HVAC Control System - General Information & Diagnostics: Other Ford Freestyle I

Climate Control System

The electronic manual temperature control (EMTC) system heats or cools the vehicle depending on the EMTC control panel selection.

1. The EMTC control panel selections determine 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.
4. During A/C operation the system also reduces the relative humidity of the air.
5. The driver side and passenger side temperature settings can be individually controlled. (Dual-zone EMTC only.)

The dual-zone electronic automatic temperature control (EATC) 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 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.

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

Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate damage to the A/C compressor, compressor anti-slugging strategy (CASS) is utilized.

CASS is initiated only under specific conditions

1. Ignition is off for more than 8 hours
2. 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 powertrain control module (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 EMTC or the EATC system settings.

The Refrigerant Cycle

During stabilized conditions (air conditioning system shutdown), the refrigerant 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 A/C condenser core.

The A/C condenser, 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 now liquid refrigerant, still at high pressure, exits from the bottom of the A/C condenser and enters the inlet side of the A/C receiver/drier. The receiver/drier is designed to remove moisture from the refrigerant.

The outlet of the receiver/drier is connected to the thermostatic expansion valve (TXV). The TXV provides the orifice which is the restriction in the refrigerant system and separates the high and low pressure sides of the A/C system. As the liquid refrigerant passes across 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 A/C evaporator, it absorbs heat from the airflow passing over the plate/fin sections of the A/C evaporator. This addition of heat causes the refrigerant to boil (convert to gas). The now cooler 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 refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and temperature of the refrigerant.

A thermistor which monitors the temperature of the air that has passed through the evaporator core controls A/C clutch cycling. If the temperature of the evaporator core discharge air is low enough to cause the condensed water vapor to freeze, the A/C clutch is disengaged by the vehicle powertrain control module (PCM).

The high-side line pressure is also monitored so that A/C compressor operation will be interrupted if the system pressure becomes too high or is determined to be too low (low charge condition).

The A/C compressor thermal protection switch will interrupt compressor operation if the compressor housing exceeds temperature limits.

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

Thermostatic Expansion Valve Type Refrigerant System

Scheme 266

Electronic Manual Temperature Control System

The electronic manual temperature control (EMTC) system operation is determined by the settings on the climate control assembly. The EMTC system is composed of the EMTC module, blower motor resistor, mode door actuator, air inlet door actuator and temperature blend door actuator to control the various functions.

The blower motor switch

1. sets the 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. directs the blower motor path directly to ground, bypassing the blower motor resistor, to allow blower motor operation in HI.

The A/C request switch

1. can command the A/C compressor ON when the function selector switch is in PANEL, FLOOR/PANEL, FLOOR/DEFROST and FLOOR when the A/C request switch is pressed. Indicator illuminates when A/C request switch is toggled ON.
2. is inoperative in MAX A/C, OFF 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 DEFROST but can be toggled ON or OFF. The A/C compressor will operate regardless of indicator status if the outside air temperature is above 6°C (43°F).
6. is serviced only with the climate control assembly.

The function selector switch

1. selects airflow direction.
2. is serviced only with the climate control assembly.

The air recirculation button

1. selects either recirculated or outside air source.
2. recirculates air in any mode except DEFROST, if requested.
3. is disabled in MAX A/C or OFF mode where recirculated air only is used.
4. is disabled in DEFROST mode where outside air only is used.
5. is serviced only with the climate control assembly.

The auxiliary climate controls

1. select the auxiliary blower motor speed.
2. select the auxiliary airflow mode/temperature.

The EMTC module also includes

1. a rear window defrost button, refer to «GLASS, FRAMES AND MECHANISMS»(ref-255263) .
2. heated/cooled seat controls, refer to «SEATING»(ref-255299) .

Electronic Automatic Temperature Control System

The electronic automatic temperature control (EATC) system operation is determined by the settings on the EATC module. The EATC system automatically maintains a selected temperature for vehicle interior comfort. The EATC system is composed of the EATC module, blower motor speed control, mode door actuator, air inlet door actuator, temperature blend door actuator, in-vehicle temperature sensor and solar radiation sensor to control the various functions.

When the EATC module is set to AUTO

1. the air distribution direction, blower motor speed and A/C compressor operation are automatically controlled based on the temperature(s) selected.

The EATC module 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 in all modes except 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 DEFROST.

The auxiliary climate controls

1. select the auxiliary blower motor speed.
2. select the auxiliary airflow mode/temperature.

The EATC module also includes

1. a rear window DEFROST button, refer to «GLASS, FRAMES AND MECHANISMS»(ref-255263) .
2. heated/cooled seat controls, refer to «SEATING»(ref-255299) .

Auxiliary Climate Control System

An auxiliary climate control system is available as optional equipment. The auxiliary climate control system operation is determined by the settings on the front or rear auxiliary climate control assembly. The auxiliary climate control assemblies include a blower motor switch and temperature control/air distribution mode knob, neither of which can be individually serviced.

Auxiliary blower motor operation is enabled when the EMTC or EATC is in any mode except OFF. The auxiliary system air can be cooled below interior air 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 front auxiliary climate controls

1. are built into the dual-zone EMTC or EATC module. The blower motor speed can be set to OFF, LO, MED LO, MED HI or HI by pressing the auxiliary blower FAN button either right (higher) or left (lower). The temperature/airflow mode can be adjusted by pressing the rear button either right (warm/floor) or left (cool/panel). If the front (main) driver side temperature is set to full COOL or full HEAT, the auxiliary temperature will be set to the same as the driver and cannot be changed. When the front auxiliary REAR button is depressed, all control of the auxiliary climate control system functions are then transferred to the rear auxiliary climate control assembly and the auxiliary temperature can be fully independently controlled.

The rear auxiliary climate control assembly

1. blower motor switch controls the auxiliary blower motor speed only when the front auxiliary climate control assembly blower motor switch is set to REAR. The blower motor speed can be set to OFF, LO, MED LO, MED HI or HI.
2. temperature/airflow mode control switch is a potentiometer that outputs a variable voltage to the auxiliary temperature blend door actuator and auxiliary mode door actuator to set the position of the auxiliary temperature blend and mode doors only when the front auxiliary climate control assembly blower motor switch is set to REAR. When A/C compressor operation has not been initiated (A/C compressor commanded on) by the EMTC or EATC module (as equipped), the auxiliary climate control system cannot cool the air below that of the interior air temperature.

Max A/C

When MAX A/C is selected

1. the air inlet door actuator closes off outside air and admits only recirculated air.
2. the recirc button is disabled and the indicator is illuminated.
3. the floor/defrost/panel door directs airflow to the instrument panel A/C registers.
4. blended air temperature is available.
5. the A/C request button is illuminated and will be disabled.
6. the A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
7. the blower motor is ON.

PANEL

When PANEL is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the instrument panel A/C registers.
3. blended air temperature is available.
4. the A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

PANEL/FLOOR

When PANEL/FLOOR is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the floor duct and the instrument panel A/C registers. A small amount of airflow from the side window demisters and defrost duct will be present.
3. blended air temperature is available.
4. the A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

OFF

When OFF is selected

1. the recirc request button is disabled.
2. the air inlet door actuator closes off outside air and admits only recirculated air.
3. the A/C request button is disabled.
4. the blower motor is OFF.

FLOOR

When FLOOR is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the floor duct. A small amount of airflow from the defroster duct and side window demisters will be present.
3. blended air temperature is available.
4. the A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

FLOOR/DEFROST

When the FLOOR/DEFROST is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the floor duct, the defroster duct and the side window demisters.
3. blended air temperature is available.
4. the A/C request button will indicate the last status and the indicator can be toggled. To reduce fogging, the A/C compressor will operate automatically, regardless of indicator status, if the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

DEFROST

When DEFROST is selected

1. the air inlet door actuator opens, admitting only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the defroster duct and side window demisters. A small amount of airflow from the floor duct will be present.
3. blended air temperature is available.
4. the A/C request button will indicate the last status and the indicator can be toggled. To reduce fogging, the A/C compressor will operate automatically, regardless of indicator status, if the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

AUTO

When AUTO is selected

1. the temperature control setting is manually set to the desired setting.
2. the air inlet door actuator is automatically controlled by the EATC module, based on the temperature setting.
3. the mode door actuators are automatically controlled by the EATC module based on the temperature setting.
4. the A/C compressor is automatically controlled by the EATC module based on the temperature setting. The A/C compressor will not operate if the outside temperature is below approximately 6°C (43°F).
5. the A/C request button or the RECIRC request button, if pressed, will transfer the system to semi-auto operation.
6. the blower motor is ON. The blower motor speed is automatically controlled by the EATC module based on the temperature setting, but can be manually overridden.

When OFF is selected

1. the RECIRC request button is disabled.
2. the air inlet door actuator closes off outside air and admits only recirculated air.
3. the floor/defrost/panel door actuator is in the DEFROST position.
4. the A/C request button is disabled.
5. the blower motor is OFF.

When PANEL is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the instrument panel A/C registers.
3. blended air temperature is available. Only when A/C compressor operation has been selected by pressing the A/C request button (indicator ON), can the airflow temperature be cooled below the outside air temperature.
4. the A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

When PANEL/FLOOR is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the floor duct and the instrument panel A/C registers. A small amount of airflow from the side window demisters and defrost duct will be present.
3. blended air temperature is available. Only when A/C compressor operation has been selected by pressing the A/C request button (indicator ON), can the airflow temperature be cooled below the outside air temperature.
4. the A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

When FLOOR is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the floor duct. A small amount of airflow from the defroster duct and side window demisters will be present.
3. blended air temperature is available. Only when A/C compressor operation has been selected by pressing the A/C request button (indicator ON), can the airflow temperature be cooled below the outside air temperature.
4. the A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

When the FLOOR/DEFROST is selected

1. the recirc request button is enabled. If the recirc request button is selected (indicator ON), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator OFF), the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the floor duct, the defroster duct and the side window demisters.
3. blended air temperature is available.
4. the A/C request button is enabled. The A/C compressor will operate automatically and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

When DEFROST is selected

1. the recirc request button and indicator is disabled. Regardless of button and indicator status, the air inlet door actuator admits only outside air into the passenger compartment.
2. the floor/defrost/panel door directs airflow to the defroster duct and side window demisters. A small amount of airflow from the floor duct will be present.
3. blended air temperature is available.
4. the A/C request button will indicate the last status and the indicator can be toggled. To reduce fogging, the A/C compressor will operate automatically, regardless of indicator status, if the outside temperature is above approximately 6°C (43°F).
5. the blower motor is ON.

CLIMATE CONTROL SYSTEM REFERENCE Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool Fluke 77111 Automotive Meter 105-R0056 or equivalent R-134a Manifold Gauge Set 176-R032A or equivalent A/C Pressure Test Adapter 412-093 (T94P-19623-E) Set, A/C Fittings 412-DS028 (014-00333, D93L-19703B) or equivalent Refrigerant Leak Detector 216-00001 or equivalent Pressure Test Kit 014-R1072 or equivalent

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Electronic Automatic Temperature Control Module - Retrieve Continuous DTCs

The EATC module 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 DEFROST buttons simultaneously and release, then press the RECIRC 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 Celsius symbol (°C) on the EATC module display. Record all DTCs displayed.
3. If any DTCs appear, carry out the diagnostic procedure. Refer to the «ELECTRONIC AUTOMATIC TEMPERATURE CONTROL MODULE DIAGNOSTIC TROUBLE CODE INDEX»(ref-255298-S00775535022007053000000) and follow the ACTION for each DTC given.
4. If a condition exists but no DTCs appear, GO to «SYMPTOM TABLE»(ref-255298-S22219051662007053000000) Condition: The EATC System Is Inoperative, Intermittent or Incorrect Operation.
5. To exit and retain all continuous DTCs, press any button except DEFROST. The EATC module will exit the retrieved continuous DTCs mode and retain all continuous DTCs.
6. To exit and clear all continuous DTCs, press the DEFROST button. The EATC module 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 door actuators to automatically recalibrate.
8. Continuous DTCs will be deleted after 80 ignition switch ON cycles after the intermittent fault occurs.

Electronic Automatic Temperature Control (EATC) Module and Electronic Manual Temperature Control (EMTC) Module Cold Boot Process

The purpose of the cold boot process is to allow the EATC or EMTC module to reinitialize 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 EATC or EMTC module electrical connectors.
3. Wait on minute.
4. Connect the EATC or EMTC module electrical connectors.
5. Turn the ignition switch to the ON position.
6. Select any position except OFF on the EATC or EMTC module.

The EATC or EMTC module will not initialize and calibrate the actuators. Calibration of the actuators will take approximately 30 seconds.

Possible Causes

1. An open in circuit 3051 (BK/YE) or 3050 (WH/OG)
2. A short to voltage in circuit 3051 (BK/YE)
3. A short to ground in circuit 3050 (WH/OG)
4. In-vehicle air temperature sensor
5. EATC module

1. An open in circuit 3051 (BK/YE) or 3060 (GY/RD)
2. A short to voltage in circuit 3051 (BK/YE)
3. A short to ground in circuit 3060 (GY/RD)
4. Ambient air temperature sensor
5. EATC module

1. An open in circuit 3051 (BK/YE) or 468 (BN)
2. A short to ground in circuit 468 (BN)
3. Solar radiation sensor
4. EATC module

1. An open, short to voltage, ground or together in circuits 1991 (LB/WH), 1990 (WH/LB), 438 (RD/WH), 436 (RD/LG) and 3053 (BN/WH)
2. Air inlet door actuator motor
3. EATC module
4. EMTC module
5. Stuck or bound linkage or door

1. An open, short to voltage, ground or together in circuits 1988 (BN/OG), 1989 (OG/LB), 438 (RD/WH), 436 (RD/LG) and 1982 (LB/BK)
2. Floor/defrost/panel mode door actuator motor
3. EATC module
4. EMTC module
5. Stuck or bound linkage or door

1. Fuse(s)
2. An open in circuit 1203 (BK/LB), 483 (RD) or 1566 (RD/YE)
3. EATC module

1. Fuse(s)
2. An open in circuit 1203 (BK/LB), 483 (RD) or 1566 (RD/YE)
3. EATC module

1. Plugged heater core
2. Coolant level
3. Temperature blend door

1. Fuse
2. An open in circuits 1424 (TN/BK), 3028 (DB/YE), 1810 (LG/OG) or 1205 (BK)
3. An short to voltage on circuit 1424 (TN/BK)
4. PCM
5. EATC module
6. EMTC module
7. A/C evaporator discharge temperature sensor
8. A/C pressure transducer
9. A/C compressor clutch field coil
10. A/C control relay
11. A/C clutch air gap

1. An short to ground on circuit 1424 (TN/BK)
2. An short to voltage on circuit 1810 (LG/OG)
3. PCM
4. EATC module
5. EMTC module
6. A/C evaporator discharge temperature sensor
7. A/C pressure transducer
8. A/C control relay
9. A/C clutch air gap

Door actuator feed A circuits

1. LH blend - 246 (VT)
2. RH blend - 660 (YE/LG)

Door actuator feed B circuits

1. LH blend - 245 (BN/LG)
2. RH blend - 1069 (OG/LB)

Door actuator return circuits

1. LH blend - 438 (RD/WH)
2. RH blend - 438 (RD/WH)

Door actuator reference circuits

1. LH blend - 436 (RD/LG)
2. RH blend - 436 (RD/LG)

Door actuator feedback circuits

1. LH blend - 437 (YE/LG)
2. RH blend - 435 (YE/LB)

1. An open, short to voltage, ground or together in door actuator open, close, return, reference or feedback circuits
2. Blend door actuator motor
3. EATC module
4. EMTC module
5. Stuck or bound linkage or door

1. Fuse(s)
2. An open in circuit 752 (YE/RD), 1205 (BK), 261 (OG/BK), 364 (BK/LG), 1322 (BN/WH) or 296 (WH/VT)
3. Blower motor
4. Blower motor relay
5. Blower motor switch

1. An open in circuit 1205 (BK), 260 (RD/OG), 269 (LB/OG) or 752 (YE/RD)
2. A short to ground in circuit 260 (RD/OG), 269 (LB/OG) or 752 (YE/RD)
3. A short together circuits 260 (RD/OG), 269 (LB/OG) or 752 (YE/RD)
4. Blower motor resistor
5. Blower motor switch

1. An open in circuit 1205 (BK), 261 (OG/BK), 1322 (BN/WH), 515 (BK/WH), 1120 (BK/WH), 296 (WH/VT) or 364 (BK/LG)
2. A short to ground in circuit 1120 (BK/WH)
3. A short to voltage in circuit 1322 (BN/WH)
4. Blower motor relay
5. Blower motor control module
6. EATC module
7. Blower motor

1. An open in circuit 1120 (BK/WH)
2. A short to ground in circuit 515 (BK/WH) or circuit 1322 (BN/WH)
3. A short to voltage in circuit 1120 (BK/WH) or circuit 261 (OG/BK)
4. Blower motor control module
5. Blower motor relay
6. EATC module

1. An open in circuit 181 (BN/OG), 1004 (LB/RD), 1371 (TN/OG), 1205 (BK), 536 (BK/LG) or 1349 (PK/LG).
2. Auxiliary blower motor
3. Auxiliary blower motor relay 1
4. Auxiliary blower motor resistor

1. An open in circuit 1372 (PK/BK), 1373 (GY/YE), 1004 (LB/RD), 751 (DB/WH), 1120 (BK/WH) or 1349 (PK/LG)
2. A short to ground in circuit 1371 (TN/OG), 1372 (PK/BK), 1373 (GY/YE), 1349 (PK/LG) or 751 (DB/WH)
3. A short to voltage in circuit 536 (BK/LG)
4. A short together circuits 751 (DB/WH), 1120 (BK/WH) and 1349 (PK/LG)
5. Auxiliary blower motor relay
6. Auxiliary blower motor speed relay 1
7. Auxiliary blower motor speed relay 2
8. Auxiliary blower motor speed relay 3
9. Auxiliary blower motor resistor
10. EATC module

1. An open, short to voltage, ground or together in circuits 1376 (BK/LB), 1375 (PK/YE), 1377 (TN/LG), 1381 (WH/LB) and 1378 (GY/WH)
2. Auxiliary temperature door actuator
3. EATC module
4. Stuck or bound linkage or door

1. An open, short to voltage, ground or together in circuits 1380 (TN/YE), 1379 (PK/LB), 1377 (TN/LG), 1381 (WH/LB) and 1382 (BK/OG)
2. Auxiliary panel/floor door actuator
3. EATC module
4. Stuck or bound linkage or door

1. An open in circuit 1377 (TN/LG), 1121 (DG/YE), 1125 (BN) or 1381 (WH/LB)
2. A short to ground in circuit 1121 (DG/YE), 1125 (BN) or 1381 (WH/LB)
3. A short to voltage in circuit 1121 (DG/YE), 1125 (BN) or 1377 (TN/LG)
4. A short together circuits 1377 (TN/LG) and 1121 (DG/YE), 1125 (BN) or 1381 (WH/LB)
5. A short together circuits 1121 (DG/YE) and 1125 (BN)
6. Rear auxiliary control
7. EATC module

Heater Core

1. Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater 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 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, feel the heater core inlet and outlet hoses to see if they are hot.
4. If the outlet only is not hot: the heater core may have an air pocket. the heater core may be plugged.
5. If the inlet only is not hot: the thermostat may not be working correctly.

Disconnect

1. Remove the nut and separate the 2 halves of the peanut fitting.
2. Remove the O-ring seal with a non-metallic tool.

Connect

1. Clean all dirt or foreign material from the fittings.
2. Install the O-ring seal.
3. Assemble the male and female fittings together.

Scheme 273

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

Fluorescent Dye Leak Detection

SPECIAL TOOL DESCRIPTION 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 120 Watt UV Spot Lamp 164-R0721 or equivalent High Intensity UV Lamp - 12 Volt 164-R6000 or equivalent R-134a Fluorescent Dye Injector 164-R0775 or equivalent Deluxe Injector Loop Kit 219-00069 or equivalent R-134a Leak Detection Dye 164-R6060

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

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.

Scheme 280

Scheme 281

1. Check for leaks using a Rotunda-approved UV lamp. 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»(ref-255298-S14835036442007053000000) .
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»(ref-255298-S14835036442007053000000) .
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.

Fluorescent Dye Injection - Using an A/C Refrigerant Center 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 ultraviolet 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. Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturer's instructions on evacuation of any non-condensable gasses from the hoses. Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation. Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off.

Scheme 282

Scheme 283

1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves.
2. Verify that the valves on the fluorescent dye injector are closed.
3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz.) of fluorescent dye.
4. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or 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 R-134a fluorescent dye injector.
8. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set.

Fluorescent Dye Injection - Using a Dye Injector Loop Kit

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 ultraviolet 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. Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturer's instructions on evacuation of non-condensable gasses from the hoses. Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F).

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

1. Verify that the valves on the deluxe injector loop kit are closed.
2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz.) of fluorescent dye.
3. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves.
4. Start the engine.
5. Open the high-pressure service valve.
6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system.
8. Close the valves on the deluxe injector loop kit.
9. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle.

Electronic Leak Detection

SPECIAL TOOL DESCRIPTION H10PM Refrigerant Leak Detector With Battery 216-00001 or equivalent

Scheme 289

Scheme 290

1. Leak test the refrigerant system using the leak detector. Follow the instructions included with the 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»(ref-255298-S14835036442007053000000) . Repair the system. Test the system for normal operation.

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

SPECIAL TOOL DESCRIPTION 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 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

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

MATERIAL SPECIFICATION

Refrigerant System Recovery

Note. Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. 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, you must verify the purity of the refrigerant. For additional information, refer to «REFRIGERANT IDENTIFICATION TESTING»(ref-255298-S15969690462007053000000) .
2. Connect an R-134a refrigerant service center 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.
4. Once the refrigerant service center 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 Service Center

Note. Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. 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 service center 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

Note. Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. 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 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 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 Service Center

Note. Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. 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»(ref-255298-S34874625932007053000000) .
2. Connect an R-134a A/C service center 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

Note. Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. 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»(ref-255298-S34874625932007053000000) .
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 A/C operation and allow the refrigerant charge to complete.

Refrigerant Oil Adding

SPECIAL TOOL DESCRIPTION Dye/Lubricant Injector 164-R0775 Add-On Module Kit 219-00069

MATERIAL SPECIFICATION

1. Refer to «PAG OIL AMOUNT REFERENCE TABLE»(ref-255298-S39520819492007053000000) for refrigerant oil adding amounts and methods of installation.

PAG OIL AMOUNT REFERENCE TABLE

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 along with the refrigerant oil.

Scheme 296

Scheme 297

1. Evacuate the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .
2. Assemble the dye/lubricant injector using the correct adapters 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

Contaminated Refrigerant Handling

Note. A new suction accumulator or receiver/drier must be installed as directed by the air conditioning 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 your area with the correct equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern.
3. Flush the air conditioning system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations.

Air Conditioning (A/C) Odor Treatment

SPECIAL TOOL DESCRIPTION Flexible Applicator Tool Kit 258-00004 30 oz. Sure Shot Pressure Sprayer 167-R4700 or equivalent

Scheme 298

MATERIAL SPECIFICATION

A/C Odor Treatment

Note. There are typically 4 types of objectionable odors found in a vehicle

1. Chemical odors
2. Environmental odors
3. Human and other interior-generated odors
4. 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. 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. 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. 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

1. foam seals.
2. rubber seals.
3. adhesives.
4. standing water.
5. water soaked carpet/trim. Identify the type of odor present in the vehicle. Do not proceed with A/C odor treatment if the odor source is found to be outside of the A/C system. Refer to «ODOR DESCRIPTION TABLE»(ref-255298-S15427045842007053000000) for examples. ODOR DESCRIPTION TABLE Odor Source Odor Description Chemical Odors Coolant Sweet smell Fuel Gasoline or diesel fuel smell Oil Oil type or burning smell Power Steering Fluid Oil type or burning smell Transmission Fluid Oil type or burning smell Washer Fluid Alcohol type smell Gear Lube Garlic/sulfur smell Refrigerant Oil Ether type smell Carpet/trim Adhesives Fishy, urine or sweet smell Evaporator Core Coating Wet cement type smell Environmental Odors Exhaust Exhaust, fuel or burning type smell Industrial Pollutants Various smells Dust Musty, mildew or wet cement type smell Pollen Sweet smell Tobacco Burning, tar smell Human and Other Interior Generated Odors Body Secretions Body odor Perfuming Agents Sweet or fragrance smell Clothing Musty, mildew or body odors Food/Beverage Sweet, musty, mildew or fishy smell Microbiological Odors Microbiological Odors Occurring Inside of A/C System Musty, mildew smell lasting about 30 seconds after A/C is turned on Microbiological Odors Occurring Outside of A/C System Musty, mildew smell lasting indefinitely and possibly more pronounced when using recirculated air Identify the source of the odor. Check the passenger and driver side carpet for moisture. Continue diagnosis if moisture is found. Check the blower motor and blower motor cover (if equipped) for moisture resulting from water bypassing the cowl baffling system. Continue diagnosis if moisture is present. Check the evaporator core drain tube for restriction. Check the cowl top panel and air inlet screen for standing water or foreign material. If possible, remove any standing water and clean the air inlet screen using a wet/dry vacuum. Open all vehicle windows. Disconnect the low-side A/C pressure switch (cycling or low-charge protection) electrical connector. Remove the evaporator air discharge temperature sensor (if equipped). Set the following. Enable the A/C using fresh air inlet. Adjust the temperature setting to full warm. Adjust the blower motor speed to HI. Run the engine for 25 minutes to dry out the A/C system. Turn the ignition OFF. Remove the blower motor. NOTE: Blower motor speed controls that are mounted outside of the evaporator core housing and not exposed to the blower motor airflow do not need to be removed. Remove the blower motor resistor (if equipped) or blower motor speed control (if equipped and exposed to the inside of the evaporator core housing). CAUTION: To avoid damage to the vehicle interior, do not spill or spray this product on any interior surface. Add one full bottle of A/C cooling coil coating to the applicator or sprayer. Insert the nozzle into the evaporator housing and direct the spray toward the evaporator core face. Spray the entire evaporator core face until empty. Install the blower motor and blower motor resistor (if equipped) or blower motor speed control (if equipped). Install the evaporator air discharge temperature sensor (if equipped), Repeat Steps 6 through 8 to cure the evaporator core coating. Connect the low-side A/C pressure switch (cycling or low-charge protection) electrical connector.