407 (YE/VT), harness side and A/C pressure transducer C1078-2, circuit LE423 (GN/VT), harness side. Is the voltage between 4.7 and 5.1 volts? YES : If diagnosing DTC P0532 , go to A3 . If diagnosing DTC P0533 , go to A5 . NO : REPAIR circuit RE407 (YE/VT) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. A3 CHECK THE A/C PRESSURE TRANSDUCER HIGH Enter the following diagnostic mode on the diagnostic tool: A/C Pressure (ACP_PRESS) PCM PID While observing the ACP_PRESS PCM PID, connect a fused jumper between A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side and A/C pressure transducer C1078-2, circuit LE423 (GN/VT), harness side. Does the ACP_PRESS PCM PID voltage read greater than 4 volts? YES : INSTALL a new A/C pressure transducer. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. NO : Go to A4 .
4. A4 CHECK CIRCUIT VH433 (VT/OG) FOR A SHORT TO GROUND Key in OFF position. Disconnect: PCM C175b Measure the resistance between ground and A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side. Is the resistance greater than 10,000 ohms? YES : Go to A7 . NO : REPAIR circuit VH433 (VT/OG) for a short to ground. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. A5 CHECK THE A/C PRESSURE TRANSDUCER HIGH Enter the following diagnostic mode on the diagnostic tool: A/C Pressure (ACP_PRESS) PCM PID While observing the ACP_PRESS PCM PID, connect a fused jumper between A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side and A/C pressure transducer C1078-1, circuit RE407 (YE/VT), harness side. Does the ACP_PRESS PCM PID voltage read less than 4.9 volts? YES : INSTALL a new A/C pressure transducer. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. NO : Go to A6 .
6. A6 CHECK CIRCUIT VH433 (VT/OG) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: PCM C175b Key in ON position. Measure the voltage between ground and A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side. Is any voltage present? YES : REPAIR circuit VH433 (VT/OG) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. NO : Go to A7 .
7. A7 CHECK CIRCUIT VH433 (VT/OG) FOR A SHORT TO CIRCUIT LE423 (GN/VT) OR RE407 (YE/VT) Key in OFF position. NOTE: For DTC P0532 only. Measure the resistance between A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side and A/C pressure transducer C1078-1, circuit RE407 (YE/VT), harness side. NOTE: For DTC P0533 only. Measure the resistance between A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side and A/C pressure transducer C1078-2, circuit LE423 (GN/VT), harness side. Is the resistance greater than 10,000 ohms? YES : Go to A8 . NO : REPAIR circuit VH433 (VT/OG) for a short to circuit LE423 (GN/VT) or RE407 (YE/VT). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
8. A8 CHECK CIRCUIT VH433 (VT/OG) FOR AN OPEN Measure the resistance between A/C pressure transducer C1078-3, circuit VH433 (VT/OG), harness side and PCM C175b-18, circuit VH433 (VT/OG), harness side. Is the resistance less than 5 ohms? YES : Go to A9 . NO : REPAIR circuit VH433 (VT/OG) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
9. A9 CHECK THE PCM CONNECTION Clear the DTCs. Disconnect all the PCM connectors. Check for: corrosion. pushed-out pins. incorrectly seated connector. Connect and correctly seat all the PCM connectors. Operate the system. Does the concern return? YES : INSTALL a new PCM. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Pinpoint Test B: DTC P0645

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, voltage is provided to the A/C clutch relay coil through circuit CBB40 (YE/GN). When A/C is requested, and A/C line pressures allow, a ground is provided to the A/C clutch relay coil from the PCM through circuit CH302 (WH/BN), energizing the A/C clutch relay.

1. DTC P0645 - A/C Clutch Relay Control Circuit - The DTC sets when the PCM grounds the relay circuit, excessive current draw is detected on the relay circuit or, with the relay circuit not grounded by the PCM, voltage is not detected on the relay circuit the PCM expects to detect voltage coming through the relay coil to the relay circuit.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. A/C clutch relay
3. PCM

Scheme 18

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Scheme 21

1. B1 CHECK THE VOLTAGE TO THE A/C CLUTCH RELAY Key in OFF position. Disconnect: A/C Clutch Relay Key in ON position. Measure the voltage between ground and the A/C clutch relay socket pin 2, circuit CBB40 (YE/GN). Is the voltage greater than 10 volts? YES : CARRY OUT the A/C clutch relay component test. Refer to COMPONENT TESTING. If the relay tests OK, go to B2 . NO : REPAIR circuit CBB40 (YE/GN) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. B2 CHECK CIRCUIT CH302 (WH/BN) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: PCM C175b Key in ON position. Measure the voltage between ground and PCM C175b-14, circuit CH302 (WH/BN), harness side. Is any voltage present? YES : REPAIR circuit CH302 (WH/BN) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. NO : Go to B3 .
3. B3 CHECK CIRCUIT CH302 (WH/BN) FOR A SHORT TO GROUND Key in OFF position. Measure the resistance between ground and PCM C175b-14, circuit CH302 (WH/BN), harness side. Is the resistance greater than 10,000 ohms? YES : Go to B4 . NO : REPAIR circuit CH302 (WH/BN) for a short to ground. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. B4 CHECK CIRCUIT CH302 (WH/BN) FOR AN OPEN Measure the resistance between A/C clutch relay socket, circuit CH302 (WH/BN) and PCM C175b-14, circuit CH302 (WH/BN), harness side. Is the resistance less than 5 ohms? YES : Go to B5 . NO : REPAIR circuit 321 (GY/WH) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. B5 CHECK THE PCM CONNECTION Clear the DTCs. Disconnect all the PCM connectors. Check for: corrosion. pushed-out pins. incorrectly seated connector. Connect and correctly seat all the PCM connectors. Operate the system. Does the concern return? YES : INSTALL a new PCM. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Pinpoint Test C: DTC B2266 or B2267

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the driver side (LH) and passenger side (RH) temperature blend door actuator motors are supplied voltage or ground on circuit CH237 (VT/GY) (LH) or circuit CH211 (YE) (RH), depending on desired actuator rotation, by the HVAC module - Dual Automatic Temperature Control (DATC). The HVAC module - DATC then supplies the appropriate voltage or ground to the other side of the actuator motor on circuit CH239 (BU/WH) (LH) or circuit CH213 (BN/GN) (RH).

The driver side (LH) and passenger side (RH) temperature blend door actuator feedback resistors are supplied a ground from the HVAC module - DATC by circuit RH111 (GY/BU) and a 5-volt reference voltage on circuit LH111 (BN/WH). The HVAC module - DATC reads the voltage on circuit VH440 (BU/BN) (LH) or circuit VH441 (WH/BN) (RH) to determine the actuator position by the position of the actuator feedback resistor wiper arm.

1. DTC B2266 Left Side Blend Door Circuit Failure - The module senses no voltage drop on the sensor reference voltage circuit, indicating an open circuit.
2. DTC B2267 Right Side Blend Door Circuit Failure - The module senses excessive voltage drop on the sensor reference voltage circuit, indicating a short directly to ground.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Driver side (LH) or passenger side (RH) temperature blend door actuator
3. HVAC module - DATC
4. Stuck or bound linkage or door

Scheme 22

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1. C1 CHECK THE FEEDBACK POTENTIOMETER TOTAL RESISTANCE Disconnect: HVAC Module - DATC C228a Disconnect: HVAC Module - DATC C228b Measure the resistance between HVAC module - DATC C228a-20, circuit LH111 (BN/WH), harness side and HVAC module - DATC C228b-1, circuit RH111 (GY/BU), harness side. Is the resistance greater than 500 ohms? YES : Go to C2 . NO : CARRY OUT the Blend Door Actuator «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . If the actuator tests OK, REPAIR circuits LH111 (BN/WH) and RH111 (GY/BU) for a short together. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. C2 CHECK THE POTENTIOMETER LOW- AND HIGH-SIDE RESISTANCE Measure the low-side resistance between HVAC module - DATC C228b-1, circuit RH111 (GY/BU), harness side and the following: For DTC B2266 , HVAC module - DATC C228a-9, circuit VH440 (BU/BN), harness side. For DTC B2267 , HVAC module - DATC C228a-10, circuit VH441 (WH/BN), harness side. Measure the high-side resistance between HVAC module - DATC C228a-20, circuit LH111 (BN/WH), harness side and the following: For DTC B2266 , HVAC module - DATC C228a-9, circuit VH440 (BU/BN), harness side. For DTC B2267 , HVAC module - DATC C228a-10, circuit VH441 (WH/BN), harness side. Is the resistance between 250 and 5,500 ohms? YES : Go to C3 . NO : CARRY OUT the Blend Door Actuator «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . If the actuator tests OK and: If the low-side resistance only is greater than 5,500 ohms, REPAIR circuit RH111 (GY/BU) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. If the low-side resistance only is less than 250 ohms, REPAIR circuit VH440 (BU/BN) or VH411 (VT/GN) for a short to circuit RH111 (GY/BU). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. If the high-side resistance only is greater than 5,500 ohms, REPAIR circuit LH111 (BN/WH) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. If the high-side resistance only is less than 250 ohms, REPAIR circuits circuit VH440 (BU/BN) or VH411 (VT/GN) for a short to circuit LH111 (BN/WH). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. If the high-side and low-side resistance is greater than 5,500 ohms, REPAIR circuit VH440 (BU/BN) or VH411 (VT/GN) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. C3 CHECK CIRCUIT LH111 (BN/WH), VH440 (BU/BN) OR CIRCUIT VH441 (WH/BN) FOR A SHORT TO GROUND Measure the resistance between ground and the following: HVAC module - DATC C228a-20, circuit LH111 (BN/WH), harness side. For DTC B2266 , HVAC module - DATC C228a-9, circuit VH440 (BU/BN), harness side. For DTC B2267 , HVAC module - DATC C228a-10, circuit VH441 (WH/BN), harness side. Is the resistance greater than 10,000 ohms? YES : Go to C4 . NO : REPAIR circuit LH111 (BN/WH), VH441 (WH/BN) or VH440 (BU/BN) for a short to ground. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. C4 CHECK CIRCUIT LH111 (BN/WH), VH440 (BU/BN) OR CIRCUIT VH441 (WH/BN) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between ground and the following: HVAC module - DATC C228a-20, circuit LH111 (BN/WH), harness side. For DTC B2266 , HVAC module - DATC C228a-9, circuit VH440 (BU/BN), harness side. For DTC B2267 , HVAC module - DATC C228a-10, circuit VH441 (WH/BN), harness side. Is any voltage present? YES : REPAIR circuit RH111 (GY/BU), VH441 (WH/BN) or VH440 (BU/BN) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. NO : For DTC B2266 , go to C5 . For DTC B2267 , go to C6 .
5. C5 CHECK THE BLEND DOOR ACTUATOR OPERATION NOTE: If a jumper fuse opens while carrying out this test step, repair the circuit(s) for a short. Measure the resistance between HVAC module - DATC C228b-1, circuit RH111 (GY/BU), harness side and HVAC module - DATC C228a-9, circuit VH440 (BU/BN), harness side. Connect fused jumper wires between: HVAC module - DATC C228b-8, circuit CH239 (BU/WH), harness side and HVAC module - DATC C228a-13, circuit SBP28 (GN/RD), harness side. HVAC module - DATC C228b-7, circuit CH237 (VT/GY), harness side and HVAC module - DATC C228a-2, circuit GD145 (BK/BU), harness side. Remove the fused jumpers. Connect fused jumper wires between: HVAC module - DATC C228b-7, circuit CH237 (VT/GY), harness side and HVAC module - DATC C228a-13, circuit SBP28 (GN/RD), harness side. HVAC module - DATC C228b-8, circuit CH239 (BU/WH), harness side and HVAC module - DATC C228a-2, circuit GD145 (BK/BU), harness side. Does the resistance increase and decrease when the jumpers are connected? YES : INSPECT for broken door and linkage. REPAIR as necessary. If no condition is found, go to C8 . NO : Go to C7 .
6. C6 CHECK THE BLEND DOOR ACTUATOR OPERATION NOTE: If a jumper fuse opens while carrying out this test step, repair the circuit(s) for a short. Measure the resistance between HVAC module - DATC C228b-1, circuit RH111 (GY/BU), harness side and HVAC module - DATC C228a-10, circuit VH441 (WH/BN), harness side. Connect fused jumper wires between: HVAC module - DATC C228b-6, circuit CH213 (BN/GN), harness side and HVAC module - DATC C228a-13, circuit SBP28 (GN/RD), harness side. HVAC module - DATC C228b-5, circuit CH211 (YE), harness side and HVAC module - DATC C228a-2, circuit GD145 (BK/BU), harness side. Remove the fused jumpers. Connect fused jumper wires between: HVAC module - DATC C228b-5, circuit CH211 (YE), harness side and HVAC module - DATC C228a-13, circuit SBP28 (GN/RD), harness side. HVAC module - DATC C228b-6, circuit CH213 (BN/GN), harness side and HVAC module - DATC C228a-2, circuit GD145 (BK/BU), harness side. Does the resistance increase and decrease when the jumpers are connected? YES : INSPECT for broken door and linkage. REPAIR as necessary. If no condition is found, go to C8 . NO : Go to C7 .
7. C7 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR AN OPEN NOTE: Due to limited connector accessibility, before carrying out this test step, visually inspect the wiring between the HVAC module and actuator for opens or shorts. If no damage is visually evident, proceed with the test. Disconnect: For DTC B2266 , LH Blend Door Actuator C2091 Disconnect: For DTC B2267 , RH Blend Door Actuator C2092 Measure the resistance between: For DTC B2266 , HVAC module - DATC C228b-8, circuit CH239 (BU/WH), harness side and temperature blend door actuator C2091-7, circuit CH239 (BU/WH), harness side. For DTC B2267 , HVAC module - DATC C228b-6, circuit CH213 (BN/GN), harness side and temperature blend door actuator C2092-7, circuit CH213 (BN/GN), harness side. Measure the resistance between: For DTC B2266 , HVAC module - DATC C228b-7, circuit CH237 (VT/GY), harness side and temperature blend door actuator C2091-8, circuit CH237 (VT/GY), harness side. For DTC B2267 , HVAC module - DATC C228b-5, circuit CH211 (YE), harness side and temperature blend door actuator C2092-8, circuit CH211 (YE), harness side. Is the resistance less than 5 ohms? YES : INSPECT for binding or broken linkage. REPAIR as necessary. If no condition is found, INSTALL a new door actuator. TEST the system for normal operation. NO : REPAIR the circuit(s) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
8. C8 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test D: DTC B1251 or B1253

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the in-vehicle air temperature sensor receives a ground from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit RH104 (BU/BN). A 5-volt reference voltage is supplied to the in-vehicle air temperature sensor from the HVAC module - DATC through circuit VH414 (GN/BU).

1. DTC B1251 Air Temperature Internal Sensor Circuit Open - The module senses no voltage drop on the sensor reference voltage circuit, indicating an open circuit.
2. DTC B1253 Air Temperature Internal Sensor Circuit Short to Ground - The module senses excessive voltage drop on the sensor reference voltage circuit, indicating a short directly to ground.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. In-vehicle air temperature sensor
3. HVAC module - DATC

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. D1 CHECK THE SENSOR RESISTANCE Key in OFF position. Disconnect: In-Vehicle Temperature Sensor C233 Measure the resistance between the in-vehicle temperature sensor terminals. Is the resistance within the specified values for these temperature ranges: 10-20°C (50-68°F), 37,000-58,000 ohms; 20-30°C (68-86°F), 24,000-37,000 ohms; 30-40°C (86-104°F), 16,000-24,000 ohms? YES : Go to D2 . NO : Go to D7 .
2. D2 CHECK THE HVAC MODULE SENSOR OUTPUT VOLTAGE Key in ON position. Press the AUTOMATIC button. Measure the voltage between in-vehicle temperature sensor C233-1, circuit VH414 (GN/BU), harness side and C233-2, circuit RH104 (BU/BN), harness side. Is the voltage between 4.7 and 5.1 volts? YES : INSTALL a new in-vehicle temperature sensor. TEST the vehicle for normal operation. If code returns, INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : For DTC B1251 , go to D3 . For DTC B1253 , go to D5 .
3. D3 CHECK CIRCUIT VH414 (GN/BU) FOR AN OPEN Key in OFF position. Disconnect: HVAC Module - DATC C228a Measure the resistance between HVAC module - DATC C228a-7, circuit VH414 (GN/BU), harness side and in-vehicle temperature sensor C233-1, circuit VH414 (GN/BU), harness side. Is the resistance less than 5 ohms? YES : Go to D4 . NO : REPAIR circuit VH414 (GN/BU) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. D4 CHECK CIRCUIT RH104 (BU/BN) FOR AN OPEN Measure the resistance between HVAC module - DATC C228a-6, circuit RH104 (BU/BN), harness side and in-vehicle temperature sensor C233-2, circuit RH104 (BU/BN), harness side. Is the resistance less than 5 ohms? YES : Go to D7 . NO : REPAIR circuit RH104 (BU/BN) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. D5 CHECK CIRCUITS VH414 (GN/BU) AND RH104 (BU/BN) FOR A SHORT TOGETHER Key in OFF position. Disconnect: HVAC Module - DATC C228a Disconnect: HVAC Module - DATC C228b Measure the resistance between in-vehicle temperature sensor C233-1, circuit VH414 (GN/BU), harness side and C233-2, circuit RH104 (BU/BN), harness side. Is the resistance greater than 10,000 ohms? YES : Go to D6 . NO : REPAIR circuits VH414 (GN/BU) and RH104 (BU/BN) for a short together. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
6. D6 CHECK CIRCUIT VH414 (GN/BU) FOR A SHORT TO GROUND Measure the resistance between ground and HVAC module - DATC C228a-7, circuit VH414 (GN/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to D7 . NO : REPAIR circuit VH414 (GN/BU) for a short to ground. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
7. D7 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test E: DTC B1255 or B1257

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the ambient air temperature sensor receives a ground from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit RH104 (BU/BN)/RMC32 (GN/BU). A 5-volt reference voltage is supplied to the ambient air temperature sensor from the HVAC module - DATC through circuit VH407 (YE/GN).

1. DTC B1255 Air Temperature External Sensor Circuit Open - The module senses no voltage drop on the sensor reference voltage circuit, indicating an open circuit.
2. DTC B1257 Air Temperature External Sensor Circuit Short to Ground - The module senses excessive voltage drop on the sensor reference voltage circuit, indicating a short directly to ground.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Ambient air temperature sensor
3. HVAC module - DATC

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. E1 CHECK THE AMBIENT TEMPERATURE SENSOR RESISTANCE Key in OFF position. Disconnect: Ambient Temperature Sensor C132 Measure the resistance between the ambient temperature sensor terminals. Is the resistance within the specified values for these temperature ranges: 10-20°C (50-68°F), 37,000-58,000 ohms; 20-30°C (68-86°F), 24,000-37,000 ohms; 30-40°C (86-104°F), 16,000-24,000 ohms? YES : Go to E2 . NO : INSTALL a new ambient air temperature sensor. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
2. E2 CHECK THE HVAC MODULE OUTPUT VOLTAGE Key in ON position. Press the AUTOMATIC button. Measure the voltage between ambient temperature sensor C132-1, circuit VH407 (YE/GN), harness side and C132-2, circuit RMC32 (GN/BU), harness side. Is the voltage between 4.7 and 5.1 volts? YES : INSTALL a new A/C ambient temperature sensor. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. If code returns, go to E7 . NO : For DTC B1255 , go to E3 . For DTC B1257 , go to E5 .
3. E3 CHECK CIRCUIT VH407 (YE/GN) FOR AN OPEN Key in OFF position. Disconnect: HVAC Module - DATC C228a Measure the resistance between HVAC module - DATC C228a-17, circuit VH407 (YE/GN), harness side and ambient temperature sensor C132-1, circuit VH407 (YE/GN), harness side. Is the resistance less than 5 ohms? YES : Go to E4 . NO : REPAIR circuit VH407 (YE/GN) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. E4 CHECK CIRCUIT RH104 (BU/BN)/RMC32 (GN/BU) FOR AN OPEN Measure the resistance between HVAC module - DATC C228a-6, circuit RH104 (BU/BN), harness side and ambient temperature sensor C132-2, circuit RMC32 (GN/BU), harness side. Is the resistance less than 5 ohms? YES : Go to E7 . NO : REPAIR circuit RH104 (BU/BN)/RMC32 (GN/BU) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. E5 CHECK CIRCUITS VH407 (YE/GN) AND RH104 (BU/BN)/RMC32 (GN/BU) FOR A SHORT TOGETHER Key in OFF position. Disconnect: HVAC Module - DATC C228a Disconnect: HVAC Module - DATC C228b Measure the resistance between ambient temperature sensor C132-1, circuit VH407 (YE/GN), harness side and C132-2, circuit RMC32 (GN/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to E6 . NO : REPAIR circuits VH407 (YE/GN) and RH104 (BU/BN)/RMC32 (GN/BU) for a short together. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
6. E6 CHECK CIRCUIT VH407 (YE/GN) FOR A SHORT TO GROUND Key in OFF position. Measure the resistance between ground and HVAC module - DATC C228a-17, circuit VH407 (YE/GN), harness side. Is the resistance greater than 10,000 ohms? YES : Go to E7 . NO : REPAIR circuit VH407 (YE/GN) for a short to ground. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
7. E7 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test F: DTC B1259 or B1261

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the solar radiation sensor receives a ground through circuit GD145 (BK/BU). A 5-volt reference voltage is supplied to the solar radiation sensor from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit (RH) VH416 (VT/GY) and (LH) VH417 (YE/OG).

1. DTC B1259 Solar Radiation Sensor Circuit Open - The module senses no voltage drop on the sensor reference voltage circuit, indicating an open circuit.
2. DTC B1261 Solar Radiation Sensor Circuit Short To Ground - The module senses excessive voltage drop on the sensor reference voltage circuit, indicating a short directly to ground.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Solar radiation sensor
3. HVAC module - DATC

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. F1 CHECK THE HVAC MODULE OUTPUT VOLTAGE Key in OFF position. Disconnect: Solar Radiation Sensor C286 Key in ON position. Press the AUTOMATIC button. Measure the voltage between solar radiation sensor C286-1, circuit VH417 (YE/OG), harness side and C286-5, circuit GD145 (BK/BU), harness side. Measure the voltage between solar radiation sensor C286-5, circuit GD145 (BK/BU), harness side and C286-6, circuit VH416 (VT/GY), harness side. Are the voltages between 4.7 and 5.1 volts? YES : INSTALL a new solar radiation sensor. CLEAR the DTCs. REPEAT the self-test. If the code returns, go to F6 . NO : For DTC B1259 , go to F2 . For DTC B1261 , go to F4 .
2. F2 CHECK CIRCUITS VH416 (VT/GY) AND VH417 (YE/OG) FOR AN OPEN Key in OFF position. Disconnect: HVAC Module - DATC C228a Measure the resistance between HVAC module - DATC C228a-18, circuit VH417 (YE/OG), harness side and solar radiation sensor C286-1, circuit VH417 (YE/OG), harness side. Measure the resistance between HVAC module - DATC C228a-16, circuit VH416 (VT/GY), harness side and solar radiation sensor C286-6, circuit VH416 (VT/GY), harness side. Is the resistance less than 5 ohms? YES : Go to F3 . NO : REPAIR circuit VH416 (VT/GY) or VH417 (YE/OG) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
3. F3 CHECK CIRCUIT GD145 (BK/BU) FOR AN OPEN Measure the resistance between ground and solar radiation sensor C286-5, circuit GD145 (BK/BU), harness side. Is the resistance less than 5 ohms? YES : Go to F6 . NO : REPAIR circuit GD145 (BK/BU) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
4. F4 CHECK CIRCUITS VH416 (VT/GY) AND VH417 (YE/OG) FOR A SHORT TO CIRCUIT GD145 (BK/BU) Key in OFF position. Disconnect: HVAC Module - DATC C228a Measure the resistance between solar radiation sensor C286-1, circuit VH417 (YE/OG), harness side and circuit C286-5, GD145 (BK/BU), harness side. Measure the resistance between solar radiation sensor C286-6, circuit VH416 (VT/GY), harness side and circuit C286-5, GD145 (BK/BU), harness side. Are the resistances greater than 10,000 ohms? YES : Go to F5 . NO : REPAIR circuit VH416 (VT/GY) or VH417 (YE/OG) for a short to circuit GD145 (BK/BU). CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
5. F5 CHECK CIRCUITS VH416 (VT/GY) AND VH417 (YE/OG) FOR A SHORT TO GROUND Measure the resistance between ground and solar radiation sensor C286-1, circuit VH417 (YE/OG), harness side. Measure the resistance between ground and solar radiation sensor C286-6, circuit VH416 (VT/GY), harness side. Are the resistances greater than 10,000 ohms? YES : Go to F6 . NO : REPAIR circuit VH416 (VT/GY) or VH417 (YE/OG) for a short to ground. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
6. F6 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test G: DTC B1676

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the HVAC module - Dual Automatic Temperature Control (DATC) receives a ground through circuit GD145 (BK/BU). The HVAC module - DATC is supplied constant battery voltage through circuit SBP28 (GN/RD) and ignition switched voltage through circuit CBP20 (YE/VT).

1. DTC B1676 Battery Pack Voltage Out Of Range - The module senses when battery voltage is less than 9 volts or greater than 16 volts.

This pinpoint test is intended to diagnose the following

1. Fuse(s)
2. Wiring, terminals or connectors
3. HVAC module - DATC

Scheme 54

Scheme 55

Scheme 56

Scheme 57

1. G1 RETRIEVE ALL CMDTCs IN ALL MODULES Enter the following diagnostic mode on the diagnostic tool: Self Test - All Continuous Memory Diagnostic Trouble Codes (CMDTCs) Is B1317, B1318 or B1676 present in more than one module AND P0563, P0620, P0625, P0626 or P065B present in the PCM? YES : REFER to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/charging-system/#charging-system-general-information) article for diagnosis of the battery and charging system. CLEAR all CMDTCs. TEST the system for normal operation. NO : Go to G2 .
2. G2 CHECK BATTERY CONDITION Refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article and carry out the Battery - Condition Test Does the battery pass the condition test? YES : If the battery passed the condition test but required a recharge, REFER to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/charging-system/#charging-system-general-information) article to diagnose the charging system. CLEAR all CMDTCs. TEST the system for normal operation. If the battery passed the condition test and did not require a recharge, go to G3 . NO : INSTALL a new battery. CLEAR all CMDTCs. TEST the system for normal operation.
3. G3 CHECK CHARGING SYSTEM VOLTAGE NOTE: Do not allow the engine speed to increase above 2,000 RPM while performing this step or the generator may self excite and result in default charging system output voltage. If engine speed goes above 2,000 RPM, shut the vehicle OFF and restart the engine before performing this step. Measure the voltage of the battery with and without a load on the charging system as follows: Turn off all accessories and run the engine at 1,500 RPM for a minimum of 2 minutes while measuring battery voltage. Turn on headlights and HVAC fan on high and run engine at 1,500 RPM for a minimum of 2 minutes while measuring battery voltage. Are the voltages between 13 and 15.2 volts? YES : Go to G4 . NO : REFER to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/charging-system/#charging-system-general-information) article to diagnose the charging system. CLEAR all CMDTCs. TEST the system for normal operation.
4. G4 CHECK FOR VOLTAGE MONITORING THE MODULE SUPPLY VOLTAGE (VBAT_CC) HVAC PID Key in ON position. Enter the following diagnostic mode on the diagnostic tool: VBAT_CC HVAC PID Monitor the battery voltage VBAT_CC HVAC PID. Is the battery voltage less than 9 or greater than 15.5 volts? YES : If voltage is less than 9 volts, go to G5 . If voltage is greater than 15.5 volts, INSTALL a new HVAC module. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. CLEAR all CMDTCs. REPEAT the self-test. NO : Go to G8 .
5. G5 CHECK CIRCUIT GD145 (BK/BU) FOR AN OPEN Key in OFF position. Measure the resistance between ground and HVAC module - DATC C228a-2, circuit GD145 (BK/BU), harness side. Is the resistance less than 5 ohms? YES : Go to G6 NO : REPAIR circuit GD145 (BK/BU) for an open. TEST the system for normal operation.
6. G6 CHECK CIRCUIT SBP28 (GN/RD) FOR AN OPEN Key in OFF position. Disconnect: HVAC Module - DATC C228a Measure the voltage between ground and HVAC module - DATC C228a-13, circuit SBP28 (GN/RD), harness side. Is the voltage greater than 10 volts? YES : Go to G7 . NO : VERIFY Smart Junction Box (SJB) fuse 28 (10A) is OK. If OK, REPAIR circuit SBP28 (GN/RD) for an open. TEST the system for normal operation.
7. G7 CHECK CIRCUIT CBP20 (YE/VT) FOR AN OPEN Key in ON position. Measure the voltage between ground and HVAC module - DATC C228a-3, circuit CBP20 (YE/VT), harness side. Is the voltage greater than 10 volts? YES : Go to G8 . NO : If DTC B1676 is present in multiple modules, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/charging-system/#charging-system-general-information) article. If DTC B1676 is present only in the HVAC module - EMTC or HVAC module - DATC, VERIFY SJB fuse 20 (10A) is OK. If OK, REPAIR circuit SBP28 (GN/RD) for an open. TEST the system for normal operation.
8. G8 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test H: HVAC Functions Verification

This pinpoint test is intended to diagnose the following

1. Incorrect functioning of the HVAC system

Note. Diagnose any HVAC module DTCs before carrying out the following pinpoint test.

Note. Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose those first. Refer to PCM DTC Chart.

1. H1 CHECK THE BLOWER MOTOR OPERATION Key in ON position. Select PANEL mode. Observe blower motor operation and select each blower motor speed. Does the blower motor operate in all selections and change speed in each? YES : Go to H2 . NO : (Manual climate control systems) If the blower motor does not operate in any setting, go to «Pinpoint Test P»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-p-the-blower-motor) . (Dual Automatic Temperature Control (DATC) systems) If the blower motor does not operate in any setting, go to «Pinpoint Test R»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-r-the-blower-motor) . (Manual climate control systems) If the blower motor does not properly change speeds or shut OFF, go to «Pinpoint Test Q»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-q-the-blower-motor) . (DATC systems) If the blower motor does not properly change speeds or shut OFF, go to «Pinpoint Test S»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-s-the-blower-motor) .
2. H2 CHECK AIRFLOW OPERATION Select the highest blower motor setting. NOTE: Refer to «DESCRIPTION AND OPERATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) for proper airflow descriptions. While observing the airflow, select each of the airflow positions (PANEL, PANEL/FLOOR, FLOOR, FLOOR/DEFROST, DEFROST). Is the airflow directed to the proper outlets? YES : Go to H3 . NO : (Manual climate control systems) Go to «Pinpoint Test I»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . (Dual Automatic Temperature Control (DATC) systems) Go to «Pinpoint Test J»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-j-incorrecterratic-direction-of) .
3. H3 VERIFY TEMPERATURE CONTROL OPERATION Start the vehicle and allow it to reach normal operating temperature. With the A/C OFF, select PANEL mode. Change the temperature setting from the coldest to the warmest and back to the coldest. Does the temperature change between very warm to cool? YES : Go to H4 . NO : If the temperature does not get very warm, go to «Pinpoint Test K»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-k-insufficient-erratic-or) . (Manual climate control systems) If the temperature does not change at all, go to «Pinpoint Test O»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-o-the-temperature-control) . (Dual Automatic Temperature Control (DATC) systems) If the temperature does not change at all, go to «Pinpoint Test C»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-c-dtc-b2266-or) .
4. H4 VERIFY THE A/C CLUTCH DOES NOT ENGAGE WITH A/C OFF With the A/C OFF, select PANEL mode. Select the coldest temperature setting. Is the outlet temperature close to ambient temperature? YES : Go to H5 . NO : (Manual climate control systems) If the temperature is warmer than ambient temperature, go to «Pinpoint Test O»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-o-the-temperature-control) and diagnose for inoperative blend door. (Dual Automatic Temperature Control (DATC) systems) If the temperature is warmer than ambient temperature, go to «Pinpoint Test C»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-c-dtc-b2266-or) and diagnose for inoperative blend door. If the outlet temperature is significantly colder than ambient temperature and the A/C compressor clutch cycles normally, go to «Pinpoint Test N»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-n-the-air-conditioning) . If the outlet temperature is significantly colder than ambient temperature and the A/C compressor clutch does not cycle, go to «Pinpoint Test M»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-m-the-air-conditioning) .
5. H5 VERIFY A/C CLUTCH ENGAGEMENT IN THE A/C MODE Make sure the ambient air temperature is above 2°C (35°F). Select PANEL mode. Press the A/C button (indicator ON). Does the A/C clutch engage when the PANEL and A/C button (indicator ON) is pressed? YES : Go to H6 . NO : Go to «Pinpoint Test L»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-l-the-air-conditioning) .
6. H6 CHECK THE RECIRC OPERATION Press the RECIRC button (indicator OFF). Select PANEL mode. Select the highest blower motor setting. Observe airflow noise. Press the RECIRC button (indicator ON). Does the airflow noise increase when the RECIRC mode is selected (indicator ON)? YES : Go to H7 . NO : (Manual climate control systems) Go to «Pinpoint Test I»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . (Dual Automatic Temperature Control (DATC) systems) Go to «Pinpoint Test J»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-j-incorrecterratic-direction-of) .
7. H7 CHECK THE AUXILIARY BLOWER MOTOR OPERATION Using the front and rear auxiliary blower motor controls, observe blower motor operation and select each auxiliary blower motor speed. Does the auxiliary blower motor operate in all selections and change speed in each? YES : Go to H8 . NO : If the auxiliary blower motor does not operate in any setting, go to «Pinpoint Test T»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-t-the-auxiliary-blower) . If the auxiliary blower motor does not properly change speeds or shut OFF, go to «Pinpoint Test U»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-u-the-auxiliary-blower) .
8. H8 VERIFY AUXILIARY TEMPERATURE/MODE OPERATION Select the highest auxiliary blower motor setting. Using the front and rear auxiliary controls, change the temperature/mode setting from the coldest to the warmest/floor and back to the coldest/overhead. Does the temperature change between very warm to cool and auxiliary airflow to the floor when warm is selected and headliner when cool is selected? YES : The system is operating normally. NO : If the auxiliary temperature control is inoperative/does not operate correctly, go to «Pinpoint Test W»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-w-the-auxiliary-temperature) . If the auxiliary panel/floor control is inoperative/does not operate correctly from the front/rear auxiliary controls, go to «Pinpoint Test V»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-v-the-auxiliary-panelfloor) .

Under normal operation, the function selector switch is provided vacuum from the engine. When a position is selected, vacuum is applied to the desired vacuum control motor that is connected to the mode door you want to control.

This pinpoint test is intended to diagnose the following

1. Function selector switch
2. Heater control valve
3. Vacuum control motor
4. Stuck or bound linkage or door
5. Leaking or plugged vacuum hose

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Scheme 68

1. I1 CHECK THE SYSTEM AIRFLOW Key in ON position. With the engine running, set the blower motor speed to maximum. Check for proper airflow in each function selector switch position at engine idle and under acceleration. Is the airflow correct in each function selector switch position? YES : The system is operating normally. NO : If the airflow is from only the defrost outlet in all settings, go to I2 . If the airflow is incorrect in one setting only or recirculate does not function, NOTE the non-functional setting. Go to I11 .
2. I2 CHECK FOR VACUUM AT THE CHECK VALVE Disconnect the vacuum check valve and connect the vacuum pump to the vacuum source line and check for manifold vacuum. Is manifold vacuum present at the check valve vacuum source line? YES : Go to I3 . NO : REPAIR or INSTALL a new check valve vacuum source line. TEST the system for normal operation.
3. I3 CHECK THE VACUUM CHECK VALVES FOR LEAKAGE Key in OFF position. Disconnect: A/C Vacuum Check Valve Connect the vacuum pump to the open port on the vacuum check valve and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum check valves? YES : Go to I4 . NO : INSTALL a new vacuum check valve. TEST the system for normal operation.
4. I4 CHECK THE VACUUM CHECK VALVES FOR BLOCKAGE Connect the vacuum pump to the opposite port on the vacuum check valve and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum check valves? YES : Go to I5 . NO : INSTALL a new vacuum check valve. TEST the system for normal operation.
5. I5 CHECK THE VACUUM RESERVOIR LINE FOR LEAKS Disconnect the vacuum reservoir line at the vacuum reservoir. Plug the vacuum reservoir line at the vacuum reservoir connection. Leak test the vacuum reservoir line, using the vacuum pump. Does the vacuum reservoir line leak? YES : REPAIR or INSTALL a new vacuum reservoir line. TEST the system for normal operation. NO : Go to I6 .
6. I6 CHECK THE VACUUM RESERVOIR LINE FOR BLOCKAGE Unplug the vacuum reservoir line at the vacuum reservoir connection. Connect the vacuum pump to the vacuum reservoir line at the vacuum check valve connection and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum reservoir line? YES : REPAIR or INSTALL a new vacuum reservoir line. TEST the system for normal operation. NO : Go to I7 .
7. I7 CHECK THE VACUUM RESERVOIR FOR A LEAK Connect the vacuum pump reservoir line to the vacuum reservoir. With the vacuum pump connected to the vacuum reservoir line, leak test the vacuum reservoir. Does the vacuum reservoir leak? YES : INSTALL a new vacuum reservoir. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to I8 .
8. I8 CHECK THE FUNCTION SELECTOR SWITCH VACUUM SOURCE LINE FOR BLOCKAGE Disconnect the function selector switch vacuum connector. Connect the vacuum pump to the function selector switch vacuum source line and attempt to pull a vacuum. Can a vacuum be pulled on the function selector switch vacuum source line? YES : REPAIR or INSTALL a new function selector switch vacuum source line. TEST the system for normal operation. NO : Go to I9 .
9. I9 CHECK THE FUNCTION SELECTOR SWITCH VACUUM SOURCE LINE FOR LEAKS Plug the function selector switch vacuum source line at the vacuum check valve connection. Leak test the function selector switch vacuum source line using the vacuum pump. Does the function selector switch vacuum source line leak? YES : Go to I10 . NO : Go to I15 .
10. I10 CHECK THE HEATER CONTROL VALVE VACUUM SWITCH Disconnect the vacuum harness from the heater control valve vacuum switch and plug the vacuum source port. Leak test the vacuum source line using the vacuum pump. Does the vacuum source line leak? YES : REPAIR or INSTALL a new vacuum source line. TEST the system for normal operation. NO : INSTALL a new heater control valve vacuum switch. TEST the system for normal operation.
11. I11 CHECK THE VACUUM CONTROL MOTOR LINE FOR BLOCKAGE Key in OFF position. Disconnect the function selector switch vacuum connector. Disconnect the vacuum line from the appropriate vacuum control motor noted in Step I1. Connect the vacuum pump to the appropriate vacuum control motor line noted in step I1, and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum control motor line? YES : REPAIR or INSTALL a new vacuum harness. TEST the system for normal operation. NO : Go to I12 .
12. I12 CHECK THE VACUUM CONTROL MOTOR LINE FOR LEAKS NOTE: Vehicles NOT equipped with a heater control valve vacuum switch: if the recirculation vacuum control motor does not function, disconnect and plug the heater control valve connection. Plug the vacuum control motor line at the vacuum control motor connection. Leak test the vacuum control motor line using the vacuum pump. Does the vacuum control motor line leak? YES : REPAIR or INSTALL a new vacuum harness. TEST the system for normal operation. NO : Go to I13 .
13. I13 CHECK THE VACUUM CONTROL MOTOR FOR LEAKS AND CORRECT OPERATION Connect the vacuum pump to the appropriate vacuum control motor and pull a vacuum. Does the vacuum control motor operate and hold vacuum? YES : Go to I15 . NO : Go to I14 .
14. I14 CHECK THE MODE DOOR LINKAGE AND MOVEMENT Inspect the mode door linkage and verify correct movement of the mode door. Is the mode door or mode door linkage broken, binding or otherwise obstructed? YES : REPAIR the mode door or mode door linkage as necessary. TEST the system for normal operation. NO : INSTALL a new vacuum control motor. TEST the system for normal operation.
15. I15 CHECK THE FUNCTION SELECTOR SWITCH FOR BLOCKAGE Connect a vacuum pump to the function selector switch vacuum supply port and try to pull a vacuum in each function selector switch position except DEFROST. If the vacuum pump can pull and hold a vacuum, the switch is plugged. If the vacuum pump pulls a vacuum that slowly decays, the switch is restricted. Is the switch plugged or restricted? YES : INSTALL a new function selector switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to I16 .
16. I16 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 each control port. At each function selector switch position, apply 51 kPa (15 in-Hg) of vacuum. Does the vacuum drop exceed 3.37 kPa (1 in-Hg) per minute? YES : INSTALL a new function selector switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating normally.

Pinpoint Test J: Incorrect/Erratic Direction of Airflow From Outlets - DATC

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the solenoid and manifold assembly receives a ground from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit RH226 (WH/VT). Depending on which solenoid is to be energized, the solenoid and manifold assembly receives voltage from the HVAC module - DATC through circuits

1. CH220 (GN/BN) for the air inlet door vacuum control motor.
2. CH221 (GY/VT) for the defrost door vacuum control motor.
3. CH222 (WH/VT) for the floor door vacuum control motor.
4. CH223 (YE/BU) for the panel door vacuum control motor.
5. CH224 (BU/OG) for the heater control valve.

Engine vacuum is supplied to the solenoid and manifold assembly. When one of the solenoids is energized, vacuum is applied to the control motor or valve and the desired door or valve is either opened or closed.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. solenoid and manifold assembly
3. HVAC module - DATC
4. Heater control valve
5. Vacuum control motor
6. Stuck or bound linkage or door
7. Leaking or plugged vacuum hose

Scheme 69

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1. J1 CHECK THE AIRFLOW IN EACH SETTING Key in ON position. With the engine running, check the airflow in each manual override setting on the HVAC module - DATC during engine idle and under acceleration. Is the airflow correct in each manual override setting? YES : The system is operating normally. NO : If the airflow is from only the defrost outlet in all settings, go to J2 . If the airflow is incorrect in one setting only, NOTE the non-functional setting. Go to J10 .
2. J2 CHECK FOR VACUUM AT THE CHECK VALVE Disconnect the vacuum check valve, connect the vacuum pump to the vacuum source line and check for manifold vacuum. Is manifold vacuum present at the check valve vacuum source line? YES : Go to J3 . NO : REPAIR or INSTALL a new check valve vacuum source line. TEST the system for normal operation.
3. J3 CHECK THE VACUUM CHECK VALVE FOR LEAKAGE Key in OFF position. Disconnect: A/C Vacuum Check Valve Connect the vacuum pump to the open port on the vacuum check valve and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum check valve? YES : Go to J4 . NO : INSTALL a new vacuum check valve. TEST the system for normal operation.
4. J4 CHECK THE VACUUM CHECK VALVE FOR BLOCKAGE Connect the vacuum pump to the opposite port on the vacuum check valve and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum check valve? YES : Go to J5 . NO : INSTALL a new vacuum check valve. TEST the system for normal operation.
5. J5 CHECK THE VACUUM RESERVOIR LINE FOR LEAKS Disconnect the vacuum reservoir line at the vacuum reservoir. Plug the vacuum reservoir line at the vacuum reservoir connection. Leak test the vacuum reservoir line, using the vacuum pump. Does the vacuum reservoir line leak? YES : REPAIR or INSTALL a new vacuum reservoir line. TEST the system for normal operation. NO : Go to J6 .
6. J6 CHECK THE VACUUM RESERVOIR LINE FOR BLOCKAGE Unplug the vacuum reservoir line at the vacuum reservoir connection. Connect the vacuum pump to the vacuum reservoir line at the vacuum check valve connection and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum reservoir line? YES : REPAIR or INSTALL a new vacuum reservoir line. TEST the system for normal operation. NO : Go to J7 .
7. J7 CHECK THE VACUUM RESERVOIR FOR A LEAK Connect the vacuum pump reservoir line to the vacuum reservoir. With the vacuum pump connected to the vacuum reservoir line, leak test the vacuum reservoir. Does the vacuum reservoir leak? YES : INSTALL a new vacuum reservoir. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to J8 .
8. J8 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY VACUUM SOURCE LINE FOR BLOCKAGE Disconnect the solenoid and manifold assembly vacuum connector. Connect the vacuum pump to the solenoid and manifold assembly vacuum source line and attempt to pull a vacuum. Can a vacuum be pulled on the solenoid and manifold assembly vacuum source line? YES : REPAIR or INSTALL a new solenoid and manifold assembly vacuum source line. TEST the system for normal operation. NO : Go to J9 .
9. J9 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY VACUUM SOURCE LINE FOR LEAKS Plug the solenoid and manifold assembly vacuum source line at the vacuum check valve connection. Leak test the solenoid and manifold assembly vacuum source line, using the vacuum pump. Does the solenoid and manifold assembly vacuum source line leak? YES : REPAIR or INSTALL a new solenoid and manifold assembly vacuum source line. TEST the system for normal operation. NO : INSTALL a new solenoid and manifold assembly. TEST the system for normal operation.
10. J10 CHECK THE VACUUM CONTROL MOTOR LINE FOR BLOCKAGE Key in OFF position. Disconnect the solenoid and manifold assembly vacuum connector. Disconnect the vacuum line from the appropriate vacuum control motor noted in Step J1. Connect the vacuum pump to the appropriate vacuum control motor line noted in Step J1, and attempt to pull a vacuum. Can a vacuum be pulled on the vacuum control motor line? YES : REPAIR or INSTALL a new vacuum or solenoid and manifold assembly harness. TEST the system for normal operation. NO : Go to J11 .
11. J11 CHECK THE VACUUM CONTROL MOTOR LINE FOR LEAKS Plug the vacuum control motor line at the vacuum control motor connection. Leak test the vacuum control motor line, using the vacuum pump. Does the vacuum control motor line leak? YES : REPAIR or INSTALL a new vacuum harness. TEST the system for normal operation. NO : Go to J12 .
12. J12 CHECK THE VACUUM CONTROL MOTOR FOR LEAKS AND CORRECT OPERATION Connect the vacuum pump to the appropriate vacuum control motor and pull a vacuum. Does the vacuum control motor operate and hold vacuum? YES : Go to J14 . NO : Go to J13 .
13. J13 CHECK THE MODE DOOR LINKAGE AND MOVEMENT Inspect the mode door linkage and verify correct movement of the mode door. Is the mode door or mode door linkage broken, binding or otherwise obstructed? YES : REPAIR the mode door or mode door linkage as necessary. TEST the system for normal operation. NO : INSTALL a new vacuum control motor. TEST the system for normal operation.
14. J14 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY Connect the vacuum harness connector to the solenoid and manifold assembly. Key in ON position. With the engine running, press the PANEL/FLOOR button then the RECIRCULATION button on the HVAC module - DATC. NOTE: The following measurements must be taken by back-probing the solenoid and manifold assembly C2093. Measure the voltage between solenoid and manifold assembly C2093-1, circuit RH226 (WH/VT), harness side and solenoid and manifold assembly: C2093-2, circuit CH220 (GN/BN), harness side. C2093-3, circuit CH221 (GY/VT), harness side. C2093-4, circuit CH222 (WH/VT), harness side. C2093-5, circuit CH223 (YE/BU), harness side. Are all the voltages greater than 10 volts? YES : INSTALL a new solenoid and manifold assembly. TEST the system for normal operation. NO : If none of the circuits measure greater than 10 volts, go to J15 . If some of the circuits measure greater than 10 volts, go to J16 .
15. J15 CHECK CIRCUIT RH226 (WH/VT) FOR AN OPEN Key in OFF position. Disconnect: HVAC Module - DATC C228b and Solenoid and Manifold Assembly C2093 Measure the resistance between HVAC module - DATC C228b-9, circuit RH226 (WH/VT), harness side and solenoid and manifold assembly C2093-1, circuit RH226 (WH/VT), harness side. Is the resistance less than 5 ohms? YES : Go to J16 . NO : REPAIR circuit RH226 (WH/VT) for an open. TEST the system for normal operation.
16. J16 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY CIRCUITS FOR AN OPEN Key in OFF position. Measure the resistance between the HVAC module - DATC connector, harness side and solenoid and manifold assembly, harness side using the following chart. HVAC Module Connector Circuit Solenoid and Manifold Assembly Connector C228b-3 CH220 (GN/BN) C2093-2 C228b-2 CH221 (GY/VT) C2093-3 C228b-10 CH222 (WH/VT) C2093-4 C228b-11 CH223 (YE/BU) C2093-5 Are the resistances less than 5 ohms? YES : Go to J17 . NO : REPAIR the affected circuit for an open. TEST the system for normal operation.
17. J17 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY CIRCUITS FOR A SHORT TO GROUND Measure the resistance between ground and solenoid and manifold assembly: C2093-2, circuit CH220 (GN/BN), harness side. C2093-3, circuit CH221 (GY/VT), harness side. C2093-4, circuit CH222 (WH/VT), harness side. C2093-5, circuit CH223 (YE/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to J18 . NO : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
18. J18 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY CIRCUITS FOR A SHORT TO CIRCUIT RH226 (WH/VT) Measure the resistance between solenoid and manifold assemblyC2093-1, circuit RH226 (WH/VT), harness side and solenoid and manifold assembly: C2093-2, circuit CH220 (GN/BN), harness side. C2093-3, circuit CH221 (GY/VT), harness side. C2093-4, circuit CH222 (WH/VT), harness side. C2093-5, circuit CH223 (YE/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to J19 . NO : REPAIR the affected circuit for a short to circuit RH226 (WH/VT). TEST the system for normal operation.
19. J19 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY Carry out the solenoid and manifold assembly «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . Does the solenoid and manifold assembly test good? YES : Go to J20 . NO : INSTALL a new solenoid and manifold assembly. TEST the system for normal operation.
20. J20 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC Module - Dual Automatic Temperature Control (DATC). REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test K: Insufficient, Erratic or No Heat

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Note. Dual Automatic Temperature Control (DATC) systems only.

Under normal operation, the solenoid and manifold assembly receives a ground from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit RH226 (WH/VT). When the heater control valve vacuum solenoid is to be energized, the solenoid and manifold assembly receives voltage from the HVAC module - DATC through circuit CH224 (BU/OG).

Note. Manual climate control systems only.

Under normal operation, the function selector switch receives engine vacuum. When OFF or MAX A/C is selected, vacuum is applied to the recirculation vacuum control motor. When the temperature is in the full COOL position, the heater control valve vacuum switch applies vacuum to the heater control valve.

This pinpoint test is intended to diagnose the following

1. (DATC systems only) An open, short to voltage, ground in circuit CH224 (BU/OG)
2. (DATC systems only) solenoid and manifold assembly
3. (DATC systems only) HVAC module - DATC
4. (Manual climate control systems only) Function selector switch
5. Heater control valve
6. Heater control valve vacuum switch (if equipped)
7. Stuck or bound linkage or door
8. Leaking or plugged vacuum hose
9. Temperature blend door actuator

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1. K1 CHECK FOR PROPER ENGINE COOLANT LEVEL Key in OFF position. Check the engine coolant level when hot and cold. Is the engine coolant at the correct level (hot/cold) as indicated on the engine coolant recovery reservoir? YES : Go to K3 . NO : Go to K2 .
2. K2 CHECK THE ENGINE COOLING SYSTEM FOR LEAKS Pressure test the cooling system for leaks. Refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article. Does the engine cooling system leak? YES : REPAIR the engine coolant leak. TEST the system for normal operation. NO : Go to K3 .
3. K3 CHECK FOR COOLANT FLOW TO THE HEATER CORE Run the engine until it reaches normal operation temperature. Select the FLOOR position on the control assembly. Set the temperature control to full warm and the blower to the lowest setting. Using a suitable temperature measuring device, check the heater core inlet hose to see if it is hot. Is the heater core inlet hose hot? YES : Go to K9 . NO : Go to K4 .
4. K4 CHECK FOR COOLANT FLOW TO THE HEATER CONTROL VALVE Using a suitable temperature measuring device, measure the heater control valve inlet hose to see if it is hot. Is the heater control valve inlet hose hot? YES : Go to K5 . NO : REFER to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
5. K5 CHECK FOR VACUUM AT THE HEATER CONTROL VALVE Disconnect the heater control valve vacuum connector and check for vacuum. Is vacuum present at the heater control valve? YES : Go to K6 . NO : INSTALL a new heater control valve. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
6. K6 CHECK FOR INCORRECT VACUUM LINE PLACEMENT Key in OFF position. Inspect the heater control valve and A/C vacuum lines for correct placement. Is the vacuum line placement correct? YES : For manual climate control systems, INSTALL a new heater control valve vacuum switch. For DATC systems, go to K7 . NO : CORRECT the vacuum line placement. TEST the system for normal operation.
7. K7 CHECK THE CIRCUIT FOR VOLTAGE Key in OFF position. Disconnect: Solenoid and Manifold Assembly C2093 Key in ON position. Measure the voltage between ground and solenoid and manifold assembly C2093-6, circuit CH224 (BU/OG), harness side. Is any voltage present? YES : Go to K8 . NO : INSTALL a new solenoid and manifold assembly. TEST the system for normal operation.
8. K8 CHECK THE CIRCUIT FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: HVAC Module - DATC C228a Key in ON position. Measure the voltage between ground and solenoid and manifold assembly C2093-6, circuit CH224 (BU/OG), harness side. Is any voltage present? YES : REPAIR circuit CH224 (BU/OG) for a short to voltage. TEST the system for normal operation. NO : INSTALL a new HVAC module - DATC. TEST the system for normal operation.
9. K9 CHECK FOR A PLUGGED OR RESTRICTED HEATER CORE Using a suitable temperature measuring device, measure the heater core outlet hose temperature. Is the heater core outlet hose temperature similar to the inlet hose temperature (within approximately 6-17°C [10-30°F])? YES : For manual climate control systems, go to «Pinpoint Test O»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-o-the-temperature-control) . For Dual Automatic Temperature Control (DATC) systems, go to «Pinpoint Test C»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-c-dtc-b2266-or) . NO : INSTALL a new heater core. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.

Pinpoint Test L: The Air Conditioning (A/C) is Inoperative

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, when A/C is requested, a message is sent over the bus to the PCM (Dual Automatic Temperature Control (DATC) systems) or sends voltage to the PCM through circuit CH443 (GN/OG) (manual climate control systems). The PCM receives input from the A/C cycling switch through circuit CH423 (YE). Ground is provided to the A/C cycling switch through circuit GD113 (BK/YE).

The PCM provides a ground for the A/C clutch relay coil through circuit CH302 (WH/BN). The A/C clutch relay coil receives ignition voltage through circuit CBB40 (YE/GN). Ignition voltage for the A/C clutch relay switch is provided through circuit SBB35 (BU/RD). When the relay is activated, ignition voltage is supplied to the A/C clutch solenoid through circuit CH401 (VT/WH). Ground is supplied for the A/C clutch through circuit GD120 (BK).

This pinpoint test is intended to diagnose the following

1. Fuse(s)
2. Wiring, terminals or connectors
3. PCM
4. (DATC systems) HVAC module - DATC
5. (Manual climate control systems) Function selector switch
6. A/C cycling switch
7. A/C compressor clutch field coil
8. A/C control relay
9. A/C clutch air gap

Note. Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose those first. Refer to the PCM DTC Chart.

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 .

Note. The ambient temperature, as indicated by the DATC display, must be over 6°C (43°F). If the ambient temperature display is inaccurate, Go to Symptom Chart - Climate Control Systems .

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Scheme 90

1. L1 CHECK THE AIR CONDITIONING COMPRESSOR CYCLING SWITCH (ACCS) PCM PID WITH THE A/C ON Enter the following diagnostic mode on the diagnostic tool: ACCS PCM PID Place the function selector switch in the MAX A/C position or press the PANEL and A/C manual override buttons on the HVAC module - DATC. Does the ACCS PCM PID read ON? YES : Go to L5 . NO : For manual climate control systems, go to L2 . For DATC systems, go to L4 .
2. L2 CHECK PCM FOR A/C SIGNAL VOLTAGE Key in OFF position. Disconnect: PCM C175b Key in ON position. Measure the voltage between ground and PCM C175b-15, circuit CH443 (GN/OG), harness side. Is the voltage greater than 10 volts? YES : Go to L16 . NO : Go to L3 .
3. L3 CHECK CIRCUIT CH443 (GN/OG) FOR AN OPEN Key in OFF position. Disconnect: Function Selector Switch C294c Measure the resistance between climate control assembly C294c-9, circuit CH443 (GN/OG), harness side and PCM C175b-15, circuit CH443 (GN/OG), harness side. Is the resistance less than 5 ohms? YES : INSTALL a new function selector switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : REPAIR circuit CH443 (GN/OG) for an open. TEST the system for normal operation.
4. L4 CHECK THE AIR CONDITIONING SWITCH STATUS (AC_SEL_SW) HVAC PID WITH THE A/C ON Enter the following diagnostic mode on the diagnostic tool: AC_SEL_SW HVAC PID Press the PANEL and press and hold the A/C manual override buttons on the HVAC module - DATC. Does the AC_SEL_SW HVAC PID read A/C? YES : Go to L16 . NO : Go to L15 .
5. L5 CHECK THE AIR CONDITIONING COMPRESSOR DIAGNOSTIC SWITCH (ACDS1) PCM PID WITH THE A/C ON Enter the following diagnostic mode on the diagnostic tool: ACDS1 PCM PID Place the function selector switch in the MAX A/C position or press the PANEL and A/C manual override buttons on the HVAC module - DATC. Does the ACDS1 PCM PID read ENABLE? YES : Go to L9 . NO : Go to L6 .
6. L6 CHECK THE A/C CYCLING SWITCH INPUT Key in OFF position. Disconnect: PCM C175b Measure the resistance between ground and PCM C175b-16, circuit CH423 (YE), harness side. Is the resistance less than 20 ohms? YES : Go to L16 . NO : Go to L7 .
7. L7 CHECK CIRCUIT CH423 (YE) FOR AN OPEN Disconnect: A/C Cycling Switch C130 Measure the resistance between A/C cycling switch C130-1, circuit CH423 (YE), harness side and PCM C175b-16, circuit CH423 (YE), harness side. Is the resistance less than 5 ohms? YES : Go to L8 . NO : REPAIR circuit CH423 (YE) for an open. TEST the system for normal operation.
8. L8 CHECK THE A/C CYCLING SWITCH Key in OFF position. Measure the resistance between the A/C cycling switch terminals. Is the resistance less than 21 ohms? YES : REPAIR circuit GD113 (BK/YE) for an open. TEST the system for normal operation. NO : INSTALL a new A/C cycling switch. TEST the system for normal operation.
9. L9 CHECK THE AIR CONDITIONING CLUTCH (WAC/ACCR) PCM PID WITH THE A/C ON Enter the following diagnostic mode on the diagnostic tool: WAC/ACCR PCM PID Place the function selector switch in the MAX A/C position or press the PANEL and A/C manual override buttons on the HVAC module - DATC. With the engine running, does the WAC/ACCR PCM PID read ON? YES : Go to L10 . NO : Go to L16 .
10. L10 CHECK CIRCUIT SBB35 (BU/RD) FOR VOLTAGE Key in OFF position. Disconnect: A/C Control Relay Key in ON position. Measure the voltage between ground and A/C control relay socket pin 3, circuit SBB35 (BU/RD). Is the voltage greater than 10 volts? YES : Go to L11 . NO : VERIFY the Battery Junction Box (BJB) fuse 35 (10A) is OK. If OK, REPAIR circuit SBB35 (BU/RD) for an open. TEST the system for normal operation.
11. L11 CHECK THE VOLTAGE AT THE A/C COMPRESSOR CLUTCH FIELD COIL Key in OFF position. Connect: A/C Control Relay Disconnect: A/C Compressor Clutch Field Coil C1110 Key in ON position. With the engine running, measure the voltage between ground and A/C compressor clutch field coil C1110-1, circuit CH401 (VT/WH)(4.0L) or circuit CH401 (GY/WH)(4.6L), harness side. Is the voltage greater than 10 volts? YES : Go to L13 . NO : Go to L12 .
12. L12 CHECK CIRCUIT CH401 (VT/WH) OR CIRCUIT CH401 (GY/WH) FOR AN OPEN Key in OFF position. Connect: A/C Control Relay Measure the resistance between A/C control relay socket pin 5, circuit CH401 (VT/WH)(4.0L) or circuit CH401 (GY/WH)(4.6L) and A/C compressor clutch field coil C1110-1, circuit CH401 (VT/WH)(4.0L) or circuit CH401 (GY/WH)(4.6L), harness side. Is the resistance less than 5 ohms? YES : INSTALL a new A/C control relay. TEST the system for normal operation. NO : REPAIR circuit CH401 (VT/WH)(4.0L) or circuit CH401 (GY/WH)(4.6L) for an open. TEST the system for normal operation.
13. L13 CHECK THE GROUND AT THE A/C COMPRESSOR CLUTCH FIELD COIL Key in OFF position. Measure the resistance between ground and A/C compressor clutch field coil C1110-2, circuit GD120 (BK/GN)(4.0L) or circuit GD120 (BK)(4.6L), harness side. Is the resistance less than 5 ohms? YES : Go to L14 . NO : REPAIR circuit GD120 (BK/GN)(4.0L) or circuit GD120 (BK)(4.6L) for an open. TEST the system for normal operation.
14. L14 CHECK THE A/C COMPRESSOR CLUTCH AIR GAP Measure the A/C compressor clutch air gap at 3 equally spaced locations between the clutch hub and the A/C compressor clutch pulley. Is the A/C compressor clutch air gap average greater than 0.65 mm (0.026 in)? YES : ADJUST the A/C compressor clutch field coil. REFER to «Air Conditioning (A/C) Clutch Air Gap Adjustment»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-clutch-air-gap) . TEST the system for normal operation. NO : INSTALL a new A/C compressor clutch field coil. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
15. L15 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.
16. L16 CHECK THE PCM CONNECTION Clear the DTCs. Disconnect all the PCM connectors. Check for: corrosion. pushed-out pins. incorrectly seated connector. Connect and correctly seat all the PCM connectors. Operate the system. Does the concern return? YES : INSTALL a new PCM. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Pinpoint Test M: The Air Conditioning (A/C) is Always On - A/C Compressor Does Not Cycle

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, when A/C is requested, a message is sent over the bus to the PCM (Dual Automatic Temperature Control (DATC) systems) or sends voltage to the PCM through circuit CH443 (GN/OG) (manual climate control systems). The PCM receives input from the A/C cycling switch through circuit CH423 (YE) and from the A/C pressure cutoff switch through circuit CH423 (YE). Ground is provided to the A/C cycling switch and A/C pressure cutoff switch through circuit GD113 (BK/YE).

The PCM provides a ground for the A/C clutch relay coil through circuit CH302 (WH/BN). The A/C clutch relay coil receives ignition voltage through circuit CBB40 (YE/GN). Ignition voltage for the A/C clutch relay switch is provided through circuit SBB35 (BU/RD). When the relay is activated, ignition voltage is supplied to the A/C clutch solenoid through circuit CH401 (VT/WH). Ground is supplied for the A/C clutch through circuit GD120 (BK).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. PCM
3. A/C compressor clutch field coil
4. A/C control relay
5. A/C clutch air gap

1. M1 CHECK THE AIR CONDITIONING CLUTCH (WAC/ACCR) PCM PID WITH THE A/C ON Key in ON position. Place the function selector switch to the OFF position. Enter the following diagnostic mode on the diagnostic tool: WAC/ACCR PCM PID Does the WAC/ACCR PCM PID read ON? YES : Go to M6 . NO : Go to M2 .
2. M2 CHECK THE AIR CONDITIONING COMPRESSOR DIAGNOSTIC SWITCH (ACDS1) PCM PID Key in OFF position. Disconnect: A/C Cycling Switch C130 Key in ON position. Enter the following diagnostic mode on the diagnostic tool: ACDS1 PCM PID Observe the ACDS1 PCM PID. Does the ACDS1 PCM PID read DISABLE? YES : Go to M3 . NO : REPAIR circuit CH423 (YE) for a short to Ground. TEST the system for normal operation.
3. M3 CHECK THE A/C CYCLING SWITCH Key in OFF position. Remove the A/C cycling switch from the vehicle. Measure the resistance between the A/C cycling switch terminals. Is the resistance greater than 10,000 ohms? YES : Go to M4 . NO : INSTALL a new A/C cycling switch. TEST the system for normal operation.
4. M4 CHECK FOR VOLTAGE TO THE A/C COMPRESSOR CLUTCH FIELD COIL Key in OFF position. Disconnect: A/C Compressor Clutch Field Coil C1110 Key in ON position. Measure the voltage between ground and A/C compressor clutch field coil C1110-1, circuit CH401 (VT/WH), harness side. Is any voltage present? YES : Go to M5 . NO : ADJUST the A/C compressor clutch air gap. REFER to «Air Conditioning (A/C) Clutch Air Gap Adjustment»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-clutch-air-gap) . TEST the system for normal operation.
5. M5 CHECK THE A/C CONTROL RELAY Key in OFF position. Disconnect: A/C Control Relay Key in ON position. Measure the voltage between ground and A/C compressor clutch field coil C1110-1, circuit CH401 (VT/WH), harness side. Is any voltage present? YES : REPAIR circuit CH401 (VT/WH) for a short to voltage. TEST the system for normal operation. NO : INSTALL a new A/C control relay. TEST the A/C clutch diode. INSTALL a new diode, if necessary. TEST the system for normal operation.
6. M6 CHECK THE PCM CONNECTION Clear the DTCs. Disconnect all the PCM connectors. Check for: corrosion. pushed-out pins. incorrectly seated connector. Connect and correctly seat all the PCM connectors. Operate the system. Does the concern return? YES : INSTALL a new PCM. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Pinpoint Test N: The Air Conditioning (A/C) is Always On - A/C Mode Always Commanded ON

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, when A/C is requested, a message is sent over the bus to the PCM (Dual Automatic Temperature Control (DATC) systems) or sends voltage to the PCM through circuit CH443 (GN/OG) (manual climate control systems). The PCM receives input from the A/C cycling switch through circuit CH423 (YE) and from the A/C pressure cutoff switch through circuit CH423 (YE). Ground is provided to the A/C cycling switch and A/C pressure cutoff switch through circuit GD113 (BK/YE).

The PCM provides a ground for the A/C clutch relay coil through circuit CH302 (WH/BN). The A/C clutch relay coil receives ignition voltage through circuit CBB40 (YE/GN). Ignition voltage for the A/C clutch relay switch is provided through circuit SBB35 (BU/RD). When the relay is activated, ignition voltage is supplied to the A/C clutch solenoid through circuit CH401 (VT/WH). Ground is supplied for the A/C clutch through circuit GD120 (BK).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. PCM
3. (DATC systems) HVAC module - DATC
4. (Manual climate control systems) Function selector switch

1. N1 CHECK THE AIR CONDITIONING COMPRESSOR CYCLING SWITCH (ACCS) PCM PID WITH THE A/C OFF Enter the following diagnostic mode on the diagnostic tool: ACCS PCM PID Place the function selector switch to the OFF position or press the OFF manual override button on the HVAC module - DATC. Does the ACCS PCM PID read OFF? YES : Go to N6 . NO : Go to N4 . For manual climate control systems, go to N2 .
2. N2 CHECK CIRCUIT CH443 (GN/OG) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: Climate Control Assembly C294b and C294c Disconnect: PCM C175b Key in ON position. Measure the voltage between ground and PCM 175b-15, circuit CH443 (GN/OG), harness side. Is any voltage present? YES : REPAIR circuit CH443 (GN/OG) for a short to voltage. TEST the system for normal operation. NO : Go to N3 .
3. N3 CHECK THE FUNCTION SELECTOR SWITCH Key in OFF position. Carry out the function selector switch «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . Does the function selector switch test good? YES : Go to N5 . NO : INSTALL a new function selector switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
4. N4 CHECK THE AIR CONDITIONING SWITCH STATUS (AC_SEL_SW) HVAC PID WITH THE A/C OFF Enter the following diagnostic mode on the diagnostic tool: AC_SEL_SW HVAC PID Select PANEL mode on the HVAC module and make sure the A/C button and indicator are OFF. Does the AC_SEL_SW HVAC PID read Not Pressed? YES : Go to N6 . NO : Go to N5 .
5. N5 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.
6. N6 CHECK THE PCM CONNECTION Clear the DTCs. Disconnect all the PCM connectors. Check for: corrosion. pushed-out pins. incorrectly seated connector. Connect and correctly seat all the PCM connectors. Operate the system. Does the concern return? YES : INSTALL a new PCM. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Pinpoint Test O: The Temperature Control is Inoperative/Does Not Operate Correctly - Manual Climate Control

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Under normal operation, the temperature blend door actuator receives ignition voltage through circuit CBP20 (YE/VT) and ground through circuit GD140 (BK/GN). As the temperature selection changes it varies the voltage on circuit VH439 (GY/VT) to the temperature blend door actuator.

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Temperature control switch
4. Temperature blend door actuator
5. Stuck or bound linkage or door

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1. O1 CHECK THE VOLTAGE TO THE BLEND DOOR ACTUATOR Key in OFF position. Disconnect: A/C Electronic Blend Door Actuator Motor C2091 Key in ON position. Measure the voltage between ground and blend door actuator motor C2091-7, circuit CBP20 (YE/VT), harness side. Is the voltage greater than 10 volts? YES : Go to O2 . NO : VERIFY Battery Junction Box (BJB) fuse 20 (10A) is OK. If OK, REPAIR circuit A_CBP20 (YE/VT) for an open. TEST the system for normal operation.
2. O2 CHECK CIRCUIT GD140 (BK/GN) FOR AN OPEN Key in OFF position. Measure the resistance between ground and blend door actuator motor C2091-8, circuit GD140 (BK/GN), harness side. Is the resistance less than 5 ohms? YES : Go to O3 . NO : REPAIR circuit GD140 (BK/GN) for an open. TEST the system for normal operation.
3. O3 CHECK THE TEMPERATURE CONTROL POTENTIOMETER TOTAL RESISTANCE Key in OFF position. Measure the resistance between temperature blend door actuator C2091-7, circuit CBP20 (YE/VT), harness side and C2091-3, circuit VH439 (GY/VT), harness side. Is the resistance between 30 and 1,600 ohms? YES : Go to O6 . NO : If the resistance is less than 30 ohms, go to O4 . If the resistance is greater than 1,600 ohms, go to O5 .
4. O4 CHECK CIRCUITS CBP20 (YE/VT) AND VH439 (GY/VT) FOR A SHORT TOGETHER Disconnect: Climate Control Switch C294c Measure the resistance between temperature blend door actuator C2091-7, circuit CBP20 (YE/VT), harness side and C2091-3, circuit VH439 (GY/VT), harness side. Is the resistance less than 5 ohms? YES : REPAIR circuits CBP20 (YE/VT) and VH439 (GY/VT) for a short together. TEST the system for normal operation. NO : INSTALL a new climate control switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
5. O5 CHECK VH439 (GY/VT) FOR AN OPEN Disconnect: Climate Control Switch C294c Measure the resistance between blend door actuator control connector C2091-3, circuit VH439 (GY/VT), harness side and front A/C climate control switch C294c-3, circuit VH439 (GY/VT), harness side. Is the resistance less than 5 ohms? YES : INSTALL a new climate control switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : REPAIR circuit VH439 (GY/VT) for an open. TEST the system for normal operation.
6. O6 CHECK THE TEMPERATURE CONTROL POTENTIOMETER OPERATION Measure the resistance between temperature blend door actuator C2091-7, circuit CBP20 (YE/VT), harness side and C2091-3, circuit CH439 (GY/VT), harness side while rotating the temperature control potentiometer from full WARM to full COOL. Does the resistance vary between 30 and 1,600 ohms? YES : Go to O7 . NO : INSTALL a new climate control switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
7. O7 CHECK CIRCUIT VH439 (GY/VT) FOR A SHORT TO GROUND Disconnect: Climate Control Switch C294c Measure the resistance between ground and blend door actuator C2091-3, circuit VH439 (GY/VT), harness side. Is the resistance greater than 10,000 ohms? YES : Go to O8 . NO : REPAIR circuit VH439 (GY/VT) for a short to ground. TEST the system for normal operation.
8. O8 CHECK FOR A BINDING, STUCK OR BROKEN BLEND DOOR Key in OFF position. Remove the actuator. Refer to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. Inspect for a binding, stuck or broken blend door or linkage. Is there a binding, stuck or broken blend door or linkage condition? YES : REPAIR the blend door/linkage. TEST the system for normal operation. NO : INSTALL a new temperature blend door actuator. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.

Pinpoint Test P: The Blower Motor is Inoperative - Manual Climate Control

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Under normal operation, the blower motor relay coil receives a ground through circuit GD120 (BK/GN). The coil receives voltage from the function selector switch through circuit CH123 (VT/GN) when any position but OFF is selected. Voltage is supplied to the relay contacts from circuit SBB16 (VT/RD). When the relay coil is energized, voltage is delivered to the blower motor and the high speed blower motor relay through circuit CH402 (YE/GN). Ground is provided from the high speed blower motor relay to the blower motor through circuit VH301 (YE/BU). Voltage for the function selector switch is supplied by circuit CBP20 (YE/VT).

This pinpoint test is intended to diagnose the following

1. Fuse(s)
2. Wiring, terminals or connectors
3. Blower motor
4. High speed blower motor relay
5. Blower motor relay

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1. P1 CHECK FOR VOLTAGE TO THE BLOWER MOTOR Disconnect: Blower Motor C2004 Key in ON position. Place the function selector switch in the FLOOR position. Measure the voltage between ground and blower motor C2004-1, circuit CH402 (YE/GN), harness side. Is the voltage greater than 10 volts? YES : Go to P2 . NO : Go to P4 .
2. P2 CHECK CIRCUIT VH301 (YE/BU) FOR AN OPEN Key in OFF position. Disconnect: High-Speed Blower Motor Relay Measure the resistance between blower motor C2004-2, circuit VH301 (YE/BU), harness side and high-speed blower motor relay socket pin 3, circuit VH301 (YE/BU). Is the resistance less than 5 ohms? YES : Go to P3 . NO : REPAIR circuit VH301 (YE/BU) for an open. TEST the system for normal operation.
3. P3 CHECK THE BLOWER MOTOR Key in ON position. Connect a fused jumper lead between high-speed blower motor relay socket pin 5, circuit GD140 (BK/GN) and pin 3, circuit VH301 (YE/BU). Does the blower motor operate? YES : INSTALL a new high-speed blower motor relay. TEST the system for normal operation. NO : INSTALL a new blower motor. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
4. P4 CHECK CIRCUIT CH402 (YE/GN) FOR AN OPEN Key in OFF position. Disconnect: Blower Motor Relay Measure the resistance between blower motor relay socket pin 5, circuit CH402 (YE/GN) and blower motor C2004-1, circuit CH402 (YE/GN), harness side. Is the resistance less than 5 ohms? YES : Go to P5 . NO : REPAIR circuit CH402 (YE/GN) for an open. TEST the system for normal operation.
5. P5 CHECK FOR VOLTAGE TO THE BLOWER MOTOR RELAY, SWITCH SIDE Measure the voltage between ground and blower motor relay socket pin 3, circuit SBB16 (VT/RD). Is the voltage greater than 10 volts? YES : Go to P6 . NO : VERIFY Battery Junction Box (BJB) fuse 16 (40A) is OK. If OK, REPAIR circuit SBB16 (VT/RD) for an open. TEST the system for normal operation.
6. P6 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN Measure the resistance between ground and blower motor relay socket pin 1, circuit GD120 (BK/GN). Is the resistance less than 5 ohms? YES : Go to P7 . NO : REPAIR circuit GD120 (BK/GN) for an open. TEST the system for normal operation.
7. P7 CHECK FOR VOLTAGE TO THE BLOWER MOTOR RELAY, COIL SIDE Key in ON position. Measure the voltage between ground and blower motor relay socket pin 2, circuit CH123 (VT/GN). Is the voltage greater than 10 volts? YES : INSTALL a new blower motor relay. TEST the system for normal operation. NO : Go to P8 .
8. P8 CHECK CIRCUIT CBP20 (YE/VT) FOR AN OPEN Key in OFF position. Disconnect: Function Selector Switch C294b Key in ON position. Measure the voltage between ground and function selector switch C294b-2, circuit CBP20 (YE/VT), harness side. Is the voltage greater than 10 volts? YES : Go to P9 . NO : VERIFY the Smart Junction Box (SJB) fuse 20 (10A) is OK. If OK, REPAIR circuit CBP20 (YE/VT) for an open. TEST the system for normal operation.
9. P9 CHECK THE FUNCTION SELECTOR SWITCH Key in OFF position. Carry out the function selector switch «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . Does the function selector switch test good? YES : REPAIR circuit CH123 (VT/GN). TEST the system for normal operation. NO : INSTALL a new function selector switch. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.

Pinpoint Test Q: The Blower Motor Does Not Operate Correctly - Manual Climate Control

Refer to SYSTEM WIRING DIAGRAMS , Manual Climate Control System for schematic and connector information.

Under normal operation, when the high speed blower relay is not energized, the blower motor is provided a ground from the resistor through circuit CH446 (BU/BN)/VH301 (YE/BU). The resistor gets a ground from circuit GD140 (BK/GN) in the lowest blower setting. In MED-LO and MED-HI, the resistor gets a ground through circuit CH428 (GN/WH) or CH429 (GY/BN), depending on selected speed. The blower switch receives its ground from circuit GD138 (BK/WH).

The high speed blower motor relay coil receives voltage through circuit CH402 (YE/GN) from the blower motor relay. The coil receives ground from the function selector switch through circuit CH430 (VT/OG) when the highest blower speed is selected. Ground for high blower speed is provided to the high speed blower relay through circuit GD140 (BK/GN) when the relay is energized. The high speed blower motor relay provides the blower motor ground through circuit VH301 (YE/BU).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Blower motor resistor
3. Blower motor switch
4. High speed blower motor relay

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Scheme 114

1. Q1 CHECK THE BLOWER MOTOR OPERATION Key in ON position. Turn the function selector switch to the FLOOR position. Select all blower speed positions. Does the blower motor operate in any position? YES : If the blower motor does not operate in HI, go to Q2 . If the blower motor does not operate in MED-HI, go to Q6 . If the blower motor does not operate in MED-LO, go to Q7 . If the blower motor does not operate in LO, go to Q8 . For all other symptoms, go to Q10 . NO : Go to «Pinpoint Test P»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-p-the-blower-motor) .
2. Q2 CHECK CIRCUIT CH402 (YE/GN) FOR AN OPEN Key in OFF position. Disconnect: High-Speed Blower Motor Relay Key in ON position. Place the function selector switch in FLOOR and the blower motor switch in HI. Measure the voltage between ground and high-speed blower motor relay pin 86, circuit CH402 (YE/GN). Is the voltage greater than 10 volts? YES : Go to Q3 . NO : REPAIR circuit CH402 (YE/GN) for an open. TEST the system for normal operation.
3. Q3 CHECK THE HIGH-SPEED BLOWER MOTOR RELAY CIRCUIT GD140 (BK/GN) FOR AN OPEN Key in OFF position. Measure the resistance between ground and high-speed blower motor relay socket pin 87, circuit GD140 (BK/GN). Is the resistance less than 5 ohms? YES : Go to Q4 . NO : REPAIR circuit GD140 (BK/GN) for an open. TEST the system for normal operation.
4. Q4 CHECK CIRCUIT CH430 (VT/OG) FOR AN OPEN Disconnect: Blower Motor Switch C294a Measure the resistance between high-speed blower motor relay socket pin 85, circuit CH430 (VT/OG) and the blower motor switch C294A-2, circuit CH430 (VT/OG), harness side. Is the resistance less than 5 ohms? YES : Go to Q5 . NO : REPAIR circuit CH430 (VT/OG) for an open. TEST the system for normal operation.
5. Q5 CHECK CIRCUIT CH430 (VT/OG) FOR A SHORT TO GROUND Disconnect: Blower Motor Switch C294a Measure the resistance between ground and blower motor switch C294a-2, circuit CH430 (VT/OG), harness side. Is the resistance greater than 10,000 ohms? YES : INSTALL a new blower motor switch. TEST the system for normal operation. NO : REPAIR circuit CH430 (VT/OG) for a short to ground. TEST the system for normal operation.
6. Q6 CHECK CIRCUIT CH429 (GY/BN) FOR AN OPEN Key in OFF position. Disconnect: Blower Motor Switch C294a Disconnect: Blower Motor Resistor C293 Measure the resistance between blower motor switch C294a-3, circuit CH429 (GY/BN), harness side and blower motor resistor C293-1, circuit CH429 (GY/BN), harness side. Is the resistance less than 5 ohms? YES : Go to Q7 . NO : REPAIR circuit CH429 (GY/BN) for an open. TEST the system for normal operation.
7. Q7 CHECK CIRCUIT CH428 (GN/WH) FOR AN OPEN Key in OFF position. Disconnect: Blower Motor Switch C294a (if not previously disconnected) Disconnect: Blower Motor Resistor C293 (if not previously disconnected) Measure the resistance between blower motor switch C294a-4, circuit CH428 (GN/WH), harness side and blower motor resistor C293-3, circuit CH428 (GN/WH), harness side. Is the resistance less than 5 ohms? YES : Go to Q8 . NO : REPAIR circuit CH428 (GN/WH) for an open. TEST the system for normal operation.
8. Q8 CHECK BLOWER MOTOR RESISTOR GROUND CIRCUIT GD140 (BK/GN) FOR AN OPEN Measure the resistance between ground and blower motor resistor C293-4, circuit GD140 (BK/GN), harness side. Is the resistance less than 5 ohms? YES : Go to Q9 . NO : REPAIR circuit GD140 (BK/GN) for an open. TEST the system for normal operation.
9. Q9 CHECK THE BLOWER MOTOR SWITCH CIRCUIT GD138 (BK/WH) FOR AN OPEN Measure the resistance between ground and blower motor switch C294a-1, circuit GD138 (BK/WH), harness side. Is the resistance less than 5 ohms? YES : Go to Q10 . NO : REPAIR circuit GD138 (BK/WH) for an open. TEST the system for normal operation.
10. Q10 CHECK THE BLOWER MOTOR RESISTOR Carry out the blower motor resistor «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . Does the blower motor resistor test good? YES : Go to Q11 . NO : INSTALL a new blower motor resistor. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
11. Q11 CHECK CIRCUITS CH446 (BU/BN), CH429 (GY/BN) AND CH428 (GN/WH) FOR A SHORT TO GROUND Key in OFF position. Disconnect: Blower Motor C2004 Disconnect: Blower Motor Resistor C293 Place the blower switch in the lowest setting. Measure the resistance between ground and blower motor resistor: C293-1, circuit CH429 (GY/BN), harness side. C293-2, circuit CH446 (BU/BN), harness side. C293-3, circuit CH428 (GN/WH), harness side. Are the resistances greater than 10,000 ohms? YES : Go to Q12 . NO : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
12. Q12 CHECK THE BLOWER MOTOR CIRCUITS FOR SHORTS TOGETHER Measure the resistance between blower motor resistor: C293-1, circuit CH429 (GY/BN), harness side and C293-2, circuit CH446 (BU/BN), harness side. C293-1, circuit CH429 (GY/BN), harness side and C293-3, circuit CH428 (GN/WH), harness side. C293-2, circuit CH446 (BU/BN), harness side and C293-3, circuit CH428 (GN/WH), harness side. Are the resistances greater than 10,000 ohms? YES : INSTALL a new blower motor switch. TEST the system for normal operation. NO : REPAIR the affected circuits for shorts. TEST the system for normal operation.

Pinpoint Test R: The Blower Motor is Inoperative - DATC System

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the blower motor relay coil receives a ground through circuit GD120 (BK/GN). The coil receives voltage from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit CH123 (VT/GN) when the HVAC module - DATC is ON. Voltage is supplied to the relay contacts from circuit SBB16 (VT/RD). When the relay coil is energized, voltage is delivered to the blower motor through circuit CH402 (YE/GN). Ground for the motor is provided through circuit VH301 (YE/BU) from the blower control module. Ground for the blower control module is provided by circuit GD140 (BK/GN).

This pinpoint test is intended to diagnose the following

1. Fuse(s)
2. Wiring, terminals or connectors
3. Blower motor control module
4. HVAC module - DATC
5. Blower motor relay
6. Blower motor

Scheme 115

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Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

1. R1 VERIFY THE BLOWER MOTOR OPERATION Key in ON position. Press the PANEL button on the HVAC module - DATC. Adjust the blower motor setting to LO and then to HI. Is the blower motor inoperative in all settings? YES : Go to R2 . NO : Go to «Pinpoint Test Q»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__pinpoint-test-q-the-blower-motor) .
2. R2 CHECK FOR VOLTAGE TO THE BLOWER MOTOR Key in OFF position. Disconnect: Blower Motor C2004 Key in ON position. Measure the voltage between ground and blower motor C2004-1, circuit CH402 (YE/GN), harness side. Is the voltage greater than 10 volts? YES : Go to R3 . NO : Go to R8 .
3. R3 CHECK CIRCUIT GD140 (BK/GN) FOR AN OPEN Key in OFF position. Disconnect: Blower Motor Speed Control C271 Measure the resistance between ground and blower motor speed control C271-5, circuit GD140 (BK/GN), harness side. Is the resistance less than 5 ohms? YES : Go to R4 . NO : REPAIR circuit GD140 (BK/GN) for an open. TEST the system for normal operation.
4. R4 CHECK CIRCUIT VH301 (YE/BU) FOR AN OPEN Measure the resistance between blower motor C2004-2, circuit VH301 (YE/BU), harness side and blower motor speed control C271-4, circuit VH301 (YE/BU), harness side. Is the resistance less than 5 ohms? YES : Go to R5 . NO : REPAIR circuit VH301 (YE/BU) for an open. TEST the system for normal operation.
5. R5 CHECK THE BLOWER MOTOR Connect: Blower Motor C2004 Connect a fused jumper lead between blower motor speed control C271-4, circuit VH301 (YE/BU), harness side and C271-5, circuit GD140 (BK/GN), harness side. Key in ON position. Does the blower motor operate? YES : Go to R6 . NO : INSTALL a new blower motor. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.
6. R6 CHECK CIRCUIT CH217 (BN) FOR AN OPEN OR SHORT TO GROUND Key in OFF position. Remove the fused jumper lead from blower motor speed control C271. Disconnect: HVAC Module - DATC C228b Measure the resistance between: HVAC module - DATC C228b-4, circuit CH217 (BN), harness side and blower motor speed control C271-3, circuit CH217 (BN), harness side. ground and HVAC module - DATC C228b-4, circuit CH217 (BN), harness side. Is the resistance less than 5 ohms between the HVAC module - DATC and the blower motor speed control and greater than 10,000 ohms between the HVAC module - DATC and ground? YES : Go to R7 . NO : REPAIR circuit CH217 (BN) for an open or a short to ground. TEST the system for normal operation.
7. R7 CHECK THE HVAC MODULE OUTPUT Connect: HVAC Module - DATC C228b Connect: Blower Motor Speed Control C271 Key in ON position. Adjust the blower motor speed to HI. Measure the voltage between ground and HVAC module - DATC C228b-4, circuit CH217 (BN), harness side by back-probing the HVAC module - DATC C228b. Is the voltage within 2 volts of battery voltage? YES : INSTALL a new blower motor speed control. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to R14 .
8. R8 CHECK CIRCUIT CH402 (YE/GN) FOR AN OPEN Key in OFF position. Disconnect: Blower Motor Relay Measure the resistance between blower motor relay socket pin 5, circuit CH402 (YE/GN) and blower motor C2004-1, circuit CH402 (YE/GN), harness side. Is the resistance less than 5 ohms? YES : Go to R9 . NO : REPAIR circuit CH402 (YE/GN) for an open. TEST the system for normal operation.
9. R9 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN Measure the resistance between ground and blower motor relay socket pin 1, circuit GD120 (BK/GN). Is the resistance less than 5 ohms? YES : Go to R10 . NO : REPAIR circuit GD120 (BK/GN) for an open. TEST the system for normal operation.
10. R10 CHECK CIRCUIT SBB16 (VT/RD) FOR VOLTAGE Measure the voltage between ground and blower motor relay socket pin 3, circuit SBB16 (VT/RD). Is the voltage greater than 10 volts? YES : Go to R11 . NO : VERIFY Battery Junction Box (BJB) fuse 16 (40A) is OK. If OK, REPAIR circuit SBB16 (VT/RD) for an open. TEST the system for normal operation.
11. R11 CHECK THE HVAC MODULE OUTPUT Key in ON position. Measure the voltage between blower motor relay socket pin 1, circuit GD120 (BK/GN) and socket pin 2, circuit CH123 (VT/GN). Is the voltage greater than 10 volts? YES : INSTALL a new blower motor relay. TEST the system for normal operation. NO : Go to R12 .
12. R12 CHECK CIRCUIT CH123 (VT/GN) FOR SHORT TO GROUND Key in OFF position. Disconnect: HVAC Module - DATC C228b Measure the resistance between ground and blower motor relay socket pin 2, circuit CH123 (VT/GN). Is the resistance greater than 10,000 ohms? YES : Go to R13 . NO : REPAIR circuit CH123 (VT/GN) for a short to ground. TEST the system for normal operation.
13. R13 CHECK CIRCUIT CH123 (VT/GN) FOR AN OPEN Measure the resistance between HVAC module - DATC C228b-13, circuit CH123 (VT/GN), harness side and blower motor relay socket pin 2, circuit CH123 (VT/GN). Is the resistance less than 5 ohms? YES : Go to R14 . NO : REPAIR circuit CH123 (VT/GN) for an open. TEST the system for normal operation.
14. R14 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test S: The Blower Motor Does Not Operate Correctly - DATC System

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the blower motor control module receives a 1-2 volt signal from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit CH218 (GN/VT) to determine the desired blower motor speed. The HVAC module - DATC receives a feedback voltage from the blower motor control module through circuit VH219 (GY) to determine actual blower motor speed. When the highest blower motor setting is selected, the HVAC module - DATC sends 12 volts to the blower control module through circuit CH217 (BN).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Blower motor control module
3. HVAC module - DATC

Scheme 123

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Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. S1 CHECK CIRCUIT VH301 (YE/BU) FOR A SHORT TO GROUND Key in OFF position. Disconnect: Blower Motor Speed Control C271 Key in ON position. Press the PANEL button on the HVAC module - DATC. Adjust the blower motor setting to LO and then to HI. Does the blower motor operate? YES : REPAIR circuit VH301 (YE/BU) for a short to ground. TEST the system for normal operation. NO : Go to S2 .
2. S2 CHECK THE BLOWER MOTOR SPEED CONTROL Key in OFF position. Connect: Blower Motor Speed Control C271 Disconnect: HVAC Module - DATC C228a Disconnect: HVAC Module - DATC C228b Disconnect: Blower Motor Relay Connect a fused jumper lead between blower motor relay socket pin 3, circuit SBB16 (VT/RD) and pin 5, circuit CH402 (YE/GN). Does the blower motor operate? YES : INSTALL a new blower motor speed control module. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to S3 .
3. S3 CHECK THE BLOWER MOTOR SPEED CONTROL CIRCUITS FOR AN OPEN Key in OFF position. Connect: Blower Motor Relay Disconnect: Blower Motor Speed Control C271 Measure the resistance between blower motor speed control C271-1, circuit VH219 (GY), harness side and HVAC module - DATC C228a-5, circuit VH219 (GY), harness side. Measure the resistance between blower motor speed control C271-2, circuit CH218 (GN/VT), harness side and HVAC module - DATC C228a-15, circuit CH218 (GN/VT), harness side. Measure the resistance between blower motor speed control C271-3, circuit CH217 (BN), harness side and HVAC module - DATC C228b-4, circuit CH217 (BN), harness side. Are the resistances less than 5 ohms? YES : Go to S4 . NO : REPAIR the affected circuit for an open. TEST the system for normal operation.
4. S4 CHECK THE BLOWER MOTOR SPEED CONTROL CIRCUITS FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between ground and blower motor speed control: C271-1, circuit VH219 (GY), harness side. C271-2, circuit CH218 (GN/VT), harness side. C271-3, circuit CH217 (BN), harness side. Is any voltage present? YES : REPAIR the affected circuit for a short to voltage. TEST the system for normal operation. NO : Go to S5 .
5. S5 CHECK THE BLOWER MOTOR SPEED CONTROL CIRCUITS FOR A SHORT TO GROUND Key in OFF position. Measure the resistance between ground and blower motor speed control: C271-1, circuit VH219 (GY), harness side. C271-2, circuit CH218 (GN/VT), harness side. C271-3, circuit CH217 (BN), harness side. Are the resistances greater than 10,000 ohms? YES : Go to S6 . NO : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
6. S6 CHECK THE BLOWER MOTOR SPEED CONTROL CIRCUITS FOR SHORTS TOGETHER Measure the resistance between blower motor speed control: C271-1, circuit VH219 (GY), harness side and C271-2, circuit CH218 (GN/VT), harness side. C271-1, circuit VH219 (GY), harness side and C271-3, circuit CH217 (BN), harness side. C271-2, circuit CH218 (GN/VT), harness side and C271-3, circuit CH217 (BN), harness side. Are the resistances greater than 10,000 ohms? YES : Go to S7 . NO : REPAIR the affected circuits for shorts. TEST the system for normal operation.
7. S7 CHECK THE HVAC MODULE HIGH BLOWER OUTPUT Connect: HVAC Module - DATC C228b Connect: Blower Motor Speed Control C271 Key in ON position. Adjust the blower motor speed to HI. Measure the voltage between ground and HVAC module - DATC C228b-4, circuit CH217 (BN), harness side by back-probing the HVAC module - DATC C228b. Is the voltage within 2 volts of battery voltage? YES : Go to S8 . NO : Go to S9 .
8. S8 CHECK THE HVAC MODULE BLOWER CONTROL OUTPUT Adjust the blower motor speed to LO. Measure the voltage between ground and HVAC module - DATC C228a-15, circuit CH218 (GN/VT), harness side by back-probing the HVAC module - DATC C228a. Is the voltage greater than 1 volt? YES : INSTALL a new blower motor speed control. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to S9 .
9. S9 CHECK MODULE CONNECTION Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) Cold Boot Process. Carry out the HVAC Module - Dual Automatic Temperature Control (DATC) On-Demand Self-Test. Operate the system. Does the concern return? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs.

Pinpoint Test T: The Auxiliary Blower Motor is Inoperative

Refer to SYSTEM WIRING DIAGRAMS , Auxiliary Climate Control for schematic and connector information.

Under normal operation, the auxiliary blower motor relay coil receives a ground through circuit GD149 (BK/GY). The coil receives voltage from circuit CH123 (VT/GN) when the HVAC module - Dual Automatic Temperature Control (DATC) is ON or the function selector switch is in any position but OFF. Voltage is supplied to the relay contacts from circuit SBB18 (YE/RD). When the relay coil is energized, voltage is delivered to the blower motor through circuit CHA02 (BN/GN). Ground for the motor is provided through circuit CHA08 (GN/OG) from the resistor and switch. Ground for the resistor and switch is provided by circuit GD149 (BK/GY).

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Auxiliary blower motor
4. Auxiliary blower motor relay
5. Front auxiliary climate control assembly

Scheme 130

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Scheme 136

1. T1 CHECK FOR VOLTAGE AND GROUND TO THE AUXILIARY BLOWER MOTOR Key in OFF position. Disconnect: Auxiliary Blower Motor C3021 Place the front auxiliary blower motor switch in its highest setting. Key in ON position. Measure the voltage between auxiliary blower motor C3021-1, circuit CHA02 (BN/GN), harness side and C3021-2, circuit CHA08 (GN/OG), harness side. Is the voltage greater than 10 volts? YES : INSTALL a new auxiliary blower motor. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to T2 .
2. T2 CHECK FOR VOLTAGE TO THE AUXILIARY BLOWER MOTOR Measure the voltage between ground and auxiliary blower motor C3021-1, circuit CHA02 (BN/GN), harness side. Is the voltage greater than 10 volts? YES : Go to T3 . NO : Go to T5 .
3. T3 CHECK CIRCUIT CHA08 (GN/OG) FOR AN OPEN Key in OFF position. Disconnect: Front Auxiliary Climate Control Assembly C951a Measure the resistance between auxiliary blower motor switch C951a-6, circuit CHA08 (GN/OG), harness side and auxiliary blower motor C3021-2, circuit CHA08 (GN/OG), harness side. Is the resistance less than 5 ohms? YES : Go to T4 . NO : REPAIR circuit CHA08 (GN/OG) for an open. TEST the system for normal operation.
4. T4 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN Measure the resistance between ground and front auxiliary climate control assembly C951a-1, circuit GD149 (BK/GY), harness side. Is the resistance less than 5 ohms? YES : INSTALL a new front auxiliary climate control assembly. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : REPAIR circuit GD149 (BK/GY) for an open. TEST the system for normal operation.
5. T5 CHECK CIRCUIT CHA02 (BN/GN) FOR AN OPEN Key in OFF position. Disconnect: Auxiliary Blower Motor Relay Measure the resistance between auxiliary blower motor relay socket pin 87, circuit CHA02 (BN/GN) and auxiliary blower motor C3021-1, circuit CHA02 (BN/GN), harness side. Is the resistance less than 5 ohms? YES : Go to T6 . NO : REPAIR circuit CHA02 (BN/GN) for an open. TEST the system for normal operation.
6. T6 CHECK CIRCUIT SBB18 (YE/RD) FOR AN OPEN Measure the voltage between ground and auxiliary blower motor relay socket pin 30, circuit SBB18 (YE/RD). Is the voltage greater than 10 volts? YES : Go to T7 . NO : VERIFY Battery Junction Box (BJB) fuse 18 (30A) is OK. If OK, REPAIR circuit SBB18 (YE/RD) for an open. TEST the system for normal operation.
7. T7 CHECK THE AUXILIARY BLOWER MOTOR RELAY Key in ON position. Press the DEFROST button on the HVAC module - DATC. Measure the voltage between auxiliary blower motor relay socket pin 85, circuit CH123 (VT/GN) and socket pin 86, circuit GD149 (BK/GY). Is the voltage greater than 10 volts? YES : INSTALL a new auxiliary blower motor relay. TEST the system for normal operation. NO : Go to T8 .
8. T8 CHECK CIRCUIT CH123 (VT/GN) FOR AN OPEN Measure the voltage between ground and auxiliary blower motor relay socket pin 85, circuit CH123 (VT/GN). Is the voltage greater than 10 volts? YES : REPAIR circuit GD140 (BK/GN) for an open. TEST the system for normal operation. NO : REPAIR circuit CH123 (VT/GN) for an open. TEST the system for normal operation.

Pinpoint Test U: The Auxiliary Blower Motor Does Not Operate Correctly Using the Front Auxiliary Blower Motor Switch

Refer to SYSTEM WIRING DIAGRAMS , Auxiliary Climate Control for schematic and connector information.

Under normal operation, the blower motor is provided a ground from the resistor through circuit CHA08 (GN/OG). The resistor gets a ground from the front auxiliary blower switch, depending on selected speed, through circuit CHA06 (YE/VT), CHA07 (BU/GY) or circuit CHA16 (BU).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Auxiliary blower motor resistor
3. Front auxiliary climate control assembly

Scheme 137

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Scheme 139

Scheme 140

1. U1 CHECK THE AUXILIARY BLOWER MOTOR RESISTOR CIRCUITS FOR AN OPEN Disconnect: Auxiliary Blower Motor Resistor C3022 Disconnect: Front Auxiliary Climate Control Assembly C951a Measure the resistance between the front auxiliary climate control assembly, harness side and auxiliary blower motor resistor, harness side using the following chart. Front Auxiliary Climate Control Assembly Circuit Auxiliary Blower Motor Resistor C951a-2 CHA06 (YE/VT) C3022-4 C951a-3 CHA07 (BU/GY) C3022-3 C951a-5 CHA16 (BU) C3022-1 C951a-6 CHA08 (GN/OG) C3022-2 Are the resistances less than 5 ohms? YES : Go to U2 . NO : REPAIR the affected circuit(s) for an open. TEST the system for normal operation.
2. U2 CHECK CIRCUIT CHA08 (GN/OG) FOR AN OPEN Measure the resistance between auxiliary blower motor resistor C3022-2, circuit CHA08 (GN/OG), harness side and the auxiliary blower motor C3021-2, circuit CHA08 (GN/OG), harness side. Is the resistance less than 5 ohms? YES : Go to U3 . NO : REPAIR circuit CHA08 (GN/OG) for an open. TEST the system for normal operation.
3. U3 CHECK THE AUXILIARY BLOWER MOTOR RESISTOR CIRCUITS FOR A SHORT TO GROUND Measure the resistance between ground and auxiliary blower motor resistor: C3022-1, circuit CHA16 (BU), harness side. C3022-2, circuit CHA08 (GN/OG), harness side. C3022-3, circuit CHA07 (BU/GY), harness side. C3022-4, circuit CHA06 (YE/VT), harness side. Are the resistances greater than 10,000 ohms? YES : Go to U4 . NO : REPAIR the affected circuit(s) for a short to ground. TEST the system for normal operation.
4. U4 CHECK THE AUXILIARY BLOWER MOTOR RESISTOR CIRCUITS FOR A SHORT TOGETHER Measure the resistance between auxiliary blower motor resistor: C3022-1, circuit CHA16 (BU), harness side and C3022-2, circuit CHA08 (GN/OG), harness side. C3022-1, circuit CHA16 (BU), harness side and C3022-3, circuit CHA07 (BU/GY), harness side. C3022-1, circuit CHA16 (BU), harness side and C3022-4, circuit CHA06 (YE/VT), harness side. C3022-2, circuit CHA08 (GN/OG), harness side and C3022-3, circuit CHA07 (BU/GY), harness side. C3022-2, circuit CHA08 (GN/OG), harness side and C3022-4, circuit CHA06 (YE/VT), harness side. C3022-3, circuit CHA07 (BU/GY), harness side and C3022-4, circuit CHA06 (YE/VT), harness side. Are the resistances greater than 10,000 ohms? YES : Go to U5 . NO : REPAIR the affected circuit(s) for shorts. TEST the system for normal operation.
5. U5 CHECK THE AUXILIARY BLOWER MOTOR RESISTOR Carry out the auxiliary blower motor resistor «Component Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) . Does the auxiliary blower motor resistor test good? YES : INSTALL a new front auxiliary climate control assembly. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : INSTALL a new blower motor resistor. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation.

Pinpoint Test V: The Auxiliary Panel/Floor Control is Inoperative Using the Front Auxiliary Climate Controls

Refer to SYSTEM WIRING DIAGRAMS , Auxiliary Climate Control for schematic and connector information.

Under normal operation, the auxiliary mode door actuator motor is driven to the floor position by supplying voltage to the motor on circuit CHA11 (WH/OG) and ground to circuit CHA12 (GN/BU).

The auxiliary mode door actuator motor is driven to the panel position by supplying voltage to the motor on circuit CHA12 (GN/BU) and ground to circuit CHA11 (WH/OG).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Front auxiliary climate control assembly
3. Auxiliary mode door actuator motor
4. Broken/binding auxiliary mode door

Scheme 141

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Scheme 146

1. V1 CHECK THE FLOOR MODE OUTPUT Disconnect: Air Distribution Door Actuator C3044 Key in ON position. Place the front auxiliary blower motor switch in HI and set the front auxiliary climate control assembly to FLOOR. Measure the voltage between air distribution door actuator C3044-8, circuit CHA11 (WH/OG), harness side and C3044-7, circuit CHA12 (GN/BU), harness side. Is the voltage greater than 10 volts? YES : Go to V2 . NO : Go to V3 .
2. V2 CHECK THE PANEL MODE OUTPUT Set the front auxiliary climate control assembly to PANEL. Measure the voltage between air distribution door actuator C3044-7, circuit CHA12 (GN/BU), harness side and C3044-8, circuit CHA11 (WH/OG), harness side. Is the voltage greater than 10 volts? YES : Check for a broken/binding auxiliary mode door. If OK, INSTALL a new air distribution door actuator. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to V3 .
3. V3 CHECK THE AIR DISTRIBUTION DOOR CIRCUITS FOR AN OPEN Key in OFF position. Disconnect: Front Auxiliary Climate Control Assembly C951b Measure the resistance between the front auxiliary climate control assembly, harness side and air distribution door actuator, harness side using the following chart. Front Auxiliary Climate Control Assembly Circuit Air Distribution Door Actuator C951b-2 CHA11 (WH/OG) C3044-7 C951b-4 CHA12 (GN/BU) C3044-8 Are the resistances less than 5 ohms? YES : Go to V4 . NO : REPAIR the affected circuit for an open. TEST the system for normal operation.
4. V4 CHECK CIRCUITS CHA11 (WH/OG) AND CHA12 (GN/BU) FOR A SHORT TO GROUND Measure the resistance between ground and front auxiliary climate control assembly: C951b-2, circuit CHA11 (WH/OG), harness side. C951b-4, circuit CHA12 (GN/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to V5 . NO : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
5. V5 CHECK CIRCUITS CHA11 (WH/OG) AND CHA12 (GN/BU) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between ground and front auxiliary climate control assembly: C951b-2, circuit CHA11 (WH/OG), harness side. C951b-4, circuit CHA12 (GN/BU), harness side. Is any voltage present? YES : REPAIR the affected circuit for a short to voltage. TEST the system for normal operation. NO : Go to V6 .
6. V6 CHECK CIRCUITS CHA12 (GN/BU) AND CHA11 (WH/OG) FOR A SHORT TOGETHER Key in OFF position. Measure the resistance between front auxiliary climate control assembly C3044-8, circuit CHA12 (GN/BU), harness side and C3044-7, circuit CHA11 (WH/OG), harness side. Is the resistance greater than 10,000 ohms? YES : INSTALL a new front auxiliary climate control assembly. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : REPAIR circuits CHA12 (GN/BU) and CHA11 (WH/OG) for a short together. TEST the system for normal operation.

Pinpoint Test W: The Auxiliary Temperature Control is Inoperative Using the Front Auxiliary Climate Controls

Refer to SYSTEM WIRING DIAGRAMS , Auxiliary Climate Control for schematic and connector information.

Under normal operation, the auxiliary temperature blend door actuator motor is supplied voltage by circuit SBP28 (GN/RD) and ground by circuit GD140 (BK/GN). A signal voltage is received by the auxiliary temperature blend door actuator motor from the front auxiliary temperature control through circuit VHA09 (VT/BN).

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Front auxiliary climate control assembly
4. Auxiliary temperature blend door actuator motor
5. Broken/binding auxiliary temperature blend door

Scheme 147

Scheme 148

Scheme 149

Scheme 150

1. W1 CHECK VOLTAGE TO BLEND DOOR ACTUATOR Disconnect: Auxiliary Temperature Blend Door Actuator C3004 Key in ON position. Measure the voltage between ground and auxiliary temperature blend door actuator C3004-7, circuit CBP18 (GY/OG), harness side. Is the voltage greater than 10 volts? YES : Go to W2 . NO : VERIFY the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR circuit CBP18 (GY/OG) for an open. TEST the system for normal operation.
2. W2 CHECK THE BLEND DOOR ACTUATOR GROUND CIRCUIT FOR AN OPEN Key in OFF position. Measure the resistance between ground and auxiliary temperature blend door actuator C3004-8, circuit GD149 (BK/GY), harness side. Is the resistance less than 5 ohms? YES : Go to W3 . NO : REPAIR circuit GD149 (BK/GY) for an open. TEST the system for normal operation.
3. W3 CHECK THE TEMPERATURE BLEND DOOR ACTUATOR SIGNAL Key in ON position. Place the front auxiliary blower motor switch in HI. Measure the voltage between ground and auxiliary temperature blend door actuator C3004-3, circuit VHA09 (VT/BN), harness side. Rotate the temperature control switch to full COOL then to full WARM. Does the voltage vary from greater than 10 volts (full COOL) to less than 1 volt (full WARM)? YES : Check for a broken/binding auxiliary temperature blend door. If OK, INSTALL a new auxiliary temperature blend door actuator. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to W4 .
4. W4 CHECK CIRCUIT VHA09 (VT/BN) FOR AN OPEN Key in OFF position. Disconnect: Front Auxiliary Climate Control Assembly C951b Measure the resistance between front auxiliary climate control assembly C951b-3, circuit VHA09 (VT/BN), harness side and auxiliary temperature blend door actuator C3004-3, circuit VHA09 (VT/BN), harness side. Is the resistance less than 5 ohms? YES : INSTALL a new front auxiliary climate control assembly. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : REPAIR circuit VHA09 (VT/BN) for an open. TEST the system for normal operation.

Pinpoint Test X: The Auxiliary Temperature and Panel/Floor Controls are Inoperative Using the Front Auxiliary Climate Controls

Refer to SYSTEM WIRING DIAGRAMS , Auxiliary Climate Control for schematic and connector information.

Under normal operation, the front auxiliary climate control assembly receives voltage from circuit CBP18 (GY/OG) and ground from GD149 (BK/GY).

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Front auxiliary climate control assembly

Scheme 151

Scheme 152

1. X1 CHECK FOR VOLTAGE TO THE FRONT AUXILIARY CLIMATE CONTROL ASSEMBLY Key in OFF position. Disconnect: Front Auxiliary Climate Control Assembly C951b Key in ON position. Measure the voltage between front auxiliary climate control assembly C951b-10, circuit CBP18 (GY/OG), harness side and C951b-9, circuit GD149 (BK/GY), harness side. Is the voltage greater than 10 volts? Checking YES : INSTALL a new front auxiliary climate control assembly. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to X2 .
2. X2 CHECK CIRCUIT CBP18 (GY/OG) FOR AN OPEN Measure the voltage between ground and front auxiliary climate control assembly C951b-10, circuit CBP18 (GY/OG), harness side. Is the voltage greater than 10 volts? YES : REPAIR circuit GD149 (BK/GY) for an open. TEST the system for normal operation. NO : VERIFY Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR circuit CBP18 (GY/OG) for an open. TEST the system for normal operation.

Pinpoint Test Y: Insufficient Air Conditioning (A/C) Cooling

Refer to SYSTEM WIRING DIAGRAMS , Automatic Climate Control System for schematic and connector information.

Under normal operation, the solenoid and manifold assembly receives a ground from the HVAC module - Dual Automatic Temperature Control (DATC) through circuit RH226 (WH/VT). When the heater control valve vacuum solenoid is to be energized, the solenoid and manifold assembly receives voltage from the HVAC module - DATC through circuit CH224 (BU/OG).

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Solenoid and manifold assembly
3. HVAC module - DATC
4. Manual climate control assembly
5. Heater control valve
6. Stuck or bound linkage or door
7. Leaking or plugged vacuum hose

Scheme 153

Scheme 154

Scheme 155

Scheme 156

1. Y1 CHECK FOR COOLANT FLOW TO THE HEATER CORE Run the engine until it reaches normal operation temperature. Press the PANEL, RECIRC and A/C buttons on the HVAC module - DATC or select MAX A/C on the function selector switch. Set the temperature control to full COOL. Using a suitable temperature measuring device, check the heater core inlet hose to see if it is hot. Is the heater core inlet hose hot? YES : Go to Y2 . NO : Go to «Refrigerant System Tests»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__refrigerant-system-tests) .
2. Y2 CHECK FOR VACUUM AT THE HEATER CONTROL VALVE Disconnect the heater control valve vacuum connector and check for vacuum. Is vacuum present at the heater control valve? YES : INSTALL a new heater control valve. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : Go to Y3 .
3. Y3 CHECK THE HEATER CONTROL VALVE VACUUM LINE FOR BLOCKAGE Key in OFF position. NOTE: Manual climate control systems only. Disconnect the function selector switch vacuum connector. Connect the vacuum pump to the heater control valve vacuum line and attempt to pull a vacuum. NOTE: DATC systems only. Disconnect the solenoid and manifold assembly vacuum connector. Connect the vacuum pump to the heater control valve vacuum line and attempt to pull a vacuum. Can a vacuum be pulled on the heater control valve vacuum line? YES : INSTALL a new vacuum harness. TEST the system for normal operation. NO : Go to Y4 .
4. Y4 CHECK THE HEATER CONTROL VALVE VACUUM LINE FOR LEAKS Plug the heater control valve vacuum line at the heater control valve connection. NOTE: Manual climate control systems only. Leak test the heater control valve vacuum line, using the vacuum pump. NOTE: DATC systems only. Leak test the heater control valve vacuum line, using the vacuum pump. Does the heater control valve vacuum line leak? YES : INSTALL a new vacuum harness. TEST the system for normal operation. NO : Go to Y5 .
5. Y5 CHECK FOR INCORRECT VACUUM LINE PLACEMENT Key in OFF position. Inspect the heater control valve and A/C vacuum lines for correct placement. Is the vacuum line placement correct? YES : Manual climate control systems, INSTALL a new climate control assembly. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. DATC systems, go to Y6 . NO : CORRECT the vacuum line placement. TEST the system for normal operation.
6. Y6 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY CIRCUIT VOLTAGE Connect the vacuum harness connector to the solenoid and manifold assembly. Key in ON position. Press the PANEL, RECIRC and A/C buttons on the HVAC module - DATC. NOTE: The following measurement must be taken by back-probing the solenoid and manifold assembly C2093. Measure the voltage between solenoid and manifold assembly C2093-1, circuit RH226 (WH/VT), harness side and C2093-6, circuit CH224 (BU/OG), harness side. Is the voltage greater than 10 volts? YES : INSTALL a new solenoid and manifold assembly. TEST the system for normal operation. NO : Go to Y7 .
7. Y7 CHECK THE SOLENOID AND MANIFOLD ASSEMBLY CIRCUIT CH224 (BU/OG) FOR AN OPEN Key in OFF position. Disconnect: HVAC Module - DATC C228b Disconnect: Solenoid and Manifold Assembly C2093 Measure the resistance between HVAC module - DATC C228b-14, circuit CH224 (BU/OG), harness side and solenoid and manifold assembly C2093-6, circuit CH224 (BU/OG), harness side. Is the resistance less than 5 ohms? YES : INSTALL a new HVAC module - DATC. REFER to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article. TEST the system for normal operation. NO : REPAIR circuit CH224 (BU/OG) for an open. TEST the system for normal operation.

Scheme 157

Resistor - Blower Motor, Auxiliary

Scheme 158

Scheme 159

Temperature Sensor - In-Vehicle

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Heater Core

1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core.
2. Check the integrity of the heater water hose clamps.

Heater Core - Plugged

1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, using a suitable temperature measuring device, check the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: the heater control valve may be stuck closed. the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. the heater core may be restricted or plugged.

Heater Core - Pressure Test

Use the Pressure Test Kit to perform the pressure test.

1. Clamp off the heater hoses.
2. Disconnect the heater water hoses from the heater core.
3. Install a short piece of heater hose, approximately 101 mm (4 in) 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 Test Kit in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the Pressure Test Kit 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.

Heater Core - Bench Test

1. Remove the heater core from the vehicle. Refer to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article.
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester from the Pressure Test Kit 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, replace the 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»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. Refer to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article.
3. Clean the spring lock couplings. Refer to «Spring Lock Coupling»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__spring-lock-coupling) .
4. Connect the appropriate test fittings from the A/C Flush Adapter Kit to the evaporator or condenser tube connections.
5. Connect the red and blue hoses from the R-134a Manifold 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 replacing the 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 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. Refer to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article.

A/C Compressor - External Leak Test

1. Install the appropriate adapter from the A/C Flush Adapter Kit on the rear head of the A/C compressor, using the existing peanut fitting nuts.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station to the corresponding fittings on the adapter.
3. Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position.
4. 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.
5. Using the Refrigerant Leak Detector, check the entire A/C compressor for leaks.
6. If an external leak is found, install a new A/C compressor. Refer to «CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) article.
7. When the leak test is complete, recover the refrigerant from the compressor.

Spring Lock Coupling

Special Tools Illustration Tool Name Tool Number Remover, Refrigerant Coupling Spring 412-039 (T84L-19623-B)

Scheme 164

Material

Disconnect

Note. If a leak has been found at a spring lock coupling, inspect the O-ring sealing surfaces on the male and female sides of the fitting for damage or scratches. Replace the affected component if damage is identified. If no damage is present, thoroughly clean both sides of the fitting using a suitable non-abrasive cloth, lubricate with PAG oil and install new O-ring seals. Due to subtle differences in O-ring sizes, it is critical for leak prevention that the correct O-ring seal be identified. Refer to the Ford master parts catalog for the specific vehicle and application. When repairs are complete, leak test the spring lock coupling to verify the repair.

1. Remove the spring lock coupling clip, if equipped.
2. Push the Refrigerant Coupling Spring Remover into the cage opening to release the female fitting from the spring lock coupling spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool.
3. Remove the spring lock coupling spring with a small hooked wire.

Connect

1. Install the spring lock coupling spring.
2. Lubricate the inside of the coupling with PAG oil.
3. Install the O-ring seals.
4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling spring snaps over the flared end of the female fitting.
5. Install the spring lock coupling clip.

Refrigerant System Tests

Special Tools Illustration Tool Name Tool Number R-134a Refrigerant Center 176-00002 or equivalent R-134a Refrigerant Center 023-00174 or equivalent R-134a Manifold Gauge Set 023-00047 or equivalent

Scheme 165

Procedure 1 - Ambient Temperature At or Below 38°C (100°F)

Note. The system performance can be evaluated and diagnosed by analysis of the compressor suction and discharge pressures. The following procedure is used to determine if the system is operating at normal pressures.

Note. The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38°C (100°F) or lower, follow Procedure 1. If the ambient temperature is over 38°C (100°F), follow Procedure 2.

Note. If the A/C compressor cycles at any time during this test, refer to the diagnostic table.

1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a manifold gauge set or refrigerant service center with high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls. If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, HI Blower. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If equipped with DATC, set temperature to 15°C (60°F) (lowest possible temp setting) with the dual function disabled (if equipped). Manually set blower on HIGH. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If the vehicle is equipped with auxiliary climate control, set the auxiliary controls to full COOL in the PANEL mode at HI blower speed.
4. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction Pressures chart.
11. Proceed to the diagnostic table.

Procedure 2 - Ambient Temperature Above 38°C (100°F)

Note. The system performance can be evaluated and diagnosed by analysis of the compressor suction and discharge pressures. The following procedure is used to determine if the system is operating at normal pressures.

Note. The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38°C (100°F) or lower, follow Procedure 1. If the ambient temperature is over 38°C (100°F), follow Procedure 2.

1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a manifold gauge set or refrigerant service center with high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls. If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, MED-LO blower. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If equipped with ATC, set temperature to 15°C (60°F) (lowest possible temp setting). Manually set blower to MED-LO (3 to 4 bars). If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If the vehicle is equipped with auxiliary climate control, set the auxiliary controls to full COOL in the PANEL mode at MED-LO blower speed.
4. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction Pressures chart.
11. Refer to the chart below.

Diagnostic Table

Air Conditioning (A/C) Clutch Air Gap Adjustment

1. Check the A/C clutch air gap at 3 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.

Electronic Leak Detection

Special Tools Illustration Tool Name Tool Number Heated Pentode Halogen Leak Detector 023-00178 or equivalent

Note. Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the Heated Pentode Halogen Leak Detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be tested before proceeding with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan should be turned off during actual testing.

Note. R-134a is heavier than air, and will tend to move downward from the source of the leak if present. It is possible that a leak may not be detected if the leak detector tip is held above the leaking fitting, line or component. Always be sure to thoroughly leak test below the fitting, line or component for the presence of R-134a as well as leak testing above and around.

1. Leak test the refrigerant system using the Heated Pentode Halogen Leak Detector. Follow the instructions included with the Heated Pentode Halogen Leak Detector for handling and operation techniques.
2. If a leak is found, recover the refrigerant. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) . Repair the system. Test the system for normal operation.

Fluorescent Dye Leak Detection

Special Tools Illustration Tool Name Tool Number Cordless/Rechargeable True UV LED Light ES 023-00182 or equivalent R-134a Leak Detection Dye 164-R6060 R-134a Loop/Add On Injector Kit-Set 219-00069 or equivalent R-134a Manifold Gauge Set 023-00047 or equivalent R-134a Refrigerant Management Machine (SAE J-2788 Compliant) 023-00181 or equivalent R-134a Refrigerant Management Machine (SAE J-2788 Compliant) 199-00067 or equivalent R-134a Refrigerant Management Machine (SAE J-2788 Compliant) 265-00012 or equivalent

Scheme 166

Scheme 167

Fluorescent Dye Injection - Using an R-134a Refrigerant Management Machine and Dye Injector

Note. Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.

Note. This method of fluorescent dye injection requires the addition of R-134a from an R-134a Refrigerant Management Machine or R-134a Manifold Gauge Set hooked to an external tank to charge the dye into the refrigerant system. If adding fluorescent dye to a refrigerant system that is already fully charged, the R-134a Loop/Add On Injector Kit-Set method should be used.

Note. Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the manufacturer's instructions on evacuation of any non-condensable gases from the hoses.

Note. Only connect the dye/lubricant injector from the R-134a Loop/Add On Injector Kit-Set when fluorescent dye is to be injected. The dye/lubricant injector has a one-way check valve that will prevent refrigerant system recovery and evacuation.

Note. Following fluorescent dye injection, the refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off and cool.

1. Connect an R-134a Refrigerant Management Machine or a R-134a Manifold Gauge Set to the refrigerant system service port valves.
2. Verify that the valves on the dye/lubricant injector from the R-134a Loop/Add On Injector Kit-Set are closed.
3. Fill the R-134a fluorescent dye injector reservoir with 7 ml (0.25 oz.) of fluorescent dye.
4. Install the dye/lubricant injector between the low-pressure service gauge port valve and the R-134a Refrigerant Management Machine or R-134a Manifold Gauge Set.
5. Open all valves and inject the fluorescent dye into the refrigerant system.
6. When fluorescent dye injection is complete, close all valves.
7. Recover the refrigerant from the dye/lubricant injector.
8. Remove the dye/lubricant injector from the low-pressure service gauge port valve and the R-134a Refrigerant Management Machine or R-134a Manifold Gauge Set.

Fluorescent Dye Injection - Using an R-134a Loop/Add On Injector Kit-Set

Note. Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.

Note. Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the equipment manufacturer's instructions on evacuation of non-condensable gases from the hoses.

Note. Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off and cool.

1. Verify that the valves on the R-134a Loop/Add On Injector Kit-Set are closed.
2. Fill the R-134a Loop/Add On Injector Kit-Set reservoir with 7 ml (0.25 oz.) of fluorescent dye.
3. Install the R-134a Loop/Add On Injector Kit-Set between the high-pressure and low-pressure service gauge port valves.
4. With the A/C off, start the engine. Allow engine speed to stabilize below 1,000 RPM.
5. Set the A/C to the ON position.
6. Open the high-pressure service valve.
7. Open the R-134a Loop/Add On Injector Kit-Set valves and inject the fluorescent dye into the refrigerant system.
8. Close the high-pressure service valve to allow the pressure inside the R-134a Loop/Add On Injector Kit-Set to equalize with the suction side of the refrigerant system.
9. Close the valves on the R-134a Loop/Add On Injector Kit-Set.
10. Disconnect the high-pressure and low-pressure service valves and remove the R-134a Loop/Add On Injector Kit-Set from the vehicle.

Fluorescent Dye Detection

Note. Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line and fitting in the refrigerant system for a leak.

1. Check for leaks using a Rotunda-approved UV lamp and dye enhancing glasses. Inspect all components, lines and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
3. Repair the refrigerant system leak(s).
4. Evacuate and charge the refrigerant system. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
5. After the leak(s) is repaired, remove any traces of fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda-approved UV lamp.

Air Conditioning (A/C) System Flushing

Special Tools Illustration Tool Name Tool Number A/C Flush Adapter Kit 219-00074 or equivalent A/C Flush and Purge Fitting Kit 219-00024 (part of 219-00023) or equivalent A/C Flush and Purge Machine 219-00022 (part of 219-00023) or equivalent

Scheme 168

Material

Note. An air conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions.

Note. Suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) and/or evaporator core orifice, and hoses with mufflers, should be removed when flushing the air conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any residual-flushing agent. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The 3.785L (1 gal) of A/C System Flushing Solvent and FL1-A filter used in A/C Flush and Purge Machine 219-00022 are intended for use on one vehicle only. They may be used to flush both the A/C condenser core and the A/C evaporator core on an individual vehicle, but under no circumstances should they be used on more than one vehicle.

Note. Only the A/C Flush and Purge Machine 219-00022, A/C Flush and Purge Fitting Kit 219-00024, A/C Flush Adapter Kit 219-00074 and A/C System Flushing Solvent are approved for use on Ford vehicles. No other flushing device or solvent is approved for flushing heat exchangers (air conditioning [A/C] condenser, A/C evaporator). Use of any other flusher or solvent may cause damage to the A/C system and the flushing unit.

Note. Prior to using the A/C Flush and Purge Machine 219-00022 for the first time, review the operating instructions.

Note. Ford Motor Company has approved a procedure to provide technicians with a non-Chlorofluorocarbons (CFC) method of flushing contaminated A/C system heat exchangers. The procedure allows the specific components to be cleaned and flushed while installed in their normal in-vehicle location. The types of contamination flushed include particle matter that results from A/C compressor or desiccant failure and gummy residue that can form when refrigerant oil is overheated during A/C compressor seizure. The flushing process is a 2-step procedure that involves the use of an A/C Flush and Purge Machine 219-00022 to: circulate the flushing solvent through the heat exchanger in the reverse direction of normal refrigerant flow (back-flushing). Particulate matter picked up during flushing is filtered from the returning solvent before the solvent is returned to the reservoir for continued circulation. remove the flushing solvent from the heat exchanger. In this step of the procedure, pressurized air (621-862 kPa [90-125 psi]) is used to push and evaporate any remaining flush solvent from the heat exchanger.

1. Recover the refrigerant. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
2. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
3. Using the correct adapters from the A/C Flush Adapter Kit or A/C Flush and Purge Fitting Kit, connect the A/C Flush and Purge Machine to the heat exchanger to be flushed. Do not flush through the evaporator core orifice (if equipped), Thermostatic Expansion Valve (TXV) (if equipped) or hoses with mufflers. Internal plumbing and material make-up of these components make it impossible to correctly remove foreign material or residual flushing solvent.
4. Flush the heat exchanger for a minimum of 15 minutes.
5. Apply 621-862 kPa (90-125 psi) pressurized air to the component for a minimum of 30 minutes. The 30-minute purge time is required to force and evaporate all residual solvent from the A/C system component. Failure to successfully remove all residual solvent within the component can result in system damage when reconnected and operated. Dispose of the used flush solvent and filter in accordance with local, state and federal regulations.
6. Install a new A/C evaporator core orifice (if equipped) and/or TXV (if equipped) in any vehicle being serviced for an internal A/C compressor or desiccant failure.
7. Install new refrigerant hoses with mufflers if clogged with foreign material.
8. Install a new suction accumulator (if equipped), receiver/drier (if equipped) or receiver/drier cartridge (if equipped) in any vehicle being serviced for an internal A/C compressor or desiccant failure.
9. Reconnect the heat exchanger being serviced.
10. If a new A/C compressor is not to be installed, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «Refrigerant Oil Adding»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__refrigerant-oil-adding) .
11. If a new A/C compressor is not to be installed, evacuate, leak test and charge the A/C system. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .

Air Conditioning (A/C) System Recovery, Evacuation and Charging

Special Tools Illustration Tool Name Tool Number 1.2 CFM Vacuum Pump 023-00162 or equivalent 4.0 CFM Vacuum Pump 023-00163 or equivalent Automatic Refrigerant Charging Meter 023-00155 or equivalent R-134a Manifold Gauge Set 023-00047 or equivalent R-134a Refrigerant Management Machine (SAE J-2788 Compliant) 023-00181 or equivalent R-134a Refrigerant Management Machine (SAE J-2788 Compliant) 199-00067 or equivalent R-134a Refrigerant Management Machine (SAE J-2788 Compliant) 265-00012 or equivalent

Material

Refrigerant System Recovery

Note. An air conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions.

Note. Ford Motor Company recommends use of an R-134a Refrigerant Management Machine to carry out recovery. If an R-134a Refrigerant Management Machine is not available, refrigerant system recovery may be accomplished using a separate recovery station.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer to «Refrigerant Identification Testing»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__refrigerant-identification-testing) .
2. Connect an R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any). Add that same amount back into the system once repairs are complete.
4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF the power supply.
5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment.
6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes.
7. Carry out the required repairs.

Refrigerant System Evacuation Using an R-134a Refrigerant Management Machine

Note. Ford Motor Company recommends use of an R-134a Refrigerant Management Machine to carry out recovery, evacuation and charging of the refrigerant system. If an R-134a Refrigerant Management Machine is not available, evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Connect an R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer.
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes.
3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again.

Refrigerant System Evacuation Using an R-134a Manifold Gauge Set and Vacuum Pump

Note. Ford Motor Company recommends use of an R-134a Refrigerant Management Machine to carry out evacuation of the refrigerant system. If an R-134a Refrigerant Management Machine is not available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves.
2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the Vacuum Pump.
3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves.
4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes.
5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service gauge port valves) and turn OFF the Vacuum Pump.
6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again.

Refrigerant System Charging Using an R-134a Refrigerant Management Machine

Note. Ford Motor Company recommends use of an R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If an R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «Refrigerant Oil Adding»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__refrigerant-oil-adding) .
2. Connect an R-134a Refrigerant Management Machine to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer.
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer.

Refrigerant System Charging Using an R-134a Manifold Gauge Set and Automatic Refrigerant Charging Motor

Note. Ford Motor Company recommends use of an R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If an R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «Refrigerant Oil Adding»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__refrigerant-oil-adding) .
2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a supply tank following the Automatic Refrigerant Charging Meter operating instructions.
3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating instructions.
4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX A/C operation and allow the refrigerant charge to complete.

Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation

Special Tools Illustration Tool Name Tool Number A/C Flush Adapter Kit 219-00074 or equivalent A/C Flush and Purge Fitting Kit 219-00024 or equivalent

Material

Note. An air conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer's procedures and instructions.

Note. On vehicles being serviced for an internal compressor or desiccant failure, a new suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and any hoses containing mufflers must be installed prior to filtering the air conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any foreign material. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The filter is intended for use on one vehicle only.

1. Orient the filter inlet toward the A/C condenser core.
2. Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2 halves of the fitting. Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush and Purge Fitting Kit.
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «Refrigerant Oil Adding»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__refrigerant-oil-adding) .
4. Evacuate and charge the refrigerant system. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly. Make sure the A/C system is operating correctly.
7. Gradually bring the engine up to 1,200 RPM by running it at lower RPM for short periods (first at 800 RPM, then at 1,000 RPM). Set the engine at 1,200 RPM and run it for one hour with the A/C system operating.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .

Refrigerant Oil Adding

Special Tools Illustration Tool Name Tool Number R-134a Loop/Add On Injector Kit-Set 219-00069 or equivalent

Material

Note. During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the PAG oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.

1. Refer to the chart below for refrigerant oil adding amounts and methods of installation. Component PAG Oil Amount Method of Adding A/C Compressor See heading below Add directly to A/C compressor low-side port before installation. Suction Accumulator or Receiver/Drier See heading below Add directly to suction accumulator inlet port or inject to low-side service port during system charging. Evaporator Core 45 ml (1.5 fl. oz.) added to the amount collected during refrigerant recovery Add directly to evaporator core inlet tube or inject to low-side service port during system charging. Condenser Core 60 ml (2 fl. oz.) added to the amount collected during refrigerant recovery Add directly to condenser core inlet or inject to low-side service port during system charging. Evaporator Core Orifice or Thermostatic Expansion Valve (TXV) The amount collected during refrigerant recovery Inject to low-side service port during system charging. A/C Pressure Relief Valve 60 ml (2 fl. oz.) added to the amount collected during refrigerant recovery Inject to low-side service port during system charging. Refrigerant Hose/Line 60 ml (2 fl. oz.) added to the amount collected during refrigerant recovery a Inject to low-side service port during system charging. O-ring Leak Repair 60 ml (2 fl. oz.) added to the amount collected during refrigerant recovery b Inject to low-side service port during system charging. Service Port Leak Repair 60 ml (2 fl. oz.) added to the amount collected during refrigerant recovery Inject to low-side service port during system charging. a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the total system PAG oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks being repaired.

Refrigerant Oil Adding for New A/C Compressor Installation

Note. This PAG oil adding method is to be used when a new A/C compressor only has been installed. If a new suction accumulator or receiver drier and evaporator core orifice or Thermostatic Expansion Valve (TXV) have also been installed due to system contamination, refer to the appropriate heading.

Note. Service A/C compressors are shipped without refrigerant oil.

1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. Add the same amount plus the amount collected during refrigerant recovery plus 30 ml (1 fl. oz.).

Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation

Note. This refrigerant oil adding method is to be used when a new suction accumulator or receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV have also been installed due to system contamination, refer to the appropriate heading.

1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup.
2. Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2 fl. oz.).

Refrigerant Oil Adding for Multiple Component Installation After A/C System Contamination

Note. This refrigerant oil adding method is to be used when a new A/C compressor, suction accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system contamination and the A/C system has been flushed.

Note. Service A/C compressors are shipped without refrigerant oil.

1. Add 60 ml (2 fl. oz.) directly to the new A/C compressor suction port.
2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl. oz.) to the low-side service port during system charging. For the total PAG oil capacity specification, refer to «SPECIFICATIONS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) .

Oil Injection Using a Dye/Lubricant Injector

Note. If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the PAG oil.

1. Evacuate the refrigerant system. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .
2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On Injector Kit-Set to match the amount of refrigerant compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil.
5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics__air-conditioning-ac-system-recovery-evacuation) .

Refrigerant Identification Testing

Special Tools Illustration Tool Name Tool Number Refrigerant Identifier with Air-Radiator 198-00003 or equivalent

Refrigerant Identification

1. Follow the instructions included with the Refrigerant Identifier with Air-Radiator to obtain the sample for testing.
2. The Refrigerant Identifier with Air-Radiator will display one of the following: If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital display. If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will be displayed on the digital display. If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The scan tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the scan tool has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the scan tool will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated.

Contaminated Refrigerant Handling

Note. If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered refrigerant supply and may damage the recovery/recycling equipment.

Note. A new suction accumulator or receiver/drier must be installed as directed by the A/C system flushing procedure.

1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. If this equipment is not available, contact an A/C service facility in the area with the correct equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern.
3. Flush the A/C system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations.

Vacuum Hose Repair - Mini-Tube

Special Tools Illustration Tool Name Tool Number Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent

Scheme 169

1. Measure the length of the damaged area of the mini-tube vacuum hose.
2. Cut a piece of standard 1/8-inch inner diameter vacuum hose approximately 25 mm (1 in) longer than the damaged area of the mini-tube vacuum hose.
3. Cut off the mini-tube vacuum hose on each side of the damaged area.
4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 in) into the ends of the standard 1/8-inch repair vacuum hose section.
6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged.
7. Test the system for a vacuum leak in the repair area. Use the Vacuum Pump Kit or equivalent.

Air Conditioning (A/C) Odor Treatment

Special Tools Illustration Tool Name Tool Number Flexible Applicator Tool 258-00004

Material

A/C Odor Treatment

Note. There are typically 4 types of objectionable odors found in a vehicle: Chemical odors Environmental odors Human and other interior-generated odors Microbiological odors Before determining that A/C order treatment is required, the source and the circumstances under which the odor occurs must be determined.

Note. Chemical odors are usually constant regardless of the climate control system setting although they may be enhanced by A/C operation. Most chemical odors are caused by fluid leaks or incorrectly cured adhesives. Chemical odors can be eliminated by repairing the leaking component and removing any residue.

Note. Environmental odors usually occur for a short time and diminish after the vehicle passes through the affected area. These odors are typically only detected when the vehicle windows are open, or when the climate control system is operating in a mode that allows for fresh air. Environmental odors cannot be eliminated because they are external in source, but they may be minimized by switching to a climate control setting that uses recirculated air.

Note. Human and other interior-generated odors occur while the source is present and may linger for a short time after. These odors may be more noticeable during A/C operation. Human odors may be eliminated by removing the source and cleaning the affected area.

Note. Microbiological odors, if in the A/C system, usually last for about 30 seconds after the system is turned on. They will be detected while the A/C is turned on and using either outside or recirculated air. Microbiological odors that occur in areas other than the A/C system (for example, water in doors or wet carpeting) may last indefinitely and will be more intense when recirculated air is used. Microbiological odors will not be present at temperatures at or below 10°C (50°F). Microbiological odors can be eliminated by removing the source and treating the affected area. Standing water must be allowed to drain and dry out. A/C systems may be treated by using A/C cooling coil coating as described in the service procedure below. Microbiological odors result from microbial growth supported by warm temperatures and moisture. Microbiological odors are described as musty/mildew type smells and may occur on/in: foam seals. rubber seals. adhesives. standing water. water soaked carpet/trim.

See also:
• GLASS, FRAMES AND MECHANISMS
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• Introduction - Gasoline Engines
• CLIMATE CONTROL
• NOISE, VIBRATION AND HARSHNESS
• CHARGING SYSTEM - GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• ENGINE COOLING
• Symptom Chart - Climate Control Systems
• Pinpoint Test D
• Pinpoint Test E
• Pinpoint Test F
• Pinpoint Test G
• Pinpoint Test C
• Pinpoint Test H
• Pinpoint Test M
• Pinpoint Test Q
• Pinpoint Test S
• Pinpoint Test J
• Pinpoint Test K
• Pinpoint Test L
• Pinpoint Test N
• Pinpoint Test O
• Pinpoint Test P
• Pinpoint Test R
• Pinpoint Test T
• Pinpoint Test U
• Pinpoint Test V
• Pinpoint Test W
• Pinpoint Test X
• Pinpoint Test Y
• Air Conditioning (A/C) Clutch Air Gap Adjustment
• Fluorescent Dye Leak Detection
• Refrigerant System Tests
• Air Conditioning (A/C) System Recovery, Evacuation and Charging
• Spring Lock Coupling
• Refrigerant Oil Adding
• Refrigerant Identification Testing