Climate Control System-General Information: Diagnosis Ford Thunderbird XI

Inspection and Verification

1. Verify the customer's concern by operating the climate control system to duplicate the condition.
2. Inspect to determine if one of the following mechanical or electrical concerns apply: Visual Inspection Chart VISUAL INSPECTION CHART Mechanical Electrical loose, missing or damaged A/C compressor drive belt loose or disconnected A/C clutch broken or leaking refrigerant lines obstructed in-vehicle temperature sensor disconnected in-vehicle temperature aspirator hose A/C registers are not working (open/close) front floor ducts not in place incorrectly installed in-vehicle temperature sensor incorrectly installed ambient air temperature sensor fuse(s) blower motor inoperative A/C compressor inoperative circuit short/open. disconnected, loose fitting, or incorrectly installed electrical connectors and pins cooling fan inoperative relays not functional or not installed
3. As pinpoint tests and measurements are being performed, be sure to inspect for any disconnected, loose fitting, or incorrectly installed component, module and in-line electrical connectors and pins.
4. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
5. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the vehicle selection cannot be entered: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position. check that the battery voltage is greater than 9V. If the scan tool still does not allow the vehicle selection to be entered, refer to the scan tool manual.
6. Carry out the Data Link Diagnostic Test using the scan tool. If the scan tool responds with: CKT 914 and CKT 915 = ALL MODULE NO RESPONSE/NOT EQUIPPED, go to «MODULE COMMUNICATIONS NETWORK»(ref-204591) to diagnose the network concern. If the powertrain control module (PCM) is not listed for a communication concern, turn the A/C controls to OFF and execute the self-test diagnostics for the PCM. If the DATC module is not listed for a communication concern, execute the self-test diagnostics for the DATC module.
7. If any PCM or DATC DTCs are retrieved, and are related to the concern, go to the «POWERTRAIN CONTROL MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-204566-S33916166692005111300000) or the «DUAL AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-204566-S34456456142005111300000) to continue the diagnostics.
8. If no DTCs related to the concern are retrieved, go to the «SYMPTOM CHART»(ref-204566-S39123079202005111300000) to continue the diagnostics.
9. If the DATC module cannot be accessed by the scan tool, go to «PINPOINT TEST A: NO COMMUNICATION WITH THE DUAL AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE»(ref-204566-S17876633762005111300000) .

Dual Automatic Temperature Control (DATC) Module Diagnostic Trouble Codes (DTCs)

Using a scan tool or front panel diagnostics to check for DATC DTCs

1. Check continuous DTCs.
2. Run DATC self-test. Refer to «FRONT PANEL DATC SELF -TEST (ON-DEMAND DIAGNOSTIC TROUBLE CODES - DTCS)»(ref-204566-S21869703172005111300000) .

General information

1. If the DTC is continuous only and does not appear in the self-test, this indicates an intermittent fault condition, such as a poor wiring connection or a loose terminal. If the DTC does not appear after running the self-test it may also indicate that the DTC may no longer exist.
2. If the DTC is continuous and appears in the self-test, this indicates a hard fault. A hard fault suggests a permanent wiring failure, disconnected connector or component failure.

Front Panel DATC Module Self-Test (On-demand Diagnostic Trouble Codes)

On-demand DTCs are those that are reported by an ECU when a failure is detected while executing a diagnostic test. For the DATC module this means that all faults (hard) that occur while the module is conducting a self-test shall be reported as an on-demand DTC.

1. The DATC module self-test will not detect concerns associated with data link messages such as engine coolant temperature or vehicle speed signals. The scan tool must be used to retrieve these concerns.
2. The vehicle interior temperature should be between 0-32°C (32-90°F) when carrying out the self-test. If the temperatures are not within the specified ranges, false temperature sensor DTCs may be displayed.

The DATC module self-test through the front panel display

1. can be initiated at any time. Normal operation of the system stops when the self-test is activated.
2. is entered by pressing the OFF and FLOOR buttons simultaneously and then pressing the AUTO button within two seconds. Record all DTCs displayed.
3. concludes by reporting all on-demand DTCs. Follow the diagnostics procedure given under ACTION in the DTC index for each DTC given.
4. reports individual on-demand DTCs as four-digit DTCs (less the alpha character).
5. will calibrate all the mode doors and check all analog inputs. The DATC module will only report on demand (hard) faults that occurred while the DATC module was conducting its self-test.
6. will light all control panel display segments if no faults are detected.
7. will report individual on-demand DTCs without the °C symbol lit.

To exit the self-test, press any button. This will clear all on-demand codes from the DATC module memory. If no button is pushed DTCs will continue to be displayed.

Upon exit from the self-test the DATC module returns to operational status. The DATC module executes a hard (cold boot) reset which places the DATC system in the OFF mode.

If a condition exists but no DTCs appear during the self-test, refer to the Symptom Chart Condition: The DATC System Is Inoperative, Intermittent or Incorrect Operation .

Always exit the self-test before powering the system down (system turned OFF).

Front Panel DATC Module Display - Retrieve Continuous Diagnostic Trouble Codes (DTCs)

Continuous DTCs are fault codes recorded by the DATC module which have occurred during normal operation. For the DATC module this means that all faults (intermittent or hard) that occur while the module is in an operational state shall be reported as a continuous DTC.

1. To retrieve continuous DTCs, press the OFF and PANEL buttons simultaneously, followed by pressing the AUTO button within two seconds.
2. The DATC module will report all continuous DTCs to the vacuum fluorescent (VF) display.
3. The DATC module will not carry out a self-test; it will only display continuous faults codes which are stored in memory.
4. All VF display segments will light if no faults are detected.
5. Individual continuous DTCs will be reported with the °C symbol lit.
6. DTCs shall be reported as a four-digit DTC (less the alpha character).
7. Pressing the front defrost button will exit the retrieve continuous DTCs mode and clear all continuous DTCs from DATC module memory.
8. Pressing any other button (other than DEFROST) will exit the retrieve continuous DTCs mode and maintain all continuous DTCs in DATC module memory.
9. Upon exit from the retrieve continuous DTCs mode the DATC module returns to operational status. The DATC module executes a hard (cold boot) reset which places the DATC system in the OFF mode.

Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index

POWERTRAIN CONTROL MODULE DIAGNOSTIC TROUBLE CODE INDEX

Dual Electronic Automatic Temperature Control (DATC) Module Diagnostic Trouble Code (DTC) Index

DUAL ELECTRONIC AUTOMATIC TEMPERATURE CONTROL MODULE DIAGNOSTIC TROUBLE CODE INDEX

Symptom Chart

SYMPTOM CHART

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PINPOINT TEST E: DTC B1946, B1947, B1966, B1967, B2428, OR B2429 - CLIMATE CONTROL A/C POST EVAPORATOR SENSOR, A/C POST HEATER SENSOR DRIVER SIDE, OR A/C POST HEATER SENSOR PASSENGER SIDE CIRCUIT FAILURE OR SHORT TO GROUND

Note. Evaporator core, driver side heater core and passenger side heater core discharge air temperature sensors have the same diagnostic procedure.

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PINPOINT TEST L: THE AIR CONDITIONING (A/C) IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

Note. The ambient temperature must be above 0°C (32°F) to permit the A/C compressor to operate.

Note. Before carrying out the following test, diagnose any PCM DTCs.

Note. Before carrying out the following test, make sure 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 .

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Heater Core-Pressure Test

Use the Pressure Test Kit to carry out the pressure test.

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1. Drain the coolant from the cooling system.
2. Disconnect the heater hoses from the heater core. For additional information, refer to «HEATING & VENTILATION»(ref-204569) .
3. Install a short piece of heater hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater hoses with water and install the two plugs BT-7422-B and the adapter BT-7422-A from the Pressure Test Kit. Secure the heater 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 three minutes.
8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test.

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1. Remove the heater core from the vehicle. For additional information, refer to «HEATING & VENTILATION»(ref-204569) .
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 inch) test heater hoses with plug and adapter to the core tubes. Then connect 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, install a new heater core.

Condenser Core-On-Vehicle Leak Test

1. Discharge and recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-204566-S12281990922005111300000) .
2. Disconnect the condenser core from the A/C system. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
3. Clean the manifold fittings.
4. Connect the appropriate test fittings from the Set, A/C Fittings to the condenser core tube connections.
5. Connect the Vacuum Check Fitting, TXV to the thermostatic expansion valve.
6. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump.
7. 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 condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak.
8. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new condenser core.
9. 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 condenser core. Then recheck for loss of vacuum. If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss.
10. If the condenser core does leak, as verified by the above procedure, install a new condenser core. For additional information, refer to «AIR CONDITIONING»(ref-204570) .

A/C Compressor-External Leak Test

1. Install the A/C Pressure Test Adapter on the port of the A/C compressor using the existing manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as the R-134a A/C service center to the corresponding fittings on the A/C Pressure Test Adapter.
3. Attach the center hose of a manifold gauge set to a refrigerant container standing in an upright position.
4. Hand-rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft.
7. If a shaft or external leak is found, install a new A/C compressor. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
8. When the leak test is complete, recover the refrigerant from the compressor.

Visual inspection

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1. Remove the A/C tube lock coupling clip, if equipped.
2. Fit the special tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring.
4. Pull the spring lock coupling fittings apart.
5. Remove the O-ring seals with a non-metallic tool.
6. Remove the A/C tube lock coupling spring with a small hooked wire.

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1. Fabricate a cleaning tool from a 1/8-inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. CLEANING SPECIFICATION Coupling Size Pad Size 3/8 inch 25 x 50 mm (1 x 2 inch) 1/2 inch 25 x 50 mm (1 x 2 inch) 5/8 inch 25 x 76 mm (1 x 3 inch) 3/4 inch 25 x 102 mm (1 x 4 inch)
3. Assemble the pad to the tool.
4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
5. Roll the pad on the tool and install it in a variable speed drill motor.
6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material.
7. Clean the fitting with a lint-free cloth.
8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component.
9. Clean the O-ring seal grooves with a 300-mm (12-inch) length of natural fiber string. Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint-free cloth.

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1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
3. Install the O-ring seals. Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting.
5. Install the A/C tube lock coupling clip.

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1. Remove the nut from the peanut fitting.
2. Pull the peanut fitting apart.
3. Remove the O-ring seal with a non-metallic tool.

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1. Clean all dirt or foreign material from the fittings.
2. Install the O-ring seal. Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
4. Assemble the male and female fittings together.

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Diagnostic Table

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1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley.
2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specifications.

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1. Turn both valves on the R-134a Manifold Gauge Set clockwise to close the low- and high-pressure hoses to the center manifold and center hose.
2. Remove the A/C charging valve cap from the high-pressure service gauge port valve.
3. Connect the R-134a Manifold Gauge Set high-pressure hose and the R-134a high side quick disconnect to the high-pressure service gauge port valve.
4. Raise the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
5. Remove the screws and the left sight shield.
6. Remove the A/C charging valve cap (19D702) from the low-pressure service gauge port valve.
7. Connect the R-134a Manifold Gauge Set low-pressure hose and the R-134a low side quick disconnect to the low-pressure service gauge port valve.
8. To disconnect the manifold and gauge set, reverse the connection procedure.

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Inspection and Assembly Requirements - Following An A/C Compressor Failure

1. Install a new thermostatic expansion valve (TXV). For additional information, refer to «AIR CONDITIONING»(ref-204570) .
2. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING»(ref-204570) . Drain the residual refrigerant oil from the A/C compressor and measure the volume for correct system oil matching. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-204566-S33276441792005111300000) .
3. Remove the receiver/drier. For additional information, refer to «AIR CONDITIONING»(ref-204570) . Drain the residual refrigerant oil from the receiver/drier and measure the volume for correct oil system matching. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-204566-S33276441792005111300000) .
4. Carry out an A/C system flushing or filtering procedure: If A/C system flushing equipment is available, clean the A/C condenser core by flushing. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM FLUSHING»(ref-204566-S13289368662005111300000) . If A/C system flushing equipment is not available, carry out a system filtering procedure. For additional information, refer to «REFRIGERANT SYSTEM FILTERING AFTER A/C COMPONENT REPLACEMENT»(ref-204566-S16480300342005111300000) .
5. Install the new A/C compressor. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
6. Install the new receiver/drier, if necessary. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
7. Install the new TXV. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
8. Correctly oil match the system. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-204566-S33276441792005111300000) .
9. Evacuate and charge the system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-204566-S12281990922005111300000) .

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