Climate Control: Other Ford Fusion I рестайлинг

Material

Material

Air Conditioning

The refrigerant system components include the following

1. A/C compressor
2. A/C clutch assembly
3. A/C condenser core
4. A/C evaporator core
5. Receiver/drier cartridge
6. Connecting refrigerant lines
7. Thermostatic Expansion Valve (TXV)

The refrigerant system incorporates an A/C compressor controlled by the PCM through an A/C clutch relay. The climate control assembly sends an A/C request signal to the instrument cluster module, which relays the request to the PCM. An evaporator discharge air temperature sensor is used to disengage the A/C compressor clutch when the evaporator core temperature falls below an acceptable temperature.

The A/C compressor clutch will only be engaged by the PCM if all of the following conditions are met

1. The HVAC module is set to a mode which provides an A/C request to the PCM via the Instrument Cluster (IC).
2. The evaporator discharge air temperature sensor is reading an acceptable temperature.
3. The A/C pressure transducer is reading an acceptable pressure in the high side of the refrigerant system.
4. The A/C compressor relay is switched to the closed position by the PCM.
5. The engine coolant temperature is not excessively high.
6. The PCM has not detected a Wide Open Throttle (WOT) condition.

An A/C pressure relief valve is installed in the A/C compressor to protect the refrigerant system against excessively high refrigerant pressures.

Refrigerant flow into the evaporator core is metered by a TXV.

A/C Pressure Relief Valve

Note. If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the A/C pressure relief valve is leaking around the threads, replace the A/C pressure relief valve and O-ring. If the A/C pressure relief valve still vents after it is replaced, diagnose the refrigerant system for a restriction.

An A/C pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C compressor and other system components by relieving unusually high system discharge pressure buildups. For specifications regarding operating pressure(s), refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

The A/C pressure relief valve is a separate component and can be replaced separately from the A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve.

A/C Condenser/Power Steering Combo Cooler

The A/C condenser/power steering combo cooler is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled.

The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier cartridge is a separate component and can be removed and installed separately from the condenser core.

The top portion of the condenser/power steering combo cooler is partitioned from the refrigerant system and is used for power steering fluid cooling.

Receiver/Drier Cartridge

Note. Installation of a new receiver/drier cartridge is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier cartridge. Damage to the receiver/drier cartridge includes physical damage or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the receiver/drier cartridge does not need to be replaced.

The receiver/drier is integral to the A/C condenser/power steering combo cooler. It stores high-pressure liquid after it leaves the condenser core. A receiver/drier cartridge mounted inside the receiver/drier removes any retained moisture from the refrigerant. The receiver/drier cartridge is a separate component and can be removed and installed separately from the A/C condenser/power steering combo cooler.

Evaporator Core

The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet tube. Air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins.

Thermostatic Expansion Valve (TXV)

The Thermostatic Expansion Valve (TXV) is located between the evaporator core lines and the TXV manifold and tube assembly at the rear of the engine compartment. The TXV provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of the refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures.

Evaporator Discharge Air Temperature Sensor

The evaporator discharge air temperature sensor contains a thermistor which receives a reference voltage from the PCM. The thermistor then varies the resistance to the reference voltage based on the evaporator discharge air temperature. The resulting voltage is returned to the PCM where it is interpreted as an evaporator air discharge temperature reading.

The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator discharge air temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels.

The evaporator discharge air temperature sensor is located inside of the heater core and evaporator core housing in the air-stream leaving the evaporator core.

A/C Pressure Transducer

The A/C pressure transducer monitors the compressor discharge pressure and communicates with the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage.

Service Gauge Port Valves

The high-pressure service gauge port valve is located on the condenser-to-evaporator line.

The low-pressure service gauge port valve is located on the TXV manifold and tube assembly.

Scheme 160

The fitting is an integral part of the refrigeration line or component.

1. Special couplings are required for both the high-side and low-side service gauge ports.
2. A very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively.
3. The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed.

Refrigerant System Dye

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. 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 or hose rupture. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

Air Distribution and Filtering

Note. This vehicle is not equipped from the factory with a cabin air filter.

There are 2 sources of air available to the air distribution system

1. Outside air
2. Recirculated air

Recirculated air is always used when the HVAC module is set to the MAX A/C mode on vehicles equipped with Electronic Manual Temperature Control (EMTC). Vehicles equipped with Electronic Automatic Temperature Control (EATC) use recirculated air only when the RECIRC function is selected in any mode other than DEFROST, or when required by the HVAC module in the AUTOMATIC mode.

Air distribution within the vehicle is determined by the EMTC systems or the EATC system in the AUTOMATIC mode. The air distribution mode on vehicles equipped with EATC can be overridden by the driver if desired. Airflow mode control doors are used to direct airflow within the heater core and evaporator core housing. Electric mode door actuators are used to position these airflow mode doors.

Vehicles equipped with dual-zone EATC use 2 separate temperature blend doors. This allows individual temperature settings to be selected for the RH and LH air outlets. The airflow mode doors are not partitioned for separate RH and LH airflow positions. Therefore, the airflow mode will always remain similar for the RH and LH sides of the vehicle regardless of the temperatures selected.

Air enters the passenger compartment from the

1. instrument panel registers.
2. floor duct.
3. windshield defroster.
4. side window demisters.
5. rear footwell duct (if equipped).

Passenger compartment air is exhausted from the vehicle through open windows or body air vents.

Electronic Manual Temperature Control

The Electronic Manual Temperature Control (EMTC) components are used to select

1. air inlet source (outside or recirculated).
2. blower motor speed.
3. discharge air temperature (temperature blend).
4. discharge air location (defrost, panel, floor).
5. A/C compressor operation.

Control System Inputs

The EMTC system has 2 system control inputs.

HVAC Module

The HVAC module integrates the temperature control, airflow mode selection, A/C request button, recirculated air request button and rear defog switch into a single unit.

The temperature control switch setting determines air temperature. Movement of the temperature display from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door and determines the air discharge temperature that the air distribution system will maintain. The temperature control switch is an integral part of the HVAC module and cannot be installed separately.

The A/C request button determines A/C compressor operation, except when the function selected is OFF, MAX or DEFROST. The A/C request button is an integral part of the HVAC module and cannot be installed separately.

The recirculated air request button can select recirculated air in any mode except DEFROST, and fresh air in any mode except MAX A/C or OFF.

The rear defog button signals activation of the heated backlight. The rear defog button is an integral part of the HVAC module and cannot be installed separately.

The HVAC module is not equipped with self-test capabilities.

Blower Motor Switch

The blower motor switch is mounted in the HVAC module and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all modes except OFF.

Control System Outputs

The EMTC system has 3 system outputs.

Blower Motor Resistor

The blower motor resistor

1. is located on the heater core and evaporator core housing near the blower motor.
2. has 3 resistor elements mounted on the resistor board to provide 4 blower motor speeds.
3. depending on the blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed.

Temperature Blend Door Actuator

The temperature blend door actuator

1. is located on the heater core and evaporator core housing.
2. moves the temperature blend door on command from the HVAC module.
3. contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the temperature blend door.
4. applies a 5-volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the HVAC module and is matched with an expected wiper voltage value. The HVAC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected HVAC module wiper voltage value.

Mode Door Actuator

The mode door actuator

1. uses a cam setup to direct system airflow to the vehicle interior as determined by the HVAC module.
2. contains a reversible electric motor.
3. contains a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the mode door.
4. applies a 5-volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the HVAC module and is matched with an expected wiper voltage value. The HVAC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected HVAC module wiper voltage value.

Air Inlet Mode Door Actuator

The air inlet mode door actuator

1. moves the air inlet door between the FRESH and RECIRC positions on command from the HVAC module.
2. contains a reversible electric motor.
3. automatically stops when it reaches the full FRESH or full RECIRC position and does not report its position back to the HVAC module.

Electronic Automatic Temperature Control (EATC)

Two different Electronic Automatic Temperature Control (EATC) systems are available

1. Single-zone EATC (Fusion/Milan)
2. Dual-zone EATC (MKZ)

The HVAC module analyzes input from the following major sources

1. Temperature, airflow direction, blower, A/C and RECIRC selection (made by the vehicle occupants)
2. In-vehicle temperature sensor
3. Ambient temperature sensor
4. Solar radiation sensor
5. Vehicle speed
6. Engine coolant temperature

Using these inputs, the HVAC module determines the correct conditions for the following outputs

1. A/C compressor operation
2. Blower speed
3. Temperature blend door position
4. DEFROST/PANEL/FLOOR door position
5. Air inlet door position

The EATC system has 4 control system inputs.

The HVAC module

1. is located in the instrument panel.
2. has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and DTCs.
3. utilizes an On-Board Diagnostic (OBD) feature to supply the technician with DTCs. These DTCs direct the technician to the inoperative component.

In-Vehicle Temperature Sensor

The in-vehicle temperature sensor operates in the following manner

1. A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger compartment.
2. An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor.
3. The aspirator hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor.
4. The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor.

Solar Radiation Sensor (Sunload Sensor)

The solar radiation sensor supplies information to the HVAC module indicating sunload.

Ambient Temperature Sensor

The ambient temperature sensor signal is received by the HVAC module and indicates the outside air temperature. The ambient temperature sensor is located in front of the radiator on the radiator support.

The EATC system has 3 control system outputs.

Blower Motor Speed Control

The blower speed control

1. is located on the heater core and evaporator core housing near the blower motor.
2. varies the blower motor speed and is controlled by the HVAC module software.

Temperature Blend Door Actuator(s)

Single-zone EATC systems use one temperature blend door actuator. Dual-zone EATC systems use 2 separate temperature blend door actuators to control 2 separate temperature blend doors for the driver and passenger sides of the vehicle. The temperature blend door actuator(s)

1. is/are located on the heater core and evaporator core housing.
2. move the temperature blend door(s) on command from the HVAC module.
3. each contain a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the temperature blend doors.

A 5-volt signal is applied to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the HVAC module and is matched with an expected wiper voltage value. The HVAC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected HVAC module wiper voltage value.

The mode door actuator

1. uses a cam setup to position the 2 airflow mode doors to direct system airflow to the vehicle interior as determined by the HVAC module settings.
2. contains a reversible electric motor.
3. contains a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the mode door.

A 5-volt signal is applied to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the HVAC module and is matched with an expected wiper voltage value. The HVAC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected HVAC module wiper voltage value.

The air inlet mode door actuator

1. moves the air inlet door between the FRESH and RECIRC positions on command from the HVAC module.
2. contains a reversible electric motor.
3. automatically stops when it reaches the full FRESH or full RECIRC position and does not report its position back to the HVAC module.

Heating and Ventilation

The heating and ventilation system has the following features

1. Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle
2. Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level
3. Cooling or heating can be adjusted to maintain the desired temperature
4. Uses a reheat method to provide conditioned air to the passenger compartment
5. All airflow from the blower motor passes through the A/C evaporator core
6. Temperature blending is controlled by the temperature blend door(s), which regulate(s) the amount of air that flows through and around the heater core, where it is then mixed and distributed

Heater Core

The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum.

Blower Motor

The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing where it is mixed and distributed.

Heater Core and Evaporator Core Housing

The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). Vehicles equipped with dual-zone Electronic Automatic Temperature Control (EATC) use a partitioned heater core and evaporator core housing with 2 electric actuator-positioned temperature blend doors. This allows for separate temperatures to be selected for the driver and passenger sides of the passenger compartment. Manual systems and single-zone EATC systems use a single electric actuator-positioned temperature blend door to direct airflow through or around the heater core.

Air Conditioning (A/C) Compressor - 2.3L

Material

Scheme 161

Air Conditioning (A/C) Compressor - 3.0L, 3.5L

Material

Note. 3.0L shown, 3.5L similar.

Scheme 162

Air Conditioning (A/C) Pressure Relief Valve

Material

Scheme 163

Clutch and Clutch Field Coil

Special Tools Illustration Tool Name Tool Number Holding Fixture, Compressor Clutch Disc and Hub 412-134

Condenser Core

Material

Scheme 164

Material

Scheme 165

Material

Scheme 166

Receiver Drier Cartridge

Material

Thermostatic Expansion Valve

Material

Scheme 167