Climate Control System: Other Lincoln LS I рестайлинг

Heat Transfer

If two 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 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.

The Refrigerant Cycle

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

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Connector Circuit Reference

DATC MODULE C228a CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 2 CKT 31-FA10 (BK) DATC module to blend door actuator Less than 5 ohms to chassis ground. 3 CKT 20-FA10 (PK/OG) DATC module to ATC solenoid and manifold Greater than 10 volts to chassis ground with the ignition ON. 6 CKT 8-FA51 WH/BK) DATC module to temperature blend door actuator (RH) Greater than 10,000 ohms to chassis ground and 0 volts. 7 CKT 8-FA53 (WH/BU) DATC module to temperature blend door actuator (LH) Greater than 10,000 ohms to chassis ground and 0 volts. 8 CKT 9-FA49 (BN/WH) DATC module to temperature blend door actuator (LH) Greater than 10,000 ohms to chassis ground and 0 volts. 9 CKT 8-FA48 (WH/GN) DATC module to ATC solenoid and manifold Resistance of 24,000-37,000 ohms to chassis ground. 10 CKT 8-FA44 (WH/RD) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 11 CKT 9-FA1 (BN) DATC module to ATC solenoid and manifold Resistance of 3,000-5,000 ohms to chassis ground. 14 CKT 29-FA10 (OG/GN) DATC module to ATC solenoid and manifold Greater than 10 volts at all times. 15 CKT 8-FA45 (WH/BU) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 16 CKT 9-FA44 (BN/RD) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 17 CKT 8-FA49 (WH/VT) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 18 CKT 8-FA47 (WH/GN) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 19 CKT 9-FA3 (BN/BU) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 20 CKT 10-FA53 (GY/VT) DATC module to ATC solenoid and manifold Greater than 10,000 ohms to chassis ground and 0 volts. 22 CKT 7-FA1 (YE) DATC module to ATC solenoid and manifold Resistance of 800-1,000 ohms to chassis ground

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DATC MODULE C228b CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 8-FB5 (WH/BK) ground Approximately 0-5 volts with the DATC ON. 2 CKT 8-FB2 (WH/RD) ground Approximately 0-5 volts with the DATC ON. 3 CKT 8-FB7 (WH) voltage supplied ignition on Approximately 0-5 volts with the DATC ON. 5 CKT 91S-FB3 (BN/BU) DATC module to front blower motor speed control module Greater than 10 volts at all times. 6 CKT 91S-FB4 (BN/GN) sensor signal return (ground) Greater than 10 volts at all times. 9 CKT 33-FB8 (YE/RD) DATC module to temperature blend door actuator (LH) Greater than 10,000 ohms to chassis ground and 0 volts. 10 CKT 32-FB8 (WH/RD) DATC module to temperature blend door actuator (RH) Greater than 10,000 ohms to chassis ground and 0 volts. 11 CKT 32-FB2 (WH/RD) DATC module to temperature blend door actuator (RH) Greater than 10,000 ohms to chassis ground and 0 volts. 12 CKT 33-FB2 (YE/RD) DATC module to temperature blend door actuator (RH) Greater than 10,000 ohms to chassis ground and 0 volts. 13 CKT 32-FB5 (WH/BK) voltage supplied at all times Greater than 10,000 ohms to chassis ground and 0 volts. 14 CKT 9-FA48 (BN/GN) DATC module to temperature blend door actuator (RH) Approximately 0-5 volts with the DATC ON. 15 CKT 8-FB8 (WH/RD) front blower motor speed control input Approximately 0-5 volts with the DATC ON. 16 CKT 8-FB6 (WH/VT) solar radiation sensor input (RH) Approximately 0-5 volts with the DATC ON. 17 CKT 9-FA2 (BN/RD) ambient air temperature sensor input Approximately 0-5 volts with the DATC ON. 18 CKT 91S-FA76 (BN/BU) solar radiation sensor input (LH) Greater than 10 volts at all times. 19 CKT 31S-FA23 (BK/BU) DATC module to temperature blend door actuator (RH) Greater than 10 volts at all times. 22 CKT 32-FB6 (WH/VT) DATC module to blend door actuator Greater than 10,000 ohms to chassis ground and 0 volts. 23 CKT 33-FB6 (YE/VT) DATC module to blend door actuator Greater than 10,000 ohms to chassis ground and 0 volts. 24 CKT 32-FB7 (WH) DATC module to blend door actuator Greater than 10,000 ohms to chassis ground and 0 volts. 25 CKT 33-FB7 (YE) DATC module to blend door actuator Greater than 10,000 ohms to chassis ground and 0 volts. 26 CKT 33-FB5 (YE/BK) DATC module to blend door actuator Greater than 10,000 ohms to chassis ground and 0 volts

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IN-VEHICLE TEMPERATURE SENSOR C233 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 8-FA48 (WH/GN) in-vehicle air temperature sensor input Approximately 5 volts with the DATC ON. 2 CKT 9-FA48 (BN/GN) sensor signal return (ground) Less than 5 ohms to chassis ground

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DISCHARGE TEMPERATURE SENSOR (LH) C235 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 8-FA47 (WH/GN) LH discharge temperature sensor input Approximately 5 volts with the DATC ON. 2 CKT 9-FA47 (BN/GN) sensor signal return (ground) Less than 5 ohms to chassis ground

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DISCHARGE TEMPERATURE SENSOR (RH) C255 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 8-FA51 (WH/BK) RH discharge temperature sensor input Approximately 5 volts with the DATC ON. 2 CKT 9-FA51 (BN/YE) sensor signal return (ground) Less than 5 ohms to chassis ground

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EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR C296 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 9-FA44 (BN/RD) sensor signal return (ground) Less than 5 ohms to chassis ground. 2 CKT 8-FA44 (WH/RD) evaporator discharge air temperature sensor input Approximately 5 volts with the DATC ON

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AMBIENT AIR TEMPERATURE SENSOR C132 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 8-FA49 (WH/VT) ambient air temperature sensor input Approximately 5 volts with the DATC ON. 2 CKT 9-FA49 (BN/WH) sensor signal return (ground) Less than 5 ohms to chassis ground

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BLOWER MOTOR SPEED CONTROL MODULE C297 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 31S-FA18 (BK/RD) blower motor speed control module to blower motor Greater than 10,000 ohms to chassis ground and 0 volts. 2 CKT 31-FA45 (BK) blower motor speed control module ground Less than 5 ohms to chassis ground. 3 CKT 8-FA45 (WH/BU) DATC module to blower motor speed control module input Less than 1 volt in the lowest blower setting to greater than 4.5 volts in the highest blower setting. 4 CKT 30S-FA18 (RD/BK) voltage supply to blower motor speed control module Greater than 10 volts with the DATC ON

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COOL AIR BYPASS DOOR ACTUATOR C295 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 32-FB2 (WH/RD) cool air bypass door actuator close circuit Greater than 10,000 ohms to chassis ground and 0 volts. 3 CKT 8-FB2 (WH/RD) cool air bypass door actuator feedback circuit Less than 5 ohms chassis ground. 4 CKT 9-FB2 (BN/RD) cool air bypass door actuator ground Less than 5 ohms chassis ground. 5 CKT 7-FB2 (YE/RD) cool air bypass door actuator reference voltage Greater than 4.5 volts to chassis ground with the DATC ON. 6 CKT 33-FB2 (YE/RD) cool air bypass door actuator open circuit Greater than 10,000 ohms to chassis ground and 0 volts

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AIR INLET DOOR ACTUATOR C289 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 33-FB8 (YE/RD) door actuator close circuit Greater than 10,000 ohms to chassis ground and 0 volts. 3 CKT 8-FB8 (WH/RD) door actuator feedback circuit Less than 5 ohms chassis ground. 4 CKT 7-FB8 (YE/RD) door actuator reference voltage Greater than 4.5 volts to chassis ground with the DATC ON. 5 CKT 9-FB8 (BN/RD) door actuator ground Less than 5 ohms chassis ground. 6 CKT 32-FB8 (WH/RD) door actuator open circuit Greater than 10,000 ohms to chassis ground and 0 volts

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FLOOR MODE DOOR ACTUATOR C234 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 32-FB6 (WH/VT) door actuator open circuit Greater than 10,000 ohms to chassis ground and 0 volts. 3 CKT 8-FB6 (WH/VT) door actuator feedback circuit Less than 5 ohms chassis ground. 4 CKT 9-FB6 (BN/WH) door actuator ground Less than 5 ohms chassis ground. 5 CKT 7-FB6 (YE/VT) door actuator reference voltage Greater than 4.5 volts to chassis ground with the DATC ON. 6 CKT 33-FB6 (YE/VT) door actuator close circuit Greater than 10,000 ohms to chassis ground and 0 volts

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PANEL MODE DOOR ACTUATOR C236 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 33-FB7 (YE) door actuator close circuit Greater than 10,000 ohms to chassis ground and 0 volts. 3 CKT 8-FB7 (WH) door actuator feedback circuit Less than 5 ohms chassis ground. 4 CKT 7-FB7 (YE) door actuator reference voltage Greater than 4.5 volts to chassis ground with the DATC ON. 5 CKT 9-FB7 (BN) door actuator ground Less than 5 ohms chassis ground. 6 CKT 32-FB7 (WH) door actuator open circuit Greater than 10,000 ohms to chassis ground and 0 volts

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DEFROST MODE DOOR ACTUATOR C232 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 33-FB5 (YE/BK) door actuator close circuit Greater than 10,000 ohms to chassis ground and 0 volts. 3 CKT 8-FB5 (WH/BK) door actuator feedback circuit Less than 5 ohms chassis ground. 4 CKT 7-FB5 (YE/BK) door actuator reference voltage Greater than 4.5 volts to chassis ground with the DATC ON. 5 CKT 9-FB5 (BN/YE) door actuator ground Less than 5 ohms chassis ground. 6 CKT 32-FB5 (WH/BK) door actuator open circuit Greater than 10,000 ohms to chassis ground and 0 volts

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SOLAR RADIATION SENSOR C286 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 10-FA53 (GY/VT) solar radiation sensor input Greater than 4.5 volts to chassis ground with the DATC ON. 2 CKT 9-FA53 (BN/BU) ground Less than 5 ohms chassis ground. 3 CKT 8-FA53 (WH/BU) solar radiation sensor input Greater than 4.5 volts to chassis ground with the DATC ON

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A/C COMPRESSOR CLUTCH FIELD COIL C100 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 31-FA6(BK/YE) ground Less than 5 ohms chassis ground. 2 CKT 15-FA6 (GN/YE) A/C compressor clutch relay switched output Greater than 10 volts with the A/C commanded on

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POWERTRAIN CONTROL MODULE (PCM) C175a CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 9 CKT 91S-FA79 (BN/BU) A/C compressor clutch relay control Greater than 10 volts with the ignition on

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BLOWER MOTOR C288 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 30S-FA18 (RD/BK) blower motor relay switched output Greater than 10 volts with the DATC ON. 2 CKT 31S-FA18 (BK/RD) blower motor relay to blower motor control module Resistance of less than 5 ohms to chassis ground with blower in the highest setting

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AUXILIARY COOLANT PUMP MOTOR C163 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 30S-FB1 (RD/YE) auxiliary coolant pump motor switched voltage from the auxiliary coolant pump relay. Greater than 10 volts with the auxiliary coolant pump relay ON. 2 CKT 31-FB1 (BK/YE) auxiliary coolant pump ground Less than 5 ohms to chassis ground

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COOLANT CONTROL VALVE SOLENOID C1034 CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 91S-FB4 (BN/GN) auxiliary temperature blend door actuator feed Less than 5 ohms with the DATC in full COOL mode. 2 CKT 30-FB3 (RD/OG) front auxiliary controls to rear auxiliary controls Greater than 10 volts at all times. 3 CKT 91S-FB3 (BN/BU) front auxiliary controls to rear auxiliary controls Less than 5 ohms with the DATC in full COOL mode

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BLOWER MOTOR RELAY CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 30 CKT 30-FA24 (RD/OG) blower motor relay switch voltage Greater than 10 volts at all times. 85 CKT 31S-FA23 (BK/BU) blower motor relay control from DATC module Less than 100 ohms to chassis ground with the blower in the lowest setting. 86 CKT 30-FA24 (RD/OG) blower motor relay coil voltage Greater than 10 volts at all times. 87 CKT 30S-FA18 (RD/BK) blower motor relay switched output Less than 5 ohms to chassis ground with the blower in the highest setting

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A/C COMPRESSOR CLUTCH RELAY CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 15S-FA79 (GN/RD) A/C clutch relay coil voltage Greater than 10 volts with the ignition on. 2 CKT 91S-FA79 (BN/BU) A/C compressor clutch relay control Resistance of less than 5 ohms to chassis ground when the A/C is commanded on. 3 CKT 30-FA79 (RD/OG) A/C clutch relay switch voltage Greater than 10 volts at all times. 5 CKT 15S-FA6 (GN/YE) A/C compressor clutch relay switched output Less than 100 ohms to chassis ground

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AUXILIARY COOLANT PUMP RELAY CONNECTOR PINS REFERENCE Pin Number(s) Circuit Designation/Description Normal Condition/Measurement 1 CKT 30-FA74 (RD/GN) auxiliary coolant pump relay coil voltage Greater than 10 volts at all times. 2 CKT 91S-FA76 (BN/BU) auxiliary coolant pump relay control Resistance of less than 5 ohms to chassis ground when the auxiliary coolant pump relay is commanded on. 3 CKT 30-FA74 (RD/GN) auxiliary coolant pump relay switch voltage Greater than 10 volts at all times. 5 CKT 30S-FB1 (RD/YE) auxiliary coolant pump relay switched output Less than 100 ohms to chassis ground

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Possible Causes

1. An open in circuit 29-FA10 (OG/GN), 20-FA10 (PK/OG) or 31-FA10 (BK).
2. DATC module.

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1. A1 CHECK THE CJB FUSE 220 (10A) Key in OFF position. Turn the headlights on. Does the DATC backlighting come on? Yes : GO to A2 . No : INSTALL a new fuse. TEST the system for normal operation.
2. A2 CHECK THE CJB FUSE 214 (10A) Key in ON position. Does the vacuum fluorescent (VF) display and indicators come on when DATC buttons are pushed? Yes : GO to A3. No : INSTALL a new fuse. TEST the system for normal operation.
3. A3 CHECK CIRCUIT 31-FA10 (BK) FOR AN OPEN Disconnect: DATC Module C228a. Measure the resistance between DATC module C228a-2, circuit 31-FA10 (BK), harness side and ground. Is the resistance less than 5 ohms? Yes : GO to A4. No : REPAIR circuit 31-FA10 (BK). TEST the system for normal operation.
4. A4 CHECK CIRCUIT 29-FA10 (OG/GN) FOR VOLTAGE Key in ON position. Measure the voltage between DATC module C228a-14, circuit 29-FA10 (OG/GN), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A5. No : REPAIR circuit 29-FA10 (OG/GN). TEST the system for normal operation.
5. A5 CHECK CIRCUIT 20-FA10 (PK/OG) FOR VOLTAGE Key in ON position. Measure the voltage between DATC module C228a-3, circuit 20-FA10 (PK/OG), harness side and ground. Is the voltage greater than 10 volts? Yes : Diagnose the network concern. No : REPAIR circuit 20-FA10 (PK/OG). TEST the system for normal operation.

1. An open in circuit 29-FA10 (OG/GN), 20-FA10 (PK/OG) or31-FA10 (BK).
2. DATC module.

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1. B1 VERIFY AUTOMATIC OPERATION Key in ON position. With the engine running, press the AUTOMATIC button. Does the indicator above the AUTO button illuminate and the selected temperature for both the driver and passenger appear in the display window? Yes : GO to B2. No : GO to B11 .
2. B2 PERFORM THE DATC MODULE SELF-TEST Key in ON position. Carry out the DATC module self-test. Record the DTCs displayed, if any. Were any DTCs displayed as a result of the DATC self-test? Yes : REFER to «DUAL ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-207561-S32794440092005113000000) . CARRY OUT the necessary diagnosis and REPAIR as required. No : GO to B3.
3. B3 CHECK THE VACUUM FLUORESCENT DISPLAY Exit self-test by pressing the DEFROST button. Observe the button indicators and function symbols displayed on the vacuum fluorescent display while changing the temperature, blower speed and functions. Are the display and indicators correct and complete without any missing elements? Yes : GO to B4. No : INSTALL a new DATC module. TEST the system for normal operation.
4. B4 CHECK THE BLOWER MANUAL OVERRIDE OPERATION Press the blower motor speed override control fully up and down. Does the blower motor speed increase from low to high speed? Yes : GO to B5. No : If the blower motor is inoperative, Go To «PINPOINT TEST N: THE BLOWER MOTOR IS INOPERATIVE»(ref-207561-S13125519342005113000000) . If the blower motor does not operate correctly, Go To «PINPOINT TEST O: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY»(ref-207561-S31086658252005113000000) .
5. B5 VERIFY THE DEFROST OVERRIDE OPERATION Press the override button for DEFROST operation. Is outside air being discharged from the windshield defroster nozzle and the side window demisters? Yes : GO to B6. No : Go To «PINPOINT TEST C»(ref-207561-S17649700632005113000000) .
6. B6 VERIFY THE FLOOR OVERRIDE OPERATION Press the override button for FLOOR operation. Is outside air being discharged from the floor duct? Yes : GO to B7. No : Go To «PINPOINT TEST C»(ref-207561-S17649700632005113000000) .
7. B7 VERIFY THE VENT OVERRIDE OPERATION Press the override button for VENT operation. Is outside air being discharged from the instrument panel registers? Yes : GO to B8. No : Go To «PINPOINT TEST C»(ref-207561-S17649700632005113000000) .
8. B8 VERIFY THE A/C CLUTCH DOES NOT ENGAGE IN THE VENT MODE Press the override button for VENT operation. Does the A/C clutch engage when the VENT override button is pressed? Yes : REFER to INTRODUCTION article to continue the diagnosis. No : GO to B9.
9. B9 VERIFY THE RECIRC OVERRIDE OPERATION Press the VENT and RECIRC override buttons. Is recirculated air being discharged from the instrument panel registers? Yes : GO to B10. No : Go To «PINPOINT TEST C»(ref-207561-S17649700632005113000000) .
10. B10 VERIFY A/C CLUTCH ENGAGEMENT IN THE A/C MODE Press the VENT and A/C override buttons for A/C operation. Does the A/C clutch engage when the VENT and A/C override buttons are pressed? Yes : The test is complete. The system is functioning normally. No : Go To «PINPOINT TEST L: THE A/C DOES NOT OPERATE/DOES NOT OPERATE CORRECTLY»(ref-207561-S13177440052005113000000) .
11. B11 CHECK THE DATC MODULE FUNCTIONS Press each function button and observe the display. Does the DATC perform and display any functions? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : GO to B12.
12. B12 CHECK THE VOLTAGE TO THE DATC Key in OFF position. Disconnect: DATC C228b. Key in ON position. Measure the voltage between ground and DATC module C228b-14, circuit 29-FA10 (OG/GN). Measure the voltage between ground and DATC module C228b-3, circuit 20-FA10 (PK/OG). Are the voltages greater than 10 volts? Yes : GO to B13. No : REPAIR the affected circuit. TEST the system for normal operation.
13. B13 CHECK THE GROUND CIRCUIT TO THE DATC Key in OFF position. Measure the resistance between the DATC module C228b-2, circuit 31-FA10 (BK) and ground. Is the resistance less than 5 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 31-FA10 (BK) for an open. TEST the system for normal operation.

1. An open, short to voltage, ground or together in door actuator open, close, return, reference or feedback circuits.
2. Cold air bypass, air inlet, defrost, panel mode and floor mode door actuator motor.
3. DATC module.
4. Stuck or bound linkage or door.

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1. C1 REQUEST CONTINUOUS DTCs AND CARRY OUT THE DATC SELF-TEST Key in ON position. Request Continuous DTCs and carry out the DATC Module Self-Test. Record the DTCs displayed, if any. Were any DTCs displayed? Yes : Record any DTCs displayed. GO to C3. No : GO to C2.
2. C2 CHECK THE ACTUATOR DOOR AND LINKAGE Inspect the actuator door and linkage for a binding or sticking condition. Was a condition found? Yes : REPAIR the door or linkage. TEST the system for normal operation. No : INSTALL a new DATC module. TEST the system for normal operation.
3. C3 CHECK THE DOOR ACTUATOR OPEN OPERATION Key in OFF position. Disconnect: DATC Module C228a. Disconnect: DATC Module C228b. Connect a fused jumper wire between DATC module C228a-14, circuit 29-FA10 (OG/GN), harness side and harness side of the connector/pin indicated below that corresponds to the recorded DTC(s). See «DATC MODULE PIN CIRCUIT 29-FA10 (OG/GN) REFERENCE - DOOR ACTUATOR OPEN OPERATION»(ref-207561-S17164216642005113000000) . DATC MODULE PIN CIRCUIT 29-FA10 (OG/GN) REFERENCE - DOOR ACTUATOR OPEN OPERATION DTC Pin Circuit Actuator/Door B1265 C228b-11 32-FB2 (WH/RD) Cold Air Bypass B1242 C228b-10 32-FB8 (WH/RD) Air Recirculation B1262 C228b-13 32-FB5 (WH/BK) Defrost B1263 C228b-24 32-FB7 (WH) Panel Mode B1264 C228b-22 32-FB6 (WH/VT) Floor Mode Connect a fused jumper wire between DATC module C228a-2, circuit 31-FA10 (BK), harness side and harness side of the connector/pin indicated below that corresponds to the recorded DTC(s). See «DATC MODULE PIN CIRCUIT 31-FA10 (BK) REFERENCE - DOOR ACTUATOR OPEN OPERATION»(ref-207561-S38729787162005113000000) . DATC MODULE PIN CIRCUIT 31-FA10 (BK) REFERENCE - DOOR ACTUATOR OPEN OPERATION DTC Pin Circuit Actuator/Door B1265 C228b-12 33-FB2 (YE/RD) Cold Air Bypass B1242 C228b-9 33-FB8 (YE/RD) Air Recirculation B1262 C228b-26 33-FB5 (YE/BK) Defrost B1263 C228b-25 33-FB7 (YE) Panel Mode B1264 C228b-23 33-FB6 (YE/VT) Floor Mode Does the actuator motor move in the open direction? Yes : GO to C4. No : GO to C5 .
4. C4 CHECK THE DOOR ACTUATOR CLOSE OPERATION Connect a fused jumper wire between DATC module C228a-14, circuit 29-FA10 (OG/GN), harness side and harness side of the connector/pin indicated below that corresponds to the recorded DTC(s). See «DATC MODULE PIN CIRCUIT 29-FA10 (OG/GN) REFERENCE - DOOR ACTUATOR CLOSE OPERATION»(ref-207561-S35681848482005113000000) . DATC MODULE PIN CIRCUIT 29-FA10 (OG/GN) REFERENCE - DOOR ACTUATOR CLOSE OPERATION DTC Pin Circuit Actuator/Door B1265 C228b-12 33-FB2 (YE/RD) Cold Air Bypass B1242 C228b-9 33-FB8 (YE/RD) Air Recirculation B1262 C228b-26 33-FB5 (YE/BK) Defrost B1263 C228b-25 33-FB7 (YE) Panel Mode B1264 C228b-23 33-FB6 (YE/VT) Floor Mode Connect a fused jumper wire between DATC module C228a-2, circuit 31-FA10 (BK), harness side and harness side of the connector/pin indicated below that corresponds to the recorded DTC(s). DATC MODULE PIN CIRCUIT 31-FA10 (BK) REFERENCE - DOOR ACTUATOR CLOSE OPERATION DTC Pin Circuit Actuator/Door B1265 C228b-11 32-FB2 (WH/RD) Cold Air Bypass B1242 C228b-10 32-FB8 (WH/RD) Air Recirculation B1262 C228b-13 32-FB5 (WH/BK) Defrost B1263 C228b-24 32-FB7 (WH) Panel Mode B1264 C228b-22 32-FB6 (WH/VT) Floor Mode Does the actuator motor move in the closed direction? Yes : GO to C11 . No : GO to C5.
5. C5 CHECK ACTUATOR MOTOR OPEN CIRCUIT FOR A SHORT TO GROUND Disconnect: Affected Actuator. Measure the resistance between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR MOTOR OPEN CIRCUIT FOR A SHORT TO GROUND PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228b-11 32-FB2 (WH/RD) B1242 C228b-10 32-FB8 (WH/RD) B1262 C228b-13 32-FB5 (WH/BK) B1263 C228b-24 32-FB7 (WH) B1264 C228b-22 32-FB6 (WH/VT) Is the resistance greater than 10,000 ohms? Yes : GO to C6. No : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
6. C6 CHECK ACTUATOR MOTOR CLOSE CIRCUIT FOR A SHORT TO GROUND Measure the resistance between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR MOTOR CLOSE CIRCUIT FOR A SHORT TO GROUND PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228b-12 33-FB2 (YE/RD) B1242 C228b-9 33-FB8 (YE/RD) B1262 C228b-26 33-FB5 (YE/BK) B1263 C228b-25 33-FB7 (YE) B1264 C228b-23 33-FB6 (YE/VT) Is the resistance greater than 10,000 ohms? Yes : GO to C7. No : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
7. C7 CHECK ACTUATOR MOTOR OPEN CIRCUIT FOR A SHORT TO POWER Key in ON position. Measure the voltage between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR MOTOR OPEN CIRCUIT FOR A SHORT TO POWER PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228b-11 32-FB2 (WH/RD) B1242 C228b-10 32-FB8 (WH/RD) B1262 C228b-13 32-FB5 (WH/BK) B1263 C228b-24 32-FB7 (WH) B1264 C228b-22 32-FB6 (WH/VT) Is voltage present? Yes : REPAIR the affected circuit for a short to power. TEST the system for normal operation. No : GO to C8.
8. C8 CHECK ACTUATOR MOTOR CLOSE CIRCUIT FOR A SHORT TO POWER Measure the voltage between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR MOTOR CLOSE CIRCUIT FOR A SHORT TO POWER PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228b-12 33-FB2 (YE/RD) B1242 C228b-9 33-FB8 (YE/RD) B1262 C228b-26 33-FB5 (YE/BK) B1263 C228b-25 33-FB7 (YE) B1264 C228b-23 33-FB6 (YE/VT) Is voltage present? Yes : REPAIR the affected circuit for a short to power. TEST the system for normal operation. No : GO to C9.
9. C9 CHECK ACTUATOR MOTOR OPEN CIRCUIT FOR AN OPEN Key in OFF position. Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING ACTUATOR MOTOR OPEN CIRCUIT FOR AN OPEN PIN CIRCUIT REFERENCE DTC Pin Circuit Pin B1265 C228b-11 32-FB2 (WH/RD) C295-1 B1242 C228b-10 32-FB8 (WH/RD) C289-6 B1262 C228b-13 32-FB5 (WH/BK) C232-6 B1263 C228b-24 32-FB7 (WH) C236-6 B1264 C228b-22 32-FB6 (WH/VT) C234-1 Is the resistance less than 5 ohms? Yes : GO to C10. No : REPAIR the affected circuit for an open. TEST the system for normal operation.
10. C10 CHECK ACTUATOR MOTOR CLOSE CIRCUIT FOR AN OPEN Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING ACTUATOR MOTOR CLOSE CIRCUIT FOR AN OPEN PIN CIRCUIT REFERENCE DTC Pin Circuit Pin B1265 C228b-12 33-FB2 (YE/RD) C295-6 B1242 C228b-9 33-FB8 (YE/RD) C289-1 B1262 C228b-26 33-FB5 (YE/BK) C232-1 B1263 C228b-25 33-FB7 (YE) C236-1 B1264 C228b-23 33-FB6 (YE/VT) C234-6 Is the resistance less than 5 ohms? Yes : INSPECT for binding or stuck linkage/door. If no condition is found, INSTALL a new door actuator. TEST the system for normal operation. No : REPAIR the affected circuit for an open. TEST the system for normal operation.
11. C11 CHECK THE FEEDBACK POTENTIOMETER TOTAL RESISTANCE Connect: Affected Actuator. Disconnect: Actuators Not Affected. Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING FEEDBACK POTENTIOMETER TOTAL RESISTANCE PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-11 9-FA1 (BN) C228a-22 7-FA1 (YE) B1242 C228a-11 9-FA1 (BN) C228a-22 7-FA1 (YE) B1262 C228b-17 9-FA2 (BN/RD) C228a-22 7-FA1 (YE) B1263 C228b-17 9-FA2 (BN/ RD) C228a-22 7-FA1 (YE) B1264 C228b-17 9-FA2 (BN/ RD) C228a-22 7-FA1 (YE) Is the resistance between 5,000 and 6,000 ohms? Yes : GO to C12. No : If the resistance is greater than 6,000 ohms, GO to C14. If the resistance is less than 5,000 ohms, GO to C22.
12. C12 CHECK POTENTIOMETER LOW SIDE RESISTANCE Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING POTENTIOMETER LOW SIDE RESISTANCE PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-11 9-FA1 (BN) C228b-2 8-FB2 (WH/RD) B1242 C228a-11 9-FA1 (BN) C228b-15 8-FB8 (WH/RD) B1262 C228b-17 9-FA2 (BN/RD) C228b-1 8-FB5 (WH/BK) B1263 C228b-17 9-FA2 (BN/RD) C228b-3 8-FB7 (WH) B1264 C228b-17 9-FA2 (BN/RD) C228b-16 8-FB6 (WH/VT) Is the resistance between 250 and 5,250 ohms? Yes : GO to C13. No : If the resistance is greater than 5,250 ohms, GO to C15. If the resistance is less than 250 ohms, GO to C23.
13. C13 CHECK POTENTIOMETER HIGH SIDE RESISTANCE Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING POTENTIOMETER HIGH SIDE RESISTANCE PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-22 7-FA1 (YE) C228b-2 8-FB2 (WH/RD) B1242 C228a-22 7-FA1 (YE) C228b-15 8-FB8 (WH/RD) B1262 C228b-22 7-FA1 (YE) C228b-1 8-FB5 (WH/BK) B1263 C228b-22 7-FA1 (YE) C228b-3 8-FB7 (WH) B1264 C228b-22 7-FA1 (YE) C228b-16 8-FB6 (WH/VT) Is the resistance between 250 and 5,250 ohms? Yes : GO to C17 . No : If the resistance is greater than 5,250 ohms, GO to C14. If the resistance is less than 250 ohms, GO to C24.
14. C14 CHECK THE ACTUATOR REFERENCE CIRCUIT FOR AN OPEN Disconnect: Affected Actuator. Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING ACTUATOR REFERENCE CIRCUIT FOR AN OPEN PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-22 7-FA1 (YE) C295-5 7-FB2 (YE/RD) B1242 C228a-22 7-FA1 (YE) C289-4 7-FB8 (YE/RD) B1262 C228b-22 7-FA1 (YE) C232-4 7-FB5 (YE/BK) B1263 C228b-22 7-FA1 (YE) C236-4 7-FB7 (YE) B1264 C228b-22 7-FA1 (YE) C234-5 7-FB6 (YE/VT) Is the resistance less than 5 ohms? Yes : GO to C15. No : REPAIR the affected circuit for an open. TEST the system for normal operation.
15. C15 CHECK THE ACTUATOR RETURN CIRCUIT FOR AN OPEN Disconnect: Affected Actuator. Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING ACTUATOR RETURN CIRCUIT FOR AN OPEN PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-11 9-FA1 (BN) C295-4 9-FB2(BN/RD) B1242 C228a-11 9-FA1 (BN) C289-5 9-FB8(BN/RD) B1262 C228b-17 9-FA2 (BN/ RD) C232-5 9-FB5(BN/YE) B1263 C228b-17 9-FA2 (BN/ RD) C236-5 9-FB7 (BN) B1264 C228b-17 9-FA2 (BN/RD) C234-4 9-FB6(BN/WH) Is the resistance less than 5 ohms? Yes : GO to C16. No : REPAIR the affected circuit for an open. TEST the system for normal operation.
16. C16 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR AN OPEN Disconnect: Affected Actuator. Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING ACTUATOR FEEDBACK CIRCUIT FOR AN OPEN PIN CIRCUIT REFERENCE DTC Pin Circuit Pin B1265 C228b-2 8-FB2 (WH/RD) C295-3 B1242 C228b-15 8-FB8 (WH/RD) C289-3 B1262 C228b-1 8-FB5 (WH/BK) C232-3 B1263 C228b-3 8-FB7 (WH) C236-3 B1264 C228b-16 8-FB6 (WH/VT) C234-3 Is the resistance less than 5 ohms? Yes : INSTALL a new door actuator. TEST the system for normal operation. No : REPAIR the affected circuit for an open. TEST the system for normal operation.
17. C17 CHECK THE ACTUATOR REFERENCE CIRCUIT FOR A SHORT TO GROUND Measure the resistance between DATC module C228a-22, circuit 7-FA1 (YE), harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to C18. No : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
18. C18 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND Measure the resistance between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR FEEDBACK CIRCUIT FOR A SHORT TO GROUND PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228b-2 8-FB2 (WH/RD) B1242 C228b-15 8-FB8 (WH/RD) B1262 C228b-1 8-FB5 (WH/BK) B1263 C228b-3 8-FB7 (WH) B1264 C228b-16 8-FB6 (WH/VT) Is the resistance greater than 10,000 ohms? Yes : GO to C19. No : REPAIR the affected circuit for a short to ground. TEST the system for normal operation.
19. C19 CHECK THE ACTUATOR REFERENCE CIRCUIT FOR A SHORT TO POWER Measure the voltage between DATC module C228a pin 22, circuit 7-FA1 (YE), harness side and ground. Is voltage present? Yes : REPAIR the affected circuit for a short to power. TEST the system for normal operation. No : GO to C20.
20. C20 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR A SHORT TO POWER Measure the voltage between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR FEEDBACK CIRCUIT FOR A SHORT TO POWER PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228b-2 8-FB2 (WH/RD) B1242 C228b-15 8-FB8 (WH/RD) B1262 C228b-1 8-FB5 (WH/BK) B1263 C228b-3 8-FB7 (WH) B1264 C228b-16 8-FB6 (WH/VT) Is voltage present? Yes : REPAIR the affected circuit for a short to power. TEST the system for normal operation. No : GO to C21.
21. C21 CHECK THE ACTUATOR RETURN CIRCUIT FOR A SHORT TO POWER Measure the voltage between the harness side of the connector/pin indicated below that corresponds to the recorded DTC(s) and ground. CHECKING ACTUATOR RETURN CIRCUIT FOR A SHORT TO POWER PIN CIRCUIT REFERENCE DTC Pin Circuit B1265 C228a-11 9-FA1 (BN) B1242 C228a-11 9-FA1 (BN) B1262 C228b-17 9-FA2 (BN/RD) B1263 C228b-17 9-FA2 (BN/RD) B1264 C228b-17 9-FA2 (BN/RD) Is voltage present? Yes : REPAIR the affected circuit for a short to power. TEST the system for normal operation. No : INSTALL a new DATC module. TEST the system for normal operation.
22. C22 CHECK THE FEEDBACK POTENTIOMETER TOTAL RESISTANCE SHORT TOGETHER Disconnect: Affected Actuator. Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING FEEDBACK POTENTIOMETER TOTAL RESISTANCE SHORT TOGETHER PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-11 9-FA1 (BN) C228a-22 7-FA1 (YE) B1242 C228a-11 9-FA1 (BN) C228a-22 7-FA1 (YE) B1262 C228b-17 9-FA2 (BN/RD) C228a-22 7-FA1 (YE) B1263 C228b-17 9-FA2 (BN/RD) C228a-22 7-FA1 (YE) B1264 C228b-17 9-FA2 (BN/RD) C228a-22 7-FA1 (YE) Is the resistance less than 5 ohms? Yes : REPAIR the affected circuits for a short together. TEST the system for normal operation. No : INSTALL a new door actuator. TEST the system for normal operation.
23. C23 CHECK POTENTIOMETER LOW SIDE RESISTANCE SHORT TOGETHER Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING POTENTIOMETER LOW SIDE RESISTANCE SHORT TOGETHER PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-11 9-FA1 (BN) C228b-2 8-FB2 (WH/RD) B1242 C228a-11 9-FA1 (BN) C228b-15 8-FB8 (WH/RD) B1262 C228b-17 9-FA2 (BN/RD) C228b-1 8-FB5 (WH/BK) B1263 C228b-17 9-FA2 (BN/RD) C228b-3 8-FB7 (WH) B1264 C228b-17 9-FA2 (BN/RD) C228b-16 8-FB6 (WH/VT) Is the resistance less than 5 ohms? Yes : REPAIR the affected circuits for a short together. TEST the system for normal operation. No : INSTALL a new door actuator. TEST the system for normal operation.
24. C24 CHECK POTENTIOMETER HIGH SIDE RESISTANCE SHORT TOGETHER Measure the resistance between the harness side of the connectors/pins indicated below that corresponds to the recorded DTC(s). CHECKING POTENTIOMETER HIGH SIDE RESISTANCE SHORT TOGETHER PIN CIRCUIT REFERENCE DTC Pin Circuit Pin Circuit B1265 C228a-22 7-FA1 (YE) C228b-2 8-FB2 (WH/RD) B1242 C228a-22 7-FA1 (YE) C228b-15 8-FB8 (WH/RD) B1262 C228b-22 7-FA1 (YE) C228b-1 8-FB5 (WH/BK) B1263 C228b-22 7-FA1 (YE) C228b-3 8-FB7 (WH) B1264 C228b-22 7-FA1 (YE) C228b-16 8-FB6 (WH/VT) Is the resistance less than 5 ohms? Yes : REPAIR the affected circuits for a short together. TEST the system for normal operation. No : INSTALL a new door actuator. TEST the system for normal operation.

1. An open in circuit 9-FA48 (BN/GN) or 8-FA48 (WH/GN).
2. A short together in circuits 9-FA48 (BN/GN) and 8-FA48 (WH/GN).
3. A short to ground in circuit 8-FA48 (WH/GN).
4. DATC module.
5. In-vehicle air temperature sensor.

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1. D1 CHECK THE SENSOR RESISTANCE Key in OFF position. Disconnect: In-Vehicle Temperature Sensor C233. Measure the resistance between in-vehicle temperature sensor terminals. Is the resistance within the specified values for these temperature ranges: 10-20°C (50-68°F) 37,000-58,000 ohms; 20-30°C (68-86°F) 24,000-37,000 ohms; 30-40°C (86-104°F) 16,000-24,000 ohms? Yes : GO to D2. No : INSTALL a new in-vehicle temperature sensor. TEST the system for normal operation.
2. D2 CHECK THE DATC SENSOR OUTPUT VOLTAGE Key in ON position. Measure the voltage between in-vehicle temperature sensor C233, circuits 9-FA48 (BN/GN), harness side and 8-FA48 (WH/GN), harness side. Is the voltage between 4.7 and 5.1 volts? Yes : INSTALL a new DATC module. No : If DTC B1253 is present, GO to D3. If DTC B1251 is present, GO to D5.
3. D3 CHECK CIRCUIT 8-FA48 (WH/GN) FOR A SHORT TO GROUND Key in OFF position. Disconnect: DATC Module C228a. Disconnect: DATC Module C228b. Measure the resistance between DATC module C228a-9, circuit 8-FA48 (WH/GN), harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to D4. No : REPAIR circuit 8-FA48 (WH/GN). TEST the system for normal operation.
4. D4 CHECK CIRCUIT 8-FA48 (WH/GN) FOR A SHORT TO CIRCUIT 9-FA48 (BN/GN) Measure the resistance between in-vehicle temperature sensor C233, circuits 9-FA48 (BN/GN), harness side and 8-FA48 (WH/GN), harness side. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 8-FA48 (WH/GN) for a short to circuit 9-FA48 (BN/GN). TEST the system for normal operation.
5. D5 CHECK CIRCUIT 8-FA48 (WH/GN) FOR AN OPEN Key in OFF position. Disconnect: DATC Module C228a. Measure the resistance between DATC module C228a-9, circuit 8-FA48 (WH/GN), harness side and the in-vehicle temperature sensor C233 circuit 8-FA48 (WH/GN), harness side. Is the resistance less than 5 ohms? Yes : GO to D6. No : REPAIR circuit 8-FA48 (WH/GN). TEST the system for normal operation.
6. D6 CHECK CIRCUIT 9-FA48 (BN/GN) FOR AN OPEN Disconnect: DATC Module C228b. Measure the resistance between DATC pin C228b-14, circuit 9-FA48 (BN/GN), harness side and the in-vehicle temperature sensor C233 circuit 9-FA48 (BN/GN), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 9-FA48 (BN/GN). TEST the system for normal operation.

1. An open in circuit 9-FA47 (BN/GN), 9-FA51 (BN/YE), 9-FA3 (BN/BL), 9-FA44 (BN/RD), 8-FA47 (WH/GN), 8-FA51 (WH/BK) or 8-FA44 (WH/RD).
2. A short together in circuits 8-FA44 (WH/RD) and 9-FA44 (BN/RD), 8-FA51 (WH/BK) and 9-FA51 (BN/YE), 8-FA47 (WH/GN) and 9-FA47 (BN/GN).
3. A short to ground in circuit 8-FA47 (WH/GN), 8-FA51 (WH/BK) or 8-FA44 (WH/RD).
4. LH discharge temperature sensor.
5. RH discharge temperature sensor.
6. Evaporator discharge temperature sensor.
7. DATC module.

1. An open in circuit 9-FA49 (BN/WH) or 8-FA49 (WH/VT).
2. A short to together in circuits 9-FA49 (BN/WH) and 8-FA49 (WH/VT).
3. A short to ground in circuit 8-FA49 (WH/VT).
4. Ambient air temperature sensor.
5. DATC module.

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1. F1 CHECK THE AMBIENT TEMPERATURE SENSOR RESISTANCE Key in OFF position. Disconnect: Ambient Temperature Sensor C132. Measure the resistance between ambient temperature sensor terminals. Is the resistance within the specified values for these temperature ranges: 10-20°C (50-68°F) 37,000-58,000 ohms; 20-30°C (68-86°F) 24,000-37,000 ohms; 30-40°C (86-104°F) 16,000-24,000 ohms? Yes : GO to F2. No : INSTALL a new A/C ambient air temperature sensor. TEST the system for normal operation.
2. F2 CHECK THE DATC SENSOR OUTPUT VOLTAGE Key in ON position. Measure the voltage between ambient temperature sensor C132, circuits 8-FA49 (WH/VT), harness side and 9-FA49 (BN/WH), harness side. Is the voltage between 4.7 and 5.1 volts? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : If DTC B1255, GO to F3. If DTC B1257, GO to F5.
3. F3 CHECK CIRCUIT 8-FA49 (WH/VT) FOR AN OPEN Key in OFF position. Disconnect: DATC Module C228b. Measure the resistance between DATC module C228b-17, circuit 8-FA49 (WH/VT), harness side and ambient temperature sensor connector C132 circuit 8-FA49 (WH/VT), harness side. Is the resistance less than 5 ohms? Yes : GO to F4. No : REPAIR circuit 8-FA49 (WH/VT). TEST the system for normal operation.
4. F4 CHECK CIRCUIT 9-FA49 (BN/WH) FOR AN OPEN Measure the resistance between DATC module C228b-8, circuit 9-FA49 (BN/WH), harness side and the ambient temperature sensor connector C132 circuit 9-FA49 (BN/WH), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 9-FA49 (BN/WH). TEST the system for normal operation.
5. F5 CHECK CIRCUIT 8-FA49 (WH/VT) FOR A SHORT TO GROUND Key in OFF position. Disconnect: DATC Module C228b. Measure the resistance between DATC module C228b-17, circuit 8-FA49 (WH/VT), harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to F6. No : REPAIR circuit 8-FA49 (WH/VT) for a short to ground. TEST the system for normal operation.
6. F6 CHECK CIRCUIT 8-FA49 (WH/VT) FOR A SHORT TO CIRCUIT 9-FA49 (BN/WH) Measure the resistance between ambient temperature sensor C132, circuits 8-FA49 (WH/VT), harness side and 9-FA49 (BN/WH), harness side. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 8-FA49 (WH/VT) for a short to circuit 9-FA49 (BN/WH). TEST the system for normal operation.

1. An open in circuit 9-FA53 (BN/BL)/9-FA3 (BN/BL), 8-FA53 (WH/BL) or 10-FA53 (GY/VT).
2. A short together in circuits 9-FA48 (BN/GN) and 8-FA48 (WH/GN) or 9-FA48 (BN/GN) and 10-FA53 (GY/VT).
3. A short to ground in circuit 8-FA53 (WH/BL) or10-FA53 (GY/VT).
4. Solar radiation sensor.
5. DATC module.

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1. G1 CHECK THE SOLAR RADIATION SENSOR RESISTANCE Key in OFF position. Disconnect: Solar Radiation Sensor C286. NOTE: Connect the ground lead of the multimeter to the sensor ground terminal. Measure the resistance between each solar radiation sensor terminal and the ground terminal. Are the resistances between 39,000 and 41,000 ohms? Yes : GO to G2. No : INSTALL a new A/C solar radiation sensor. TEST the system for normal operation.
2. G2 CHECK THE DATC OUTPUT VOLTAGE Key in ON position. Measure the voltage between solar radiation C286-3, circuit 8-FA53 (WH/BU), harness side and C286-2, circuit 9-FA53 (BN/BU), harness side and between C286-1 circuit 10-FA53 (GY/VT), harness side and C286-2, circuit 9-FA53 (BN/BU), harness side. Are the voltages between 4.7 and 5.1 volts? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : If DTC B1259 is present, GO to G6. If DTC B1261 is present, GO to G3.
3. G3 CHECK CIRCUIT 10-FA53 (GY/VT) FOR A SHORT TO GROUND Key in OFF position. Disconnect: DATC Module C228a. Measure the resistance between DATC module C228a-20, circuit 10-FA53 (GY/VT), harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to G4. No : REPAIR circuit 10-FA53 (GY/VT). TEST the system for normal operation.
4. G4 CHECK CIRCUIT 8-FA53 (WH/BU) FOR A SHORT TO GROUND Measure the resistance between DATC module C228a-7, circuit 8-FA53 (WH/BU), harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to G5. No : REPAIR circuit 8-FA53 (WH/BU). TEST the system for normal operation.
5. G5 CHECK THE REFERENCE CIRCUIT FOR A SHORT TO THE RETURN CIRCUIT Measure the resistance between solar radiation C286-3, circuit 8-FA53 (WH/BU), harness side and C286-2, circuit 9-FA53 (BN/BU), harness side and between C286-1 circuit 10-FA53 (GY/VT), harness side and C286-2, circuit 9-FA53 (BN/BU), harness side. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR the reference circuit for a short to the return circuit. TEST the system for normal operation.
6. G6 CHECK CIRCUIT 10-FA53 (GY/VT) FOR AN OPEN Key in OFF position. Disconnect: DATC Module C228a. Measure the resistance between DATC module C228a-20, circuit 10-FA53 (GY/VT), harness side and solar radiation sensor C286-1, circuit 10-FA53 (GY/VT), harness side. Is the resistance less than 5 ohms? Yes : GO to G7. No : REPAIR circuit 10-FA53 (GY/VT). TEST the system for normal operation.
7. G7 CHECK CIRCUIT 8-FA53 (WH/BU) FOR AN OPEN Measure the resistance between DATC module C228a-7, circuit 8-FA53 (WH/BU), harness side and the solar radiation sensor C286-3, circuit 8-FA53 (WH/BU), harness side. Is the resistance less than 5 ohms? Yes : GO to G8. No : REPAIR circuit 8-FA53 (WH/BU). TEST the system for normal operation.
8. G8 CHECK THE RETURN CIRCUIT FOR AN OPEN Measure the resistance between DATC module C228a-19, circuit 9-FA3 (BN/RD), harness side and solar radiation C286-2, circuit 9-FA53 (BN/BU), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR the affected circuit. TEST the system for normal operation.

1. An open in circuit 30-FB3 (RD/OG), 91S-FB3 (BN/BL) or 91S-FB4 (BN/GN).
2. A short to ground or voltage in circuit 91S-FB3 (BN/BL) or 91S-FB4 (BN/GN).
3. Coolant control valve.
4. DATC module.
5. Evaporator discharge air temperature sensor.
6. Thermostat.

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Scheme 121

1. H1 CHECK FOR CORRECT COOLANT LEVEL Key in OFF position. Check the engine coolant level with the engine at cold and hot temperatures. Is the engine coolant at the correct level (both cold and hot)? Yes : GO to H4 . No : GO to H2.
2. H2 CHECK THE ENGINE COOLING SYSTEM FOR LEAKS WARNING: Never remove the pressure relief cap under any condition while the engine is operating. Failure to follow these instructions can result in damage to the cooling system or engine, or can result in personal injury. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap from a hot degas bottle. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When certain all the pressure has been released, use the cloth to remove the pressure relief cap. Fill and bleed the engine cooling system. Pressure check the engine cooling system, including the pressure relief cap. Does the engine cooling system, including the pressure relief cap, hold pressure? Yes : GO to H3. No : REPAIR the engine cooling system leak. TEST the system for normal operation.
3. H3 VERIFY THE FAULT WAS A LOW ENGINE COOLANT LEVEL NOTE: When carrying out this test step, allow time for the system to respond. With the engine at normal operating temperature, set the DATC module driver and passenger side temperature settings to full hot (32°C [90°F]) and note the discharge air temperature. Is the discharge air temperature at full hot? Yes : Test is complete. No : GO to H4.
4. H4 BLEED THE ENGINE COOLING SYSTEM WARNING: Never remove the pressure relief cap under any condition while the engine is operating. Failure to follow these instructions can result in damage to the cooling system or engine, or can result in personal injury. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap from a hot degas bottle. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When certain all the pressure has been released, use the cloth to remove the pressure relief cap. NOTE: When carrying out this test step, allow time for the system to respond. Bleed the engine cooling system. With the engine at normal operating temperature, set the DATC module driver and passenger side temperature settings to full hot (32°C [90 °F]) and note the discharge air temperature. Is the discharge air temperature at full hot? Yes : Test is complete. No : GO to H5.
5. H5 CHECK FOR HOT COOLANT AT THE HEATER CORE INLET HOSES WARNING: The heater core inlet hoses will become too hot to handle and can cause serious burns if the system is working correctly. Failure to follow these instructions can result in personal injury. Key in ON position. With the engine running, carefully feel both heater core inlet hoses. Are both heater core inlet hoses too hot to handle? Yes : CARRY OUT the heater core component test. REFER to «HEATER CORE»(ref-207561-S29662335042005113000000) under Component Tests in this section to determine whether a plugged or partially plugged condition exists. No : GO to H6.
6. H6 CHECK THE COOLANT CONTROL VALVE INLET HOSE WARNING: The coolant control valve inlet hose will become too hot to handle and can cause serious burns if the system is working correctly. Failure to follow these instructions can result in personal injury. Carefully feel both heater core inlet hoses. Is the coolant control valve inlet hose too hot to handle? Yes : GO to H7. No : INSTALL a new thermostat. TEST the system for normal operation.
7. H7 CHECK DATC DTCS Check the DATC for DTCs. Is DTC B2798 or B2800 present? Yes : GO to H10 . No : GO to H8.
8. H8 CHECK CIRCUITS 91S-FB4 (BN/GN) AND 91S-FB3 (BN/BU) FOR GROUND Key in OFF position. Disconnect: Coolant Control Valve C1034. Key in ON position. Set the DATC module driver and passenger side temperature settings to full hot. Measure the voltage between coolant control valve C1034-2, circuit 30-FB3 (RD/OG) and: Coolant control valve C1034-1, circuit 91S-FB4 (BN/GN). Coolant control valve C1034-3, circuit 91S-FB3 (BN/BU). Is voltage present? Yes : GO to H9. No : INSTALL a new coolant control valve. TEST the system for normal operation.
9. H9 CHECK CIRCUITS 91S-FB4 (BN/GN) AND 91S-FB3 (BN/BU) FOR A SHORT TOGETHER Key in OFF position. Disconnect: DATC Module C228b. Measure the resistance between coolant control valve C1034-1, circuit 91S-FB4 (BN/GN) and C1034-3, circuit 91S-FB3 (BN/BU). Is the resistance greater than 10,000 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 91S-FB4 (BN/GN) for a short to circuit 91S-FB3 (BN/BU). TEST the system for normal operation.
10. H10 CHECK CIRCUITS 91S-FB4 (BN/GN) AND 91S-FB3 (BN/BU) FOR A SHORT TO GROUND Key in OFF position. Disconnect: DATC Module C228b. Disconnect: Coolant Control Valve C1034. Measure the resistance between ground and: Coolant control valve C1034-1, circuit 91S-FB4 (BN/GN). Coolant control valve C1034-3, circuit 91S-FB3 (BN/BU). Are the resistances greater than 10,000 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 91S-FB4 (BN/GN) or circuit 91S-FB3 (BN/BU) for a short to ground. TEST the system for normal operation.

1. An open in circuit 31-FB1 (BK/YE), 30-FA74 (RD/GN), 30S-FB1 (RD/YE) or 91S-FA76 (BN/BL).
2. A short to voltage in circuit 91S-FA76 (BN/BL).
3. Auxiliary coolant pump relay.
4. Auxiliary coolant pump motor.
5. DATC module.

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

1. I1 CARRY OUT THE DATC MODULE SELF-TEST Key in ON position. Carry out the DATC module self-test and retrieve continuous DTCs. Refer to «CLIMATE CONTROL SYSTEM»(ref-207561-S19062633142005113000000) . Record the DTCs displayed, if any. Are any DTCs displayed? Yes : REFER to «DUAL ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-207561-S32794440092005113000000) . CARRY OUT the necessary diagnosis and REPAIR as necessary. No : GO to I2.
2. I2 RECHECK DATC MODULE CONFIGURATION Enter Module Identification mode. Enter the following diagnostic mode on the diagnostic tool: PIDCNFG Data. Does the data read 4N_3N_2Y? Yes : GO to I3. No : RECONFIGURE the DATC module.
3. I3 CHECK THE COOLANT LEVEL Check the coolant level with the engine at hot and cold temperatures. Is the engine coolant at the correct level (hot and cold)? Yes : GO to I4. No : REFILL the system and PRESSURE TEST for leaks. In addition, if the coolant level had dropped below the "MIN" level, SET the system to MAX heat and RUN the engine at 3,000 RPM for 3 to 5 minutes until hot air blows from the outlets. RECHECK coolant level. GO to I4.
4. I4 CHECK FOR AUXILIARY COOLANT PUMP OPERATION Connect the diagnostic tool. Key in ON position. In the active command mode, request Climate Control System and select Pump/VCB or set driver side temperature to 32°C (90°F). Can the auxiliary cooling pump be heard running or be felt running? Yes : System is operating correctly. No : GO to I5.
5. I5 CHECK THE AUXILIARY PUMP MOTOR Key in OFF position. Disconnect: Auxiliary Coolant Pump C163. Key in ON position. Make sure the active command Pump/VBC is still selected or the driver side temperature is set to 32°C (90°F). Measure the voltage between auxiliary coolant pump C163, circuit 30S-FB1 (RD/YE), harness side and circuit 31-FB1 (BK), harness side. Is the voltage greater than 10 volts? Yes : INSPECT terminals for damage and correct installation. If pins are installed correctly, INSTALL a new auxiliary coolant pump. TEST the system for normal operation. No : GO to I6.
6. I6 CHECK CIRCUIT 31-FB1 (BK) FOR AN OPEN Measure the resistance between auxiliary coolant pump C163, circuit 31-FB1 (BK), harness side and ground. Is the resistance less than 5 ohms? Yes : GO to I7. No : REPAIR circuit 31-FB1 (BK). TEST the system for normal operation.
7. I7 CHECK THE AUXILIARY COOLANT PUMP RELAY Key in OFF position. Disconnect: Auxiliary Coolant Pump Relay C1005. Measure the voltage between CJB auxiliary coolant pump relay pins 2 and 5, circuit 30-FA74A (RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to I8. No : REPAIR circuit 30-FA74A (RD). TEST the system for normal operation.
8. I8 CARRY OUT THE RELAY COMPONENT TEST Carry out the relay component test. Refer to «SYSTEM WIRING DIAGRAMS»(ref-163987) for schematic and connector information. Is the relay OK? Yes : GO to I9. No : INSTALL a new auxiliary coolant pump relay. TEST the system for normal operation.
9. I9 CHECK CIRCUIT 30S-FB1 (RD/YE) FOR AN OPEN Disconnect: Auxiliary Coolant Pump Relay C1005. Measure the resistance between auxiliary coolant pump C163, circuit 30S-FB1 (RD/YE), harness side and auxiliary coolant pump relay pin 3, circuit 30S-FB1 (RD/YE), harness side. Is the resistance less than 5 ohms? Yes : GO to I10. No : REPAIR circuit 30S-FB1 (RD/YE). TEST the system for normal operation.
10. I10 CHECK THE DATC MODULE Key in OFF position. Connect: Auxiliary Coolant Pump Relay C1005. Connect: Auxiliary Coolant Pump C163. Disconnect: DATC Module C228a. Disconnect: DATC Module C228b. Connect a fused jumper wire between DATC module C228b-18, circuit 91S-FA76 (BN/BU), harness side and DATC module C228a-2, circuit 31-FA10 (BK), harness side. Does the auxiliary coolant pump motor operate? Yes : INSPECT all connectors and terminals, RECONNECT the connectors, and TEST the system for normal operation. If condition still exists, INSTALL a new DATC module. TEST the system for normal operation. No : GO to I11.
11. I11 CHECK CIRCUIT 91S-FA76 (BK/OG) FOR A SHORT TO POWER NOTE: If a short to power is found, it is necessary to install a new DATC module. Disconnect: Auxiliary Coolant Pump Relay C1005. Measure the voltage between auxiliary coolant pump relay pin 2, circuit 91S-FA76 (BK/OG), harness side and ground. Is any voltage present? Yes : REPAIR circuit 91S-FA76 (BK/OG). INSTALL a new DATC module. TEST the system for normal operation. No : GO to I12.
12. I12 CHECK CIRCUIT 91S-FA76 (BK/OG) FOR AN OPEN Measure the resistance between auxiliary coolant pump relay circuit 91S-FA76 (BK/OG), harness side and DATC module C228b-18, circuit 91S-FA76 (BK/OG), harness side. Is the resistance less than 5 ohms? Yes : INSPECT all connectors and terminals, RECONNECT the connectors and TEST the system. If condition still exists, INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 91S-FA76 (BK/OG). TEST the system for normal operation.

1. An open in circuit 30-FB3 (RD/OG)/30-FA1 (RD), 91S-FB3 (BN/BL) or 91S-FB4 (BN/GN).
2. A short to ground or voltage in circuit 91S-FB3 (BN/BL) or 91S-FB4 (BN/GN).
3. A short to voltage in circuit 91S-FB3 (BN/BL) or 91S-FB4 (BN/GN).
4. Coolant control valve.
5. Evaporator discharge air temperature sensor.
6. DATC module.

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

1. J1 CHECK DATC DTCS Check the DATC for DTCs. Is DTC B2797 or B2799 present? Yes : GO to J3 . No : GO to J2.
2. J2 CHECK CIRCUITS 91S-FB4 (BN/GN) AND 91S-FB3 (BN/BU) FOR GROUND Key in OFF position. Disconnect: Coolant Control Valve C1034. Key in ON position. Set the DATC module driver and passenger side temperature settings to full Cool. Measure the voltage between coolant control valve C1034-2, circuit 30-FB3 (RD/OG) and: Coolant control valve C1034-1, circuit 91S-FB4 (BN/GN). Coolant control valve C1034-3, circuit 91S-FB3 (BN/BU). Is voltage present? Yes : INSTALL a new coolant control valve. TEST the system for normal operation. No : INSTALL a new DATC module. TEST the system for normal operation.
3. J3 CHECK CIRCUIT 30-FB3 (RD/OG) FOR VOLTAGE Key in OFF position. Disconnect: Coolant Control Valve C1034. Key in ON position. Measure the voltage between ground and coolant control valve C1034-2, circuit 30-FB3 (RD/OG). Is the voltage greater than 10 volts? Yes : GO to J4. No : REPAIR circuit 30-FB3 (RD/OG) for an open. TEST the system for normal operation.
4. J4 CHECK CIRCUITS 91S-FB4 (BN/GN) AND 91S-FB3 (BN/BU) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: DATC Module C228b. Key in ON position. Measure the voltage between ground and: Coolant control valve C1034-1, circuit 91S-FB4 (BN/GN). Coolant control valve C1034-3, circuit 91S-FB3 (BN/BU). Is voltage present? Yes : REPAIR circuit 91S-FB4 (BN/GN) or 91S-FB3 (BN/BU) for a short to voltage. TEST the system for normal operation. No : GO to J5.
5. J5 CHECK CIRCUITS 91S-FB4 (BN/GN) OR 91S-FB3 (BN/BU) FOR AN OPEN Key in OFF position. NOTE: DTC B2797 only. Measure the resistance between the coolant control valve C1034-1, circuit 91S-FB4 (BN/GN) and DATC module C228b-6, circuit 91S-FB4 (BN/GN). NOTE: DTC B2799 only. Measure the resistance between the coolant control valve C1034-3, circuit 91S-FB3 (BN/BU) and DATC module C228b-5, circuit 91S-FB3 (BN/BU). Are the resistances less than 5 ohms? Yes : CARRY OUT the «COOLANT CONTROL VALVE»(ref-207561-S14611395962005113000000) component test. If OK, INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 91S-FB4 (BN/GN) or 91S-FB3 (BN/BU) for an open. TEST the system for normal operation.

1. An open in circuit 9-FA47 (BN/GN) or 9-FA51 (BN/YE)
2. DATC module.

Scheme 134

Scheme 135

Scheme 136

1. K1 VERIFY THE CONCERN NOTE: When carrying out this test step, allow time for the system to respond. With the engine at normal operating temperature, select PANEL mode and A/C on the DATC module. Using the driver side temperature control, set the driver side temperature to 16°C (60°F) and then set to 32°C (90°F). Do both the driver side and passenger side air temperatures go to full cool then to full heat? Yes : GO to K2. No : If driver or passenger side only does not go to full cool and then full heat, GO to K6.
2. K2 CHECK MODULE CONFIGURATION Enter Module Identification mode. Enter the following diagnostic mode on the diagnostic tool: PID CNFG Data. Does PID CNFG data read ON and 4N_3N_2Y? Yes : GO to K3. No : RECONFIGURE the DATC module.
3. K3 REQUEST CONTINUOUS CODES AND CARRY OUT THE DATC SELF-TEST Request Continuous DTCs and carry out the DATC Module Self-Test. Refer to «CLIMATE CONTROL SYSTEM»(ref-207561-S19062633142005113000000) . Record the DTCs displayed, if any. Are any DTCs displayed? Yes : REFER to «DUAL ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-207561-S32794440092005113000000) . CARRY OUT the necessary diagnosis and REPAIR as necessary. No : GO to K4.
4. K4 CHECK THE TEMPERATURE SENSORS FOR CORRECT INSTALLATION Key in OFF position. Check the driver side, passenger side, evaporator core and ambient air temperature sensors for correct installation. Check the in-vehicle temperature sensor and venturi hose for correct installation. Are the sensors installed correctly? Yes : GO to K5. No : CORRECT the sensor installation. TEST the system for normal operation.
5. K5 CHECK FOR CORRECT HEATER HOSE CONNECTIONS NOTE: The hose assembly that connects to the inboard port on the coolant control valve connects to the inboard port (driver side) on the heater core. Check the heater hose connections for correct installation. Are the heater hoses installed correctly? Yes : GO to K6. No : CORRECT the heater hose installation. TEST the system for normal operation.
6. K6 CHECK FOR CORRECT COOLANT FLOW TO THE HEATER CORE WARNING: The heater core inlet hoses will become too hot to handle and can cause serious burns if the system is working correctly. Failure to follow these instructions can result in personal injury. Remove the passenger side cowl cover. With the engine running at normal operating temperature and the DATC module set to 32°C (90°F), see if both inlet heater hoses are too hot to handle. Are both inlet heater hoses too hot to handle? Yes : GO to K7. No : Go To «PINPOINT TEST H: INSUFFICIENT, ERRATIC OR NO HEAT»(ref-207561-S00765865142005113000000) .
7. K7 CHECK CORRECT COOLANT CONTROL VALVE OPERATION Remove the passenger side cowl cover. Clamp off the three heater hoses going to the heater core, as close to the heater core as possible. Key in ON position. With the engine running, set the DATC module to 16°C (60°F). Is cooling restored? Yes : Concern is with coolant control valve operation. Go To «PINPOINT TEST J: FULL HEAT ONLY IN ALL MODES»(ref-207561-S03883857102005113000000) . No : GO to K8.
8. K8 CHECK CIRCUITS 8-FA51 (WH/BK) AND 8-FA47 (WH/GN) Key in OFF position. Disconnect: Passenger Side Discharge Air Temperature Sensor C255. Disconnect: Driver Side Discharge Air Temperature Sensor C235. Disconnect: DATC Module C228a. Measure the resistance between the passenger side discharge air temperature sensor C255, circuit 8-FA51 (WH/BK) and the DATC module C228a-18, circuit 8-FA51 (WH/BK). Measure the resistance between the driver side discharge air temperature sensor C235, circuit 8-FA47 (WH/GN) and the DATC module C228a-6, circuit 8-FA47 (WH/GN). Are the resistances less than 5 ohms? Yes : RECHECK all connections, RECONNECT and RETEST the system. If the condition still exists, INSTALL a new DATC module. TEST the system for normal operation. No : CHECK to make sure that circuit 8-FA47 (WH/GN) is connected to DATC module C228a-6 and that circuit 8-FA51 (WH/BK) is connected to DATC module C228b-18. REPAIR as required. TEST the system for normal operation.

1. An open in circuit 31-FA6 (BK/YE), 30S-FA79 (RD), 91S-FA79 (BN/BL), 15S-FA79 (GN/RD) or 15-FA6 (GN/YE).
2. A short to voltage in circuit 91S-FA79 (BN/BL).
3. A/C clutch relay.
4. A/C compressor clutch/field coil.
5. DATC module.
6. Evaporator discharge air temperature sensor.
7. PCM

1. A short to voltage in circuit 15-FA6 (GN/YE).
2. A/C clutch relay.
3. A/C compressor clutch/field coil.
4. DATC module.
5. PCM

Scheme 137

Scheme 138

1. M1 CARRY OUT THE PCM AND DATC MODULE SELF-TESTS Enter the following diagnostic mode on the diagnostic tool: PCM Self Test. Key in ON position. Carry out the PCM self-test. Record any DTCs. Carry out the DATC module self-test and retrieve continuous DTCs. Refer to «CLIMATE CONTROL SYSTEM»(ref-207561-S19062633142005113000000) under Diagnosis and Testing. Record the DTCs displayed, if any. Are any PCM or DATC DTCs displayed? Yes : REFER to «POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-207561-S17276277902005113000000) or «DUAL ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(ref-207561-S32794440092005113000000) . CARRY OUT the necessary diagnosis and REPAIR as necessary. No : GO to M2.
2. M2 CHECK DATC BUTTONS With the engine running, toggle between DATC OFF button and the A/C button. DOES the A/C indicator light turn on when the A/C button is pushed, and off when the OFF button is pushed? Yes : GO to M3. No : INSTALL a new DATC module. TEST the system for normal operation.
3. M3 CHECK PCM PID ACCS Enter the following diagnostic mode on the diagnostic tool: PCM PID ACCS. Key in ON position. Push the DATC OFF button, then push the A/C button. Does the A/C indicator light turn off and on and the PCM PID ACCS continue to read ON? Yes : RERUN the Data Link Diagnostic Test. No : GO to M4.
4. M4 CHECK PID WACF WITH THE A/C OFF Key in ON position. Push the DATC OFF button. Enter the following diagnostic mode on the diagnostic tool: PCM PID WACF. Does PCM PID WACF read YES? Yes : REPAIR circuit 91S-FA79 (BK/OG) for a short to ground. TEST the system for normal operation. No : GO to M5.
5. M5 CHECK FOR POWER ALWAYS ON CIRCUIT 15S-FA6 (GN/YE) Key in OFF position. Disconnect: A/C Clutch C100. Key in ON position. Make sure the DATC is in the OFF position. Measure the voltage between A/C clutch field coil C100-2, circuit 15S-FA6 (GN/YE), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to M7 . No : GO to M6.
6. M6 CHECK THE CLUTCH AIR GAP Measure the A/C compressor clutch air gap at three equally spaced locations between the clutch hub and the A/C compressor clutch pulley. Is the A/C compressor clutch air gap greater than 0.75 mm (0.030 in)? Yes : ADJUST the A/C compressor clutch field coil. TEST the system for normal operation. No : INSTALL a new A/C compressor clutch field coil. TEST the system for normal operation.
7. M7 CHECK CIRCUIT 15-FA6 (GN/YE) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: A/C Clutch Relay. Key in ON position. With the engine running, measure the voltage between A/C clutch field coil C100-2, circuit 15S-FA6 (GN/YE), harness side and ground. Is the voltage greater than 10 volts? Yes : REPAIR circuit 15S-FA6 (GN/YE) for a short to voltage. TEST the system for normal operation. No : INSTALL a new A/C clutch relay. TEST the system for normal operation.

1. An open in circuit 31-FA45 (BK), 31S-FA18 (BK/RD), 30S-FA18 (RD/BK), 30-FA24 (RD/OG) or31S-FA23 (BK/BU).
2. A short to ground in circuit 8-FA45 (BN/BU).
3. A short to voltage in circuit 31S-FA23 (BK/BU).
4. A/C blower relay.
5. Blower motor control module.
6. DATC module.

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

1. N1 VERIFY THE BLOWER MOTOR OPERATION Key in ON position. Press the PANEL button on the DATC module. Adjust the blower motor setting to LO and then to HI. Is the blower motor inoperative in all settings? Yes : GO to N2. No : Go To «PINPOINT TEST O: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY»(ref-207561-S31086658252005113000000) .
2. N2 CHECK FOR VOLTAGE TO THE BLOWER MOTOR Key in OFF position. Disconnect: Blower Motor C288. Key in ON position. Measure the voltage between the blower motor C288, circuit 30S-FA18 (RD/BK) and ground. Is the voltage greater than 10 volts? Yes : GO to N3. No : GO to N9 .
3. N3 CHECK FOR VOLTAGE TO THE BLOWER MOTOR CONTROLLER Key in OFF position. Disconnect: Blower Motor Speed Control C297. Key in ON position. Measure the voltage between the blower motor speed control C297-4, circuit 30S-FA45 (RD/OG) and ground. Is the voltage greater than 10 volts? Yes : GO to N4. No : REPAIR circuit 30S-FA45 (RD/OG) for an open. TEST the system for normal operation.
4. N4 CHECK CIRCUIT 31-FA45 (BK) FOR AN OPEN Measure the resistance between the blower motor speed control C297-2, circuit 31-FA45 (BK) and ground. Is the resistance less than 5 ohms? Yes : GO to N5. No : REPAIR circuit 31-FA45 (BK) for an open. TEST the system for normal operation.
5. N5 CHECK CIRCUIT 31S-FA18 (BK/RD) FOR AN OPEN Measure the resistance between the blower motor C288, circuit 31S-FA18 (BK/RD) and the blower motor speed control C197-1, circuit 31S-FA18 (BK/RD). Is the resistance less than 5 ohms? Yes : GO to N6. No : REPAIR circuit 31S-FA18 (BK/RD) for an open. TEST the system for normal operation.
6. N6 CHECK THE BLOWER MOTOR Connect: Blower Motor C288. Connect a fused jumper lead between the blower motor speed control C197-1, circuit 31S-FA18 (BK/RD) and C197-2, circuit 31-FA45 (BK). Key in ON position. Does the blower motor operate? Yes : GO to N7. No : INSTALL a new blower motor. TEST the system for normal operation.
7. N7 CHECK CIRCUIT 8-FA45 (WH/BU) FOR A SHORT TO GROUND Key in OFF position. Removed the fused jumper lead from the blower motor speed control C297. Disconnect: DATC Module C228b. Measure the resistance between the blower motor speed control C197-3, circuit 8-FA45 (WH/BU) and ground. Is the resistance greater than 10,000 ohms? Yes : GO to N8. No : REPAIR circuit 8-FA45 (WH/BU). TEST the system for normal operation.
8. N8 CHECK THE DATC MODULE OUTPUT Connect: DATC Module C228b. Connect: Blower Motor Speed Control C297. Key in ON position. Adjust the blower motor speed to HI (7 bars). Measure the voltage between the DATC module C228a-15, circuit 8-FA45 (WH/BU) and ground by back-probing the DATC module C228a. Is the voltage greater than 4.5 volts? Yes : INSTALL a new blower motor speed control. TEST the system for normal operation. No : INSTALL a new DATC module. TEST the system for normal operation.
9. N9 CHECK CIRCUIT 30S-FA18 (RD/BK) FOR AN OPEN Key in OFF position. Disconnect: Blower Motor Relay C1011. Measure the resistance between the blower motor relay C1011 socket pin 87, circuit 30S-FA18 (RD/BK) and the blower motor C288, circuit 30S-FA18 (RD/BK). Is the resistance less than 5 ohms? Yes : GO to N10. No : REPAIR circuit 30S-FA18 (RD/BK) for an open. TEST the system for normal operation.
10. N10 CHECK CIRCUIT 30-FA24A (RD/OG) FOR AN OPEN Measure the voltage between the blower motor relay C1011 socket pin 86, circuit 30-FA24A (RD/OG) and ground. Is the voltage greater than 10 volts? Yes : GO to N11. No : REPAIR circuit 30-FA24A (RD/OG) for an open. TEST the system for normal operation.
11. N11 CHECK CIRCUIT 30-FA24 (RD/OG) FOR AN OPEN Measure the voltage between the blower motor relay C1011 socket pin 30, circuit 30-FA24 (RD/OG) and ground. Is the voltage greater than 10 volts? Yes : GO to N12. No : REPAIR circuit 30-FA24 (RD/OG) for an open. TEST the system for normal operation.
12. N12 CHECK THE DATC MODULE OUTPUT Key in ON position. Measure the voltage between the blower motor relay C1011 socket pin 86, circuit 30-FA24A (RD/OG) and socket pin 85, circuit 31S-FA23 (BK/BU). Is the voltage greater than 10 volts? Yes : INSTALL a new blower motor relay. TEST the system for normal operation. No : GO to N13.
13. N13 CHECK CIRCUIT 31S-FA23 (BK/BU) FOR SHORT TO VOLTAGE Key in OFF position. Disconnect: DATC Module C228b. Key in ON position. Measure the voltage between the blower motor relay C1011 socket pin 85, circuit 31S-FA23 (BK/BU) and ground. Is voltage present? Yes : REPAIR circuit 31S-FA23 (BK/BU). TEST the system for normal operation. No : GO to N14.
14. N14 CHECK CIRCUIT 31S-FA23 (BK/BU) FOR AN OPEN Measure the resistance between the DATC module C228b-19, circuit 31S-FA23 (BK/BU) and the blower motor relay C1011 socket pin 85, circuit 31S-FA23 (BK/BU). Is the resistance less than 5 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 31S-FA23 (BK/BU) for an open. TEST the system for normal operation.

1. An open in circuit 8-FA45 (BN/BU).
2. A short to ground in circuit 31S-FA18 (BK/RD) or31S-FA23 (BK/BU).
3. A short to voltage in circuit 8-FA45 (BN/BU) or 30S-FA18 (RD/BK).
4. Blower motor control module.
5. DATC module.

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

1. O1 VERIFY THE BLOWER MOTOR OPERATION Key in ON position. Press the PANEL button on the DATC module. Adjust the blower motor setting to LO and then to HI. Does the blower motor operate at any setting? Yes : If the blower motor operates always in HIGH, GO to O2. If the blower motor is always ON, GO to O5. No : Go To «PINPOINT TEST N: THE BLOWER MOTOR IS INOPERATIVE»(ref-207561-S13125519342005113000000) .
2. O2 CHECK CIRCUIT 31S-FA18 (BK/RD) FOR A SHORT TO GROUND Key in OFF position. Disconnect: Blower Motor Speed Control C297. Key in ON position. Does the blower motor operate? Yes : REPAIR circuit 31S-FA18 (BK/RD) for a short to ground. TEST the system for normal operation. No : GO to O3.
3. O3 CHECK CIRCUIT 8-FA45 (WH/BU) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: DATC Module C228a. Key in ON position. Measure the voltage between the blower motor speed control C197-3, circuit 8-FA45 (WH/BU) and ground. Is voltage present? Yes : REPAIR circuit 8-FA45 (WH/BU) for a short to voltage. TEST the system for normal operation. No : GO to O4.
4. O4 CHECK CIRCUIT 8-FA45 (WH/BU) FOR AN OPEN Key in OFF position. Measure the resistance between the blower motor speed control C197-3, circuit 8-FA45 (WH/BU) and DATC Module C228a-15, circuit 8-FA45 (WH/BU). Is the resistance less than 5 ohms? Yes : INSTALL a new blower motor speed control. TEST the system for normal operation. No : REPAIR circuit 8-FA45 (WH/BU) for an open. TEST the system for normal operation.
5. O5 CHECK THE DATC MODULE OUTPUT Key in OFF position. Disconnect: Blower Motor Relay C1011. Key in ON position. Measure the voltage between the blower motor relay C1011 socket pin 86, circuit 30-FA24A (RD/OG) and socket pin 85, circuit 31S-FA23(BK/BU). Is the voltage greater than 10 volts? Yes : GO to O6. No : GO to O7 .
6. O6 CHECK CIRCUIT 31S-FA23 (BK/BU) FOR A SHORT TO GROUND Key in OFF position. Disconnect: DATC Module C228a. Measure the resistance between the blower motor relay C1011 socket pin 85, circuit 31S-FA23 (BK/BU) and ground. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new DATC module. TEST the system for normal operation. No : REPAIR circuit 31S-FA23 (BK/BU) for a short to ground. TEST the system for normal operation.
7. O7 CHECK CIRCUIT 30S-FA18 (RD/BK) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: Blower Motor C288. Key in ON position. Measure the voltage between the blower motor C288, circuit 30S-FA18 (RD/BK) and ground. Is the voltage greater than 10 volts? Yes : REPAIR circuit 30S-FA18 (RD/BK) for a short to voltage. TEST the system for normal operation. No : GO to O8.
8. O8 CHECK THE DATC MODULE BLOWER CONTROL OUTPUT Adjust the blower motor speed to LO (1 bar). Measure the voltage between the DATC module C228a-15, circuit 8-FA45 (WH/BU) and ground by back-probing the DATC module C228a. Is the voltage less than 1 volt? Yes : INSTALL a new blower motor speed control. TEST the system for normal operation. No : INSTALL a new DATC module. TEST the system for normal operation.

A/C Evaporator Discharge Temperature Sensor

TEMPERATURE RESISTANCE REFERENCE Temperature Resistance -40°C (-40°F) 832,500-1,017,500 ohms -20°C (-4°F) 263,100-290,800 ohms 0°C (32°F) 91,050-100,600 ohms 20°C (68°F) 35,500-39,000 ohms 25°C (77°F) 28,500-31,500 ohms 40°C (104°F) 15,300-16,900 ohms 60°C (140°F) 7,170-7,930 ohms 100°C (212°F) 1,975-2,185 ohms 120°C (248°F) 1,130-1,250 ohms

Scheme 158

Coolant Control Valve

COOLANT CONTROL VALVE PINS RESISTANCE REFERENCE Coolant Control Valve Pins Resistance 1 and 2 10-23 ohms 2 and 3 10-23 ohms

Scheme 159

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. The coolant control valve may not be working correctly.

Air Conditioning (A/C) System Check - Retail Procedure

Note. This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).

Note. The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C before carrying out this retail procedure.

Note. Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before continuing.

System Check Procedure

1. Visual Inspection Open the hood and visually inspect the heating and air conditioning systems for the following: Coolant reservoir for correct coolant level Heater hoses for deterioration or loose connections Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or connections Accessory drive belt(s) and cooling fan(s) for wear or physical damage Refrigerant lines and connections for physical damage or loose connections Compressor for physical damage or loose connections Receiver/drier for physical damage or loose connections Wiring and connectors for excessive wear, loose or damaged connections, or incorrect routing
2. A/C Refrigerant Analysis Carry out air conditioning refrigerant analysis. For additional information, refer to «REFRIGERANT IDENTIFICATION TESTING»(ref-207561-S10242079072005113000000) . If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for repairs. If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air Conditioning System Check Connect manifold gauge set or charging station with gauges to refrigerant system. With the vehicle in park, parking brake set, thermometer installed in center panel vent, and air conditioning system on and set to FULL COOL, start the engine. Record air refrigerant system pressures while running the engine at 1,500 RPM and allow engine to return to idle. Operate the blower motor in all control positions and check for correct blower speed changes. With the blower motor on HI, operate air discharge mode selector in all positions and check for correct airflow in each position. Operate the temperature blend selector in all positions and check for correct change in discharge temperature. Check the air discharge temperature with the selector in the coolest position and the air conditioning on and set to FULL COOL to determine if the air discharge temperature is acceptable for the current ambient air temperature. Carry out the DATC self-test (if applicable). If the refrigerant system pressures were low, carry out the refrigerant system leak test.
4. Refrigerant System Leak Test Use either an ultraviolet (UV) or an electronic leak detector to check for leaks at all refrigerant lines, connections, and components. After all tests have been completed, report all findings and recommended repairs to your service advisor before carrying out further diagnostic procedures.

Scheme 160

Material

ITEM SPECIFICATION

Scheme 161

Scheme 162

Scheme 163

Scheme 164

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.

Scheme 165

Scheme 166

Scheme 167

1. Fabricate a cleaning tool from a 1/8-inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite® with the dimensions corresponding to the coupling size. COUPLING AND PAD SIZE SPECIFICATIONS 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.

Scheme 168

Scheme 169

Scheme 170

Scheme 171

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.

Scheme 172

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.

Connect

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.

Scheme 173

ITEM SPECIFICATION

Disconnect

Scheme 174

1. Depressurize the engine cooling system.
2. Push the heater hose toward the tube to fully expose the locking tabs.
3. Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
4. Pull the heater hose away from the heater core tube.
5. Spread the retainer tabs apart and slide the retainer off the tube. Discard the retainer.

Scheme 175

Scheme 176

1. Clean the tubes and lubricate with coolant hose lubricant or plain water.
2. Install a new coupling retainer (18D434) into the heater hose coupling housing.
3. Push the heater hose coupling onto the tube.
4. Make sure the heater hose coupling is fully engaged by lightly pulling on the heater hose.

Scheme 177

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

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

Note. The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38°C (100°F) or lower, follow Procedure 1 - Ambient Temperature At or Below 38°C (100°F) . If the ambient temperature is over 38°C (100°F), follow PROCEDURE 2 - AMBIENT TEMPERATURE ABOVE 38°C (100°F) .

Note. If the A/C compressor cycles at any time during this test, refer to DIAGNOSTIC TABLE. Drive the vehicle or run the engine until it reaches normal operating temperature. Connect a manifold gauge set or refrigerant service center with high-pressure and low-pressure gauges to the refrigerant system. Set the climate controls. If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, HI Blower. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If equipped with ATC, set temperature to 15°C (60°F) (lowest possible temp setting) with the dual function disabled (if equipped). Manually set blower on high. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If the vehicle is equipped with auxiliary climate control, set the auxiliary controls to full COOL in the PANEL mode at HI blower speed. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if equipped). Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range that repeats. Record the ambient (shop) temperature. Record the discharge pressure. If the pressure is fluctuating, record the average value. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant Discharge Pressures chart. Record the suction pressure. If the pressure is fluctuating, record the average value. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction Pressures chart. (Scheme 165) Proceed to DIAGNOSTIC TABLE.

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

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

Note. The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38°C (100°F) or lower, follow PROCEDURE 1 - AMBIENT TEMPERATURE AT OR BELOW 38°C (100°F) procedure 1. If the ambient temperature is over 38°C (100°F), follow PROCEDURE 2 - AMBIENT TEMPERATURE ABOVE 38°C (100°F) .

Scheme 178

Scheme 179

1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a manifold gauge set or refrigerant service center with high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls. If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, MED LO blower. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If equipped with ATC, set temperature to 15°C (60°F) (lowest possible temp setting). Manually set blower to MED LO (3 to 4 bars). If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If the vehicle is equipped with auxiliary climate control, set the auxiliary controls to full COOL in the PANEL mode at MED LO blower speed.
4. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction Pressures chart.
11. Proceed to «DIAGNOSTIC TABLE»(ref-207561-S36238308802005113000000) .

Electronic Leak Detection Procedure

Scheme 180

1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) . Repair the system. Test the system for normal operation.

Scheme 181

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 182

Scheme 183

1. Check for leaks using the special tool. 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-207561-S32152738792005113000000) .
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-207561-S32152738792005113000000) .
5. After the leak(s) is/are 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 the special tool.

Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector

Note. 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.

Note. 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.

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

Scheme 184

Scheme 185

1. Install an R-134a A/C refrigerant service center or a manifold and gauge set. For additional information, refer to «MANIFOLD GAUGE SET CONNECTION»(ref-207561-S42669147032005113000000) .
2. Verify that the valves on the special tool are closed.
3. Fill the special tool reservoir with 7 ml (0.25 oz) of fluorescent dye.
4. Install the special tool 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. Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses.

Note. Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F).

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

1. Verify that the valves on the special tool are closed.
2. Fill the special tool reservoir with 7 ml (0.25 oz) of fluorescent dye.
3. Install the special tool 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 special tool valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the special tool to equalize with the suction side of the refrigerant system.
8. Close the valves on the special tool.
9. Disconnect the high-pressure and low-pressure service valves and remove the special tool from the vehicle.

Scheme 191

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 cylinder, and manifold gauge set.

1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to «REFRIGERANT IDENTIFICATION TESTING»(ref-207561-S10242079072005113000000) .
2. Connect an R-134a A/C service center to the low- and high-pressure service gauge port valves. For additional information, refer to «MANIFOLD GAUGE SET CONNECTION»(ref-207561-S42669147032005113000000) .
3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer.
4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the vacuum does not decrease, disconnect the refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 3 through 5 until the vacuum level remains stable for two minutes.
7. Carry out the required repairs.

Refrigerant System Evacuation

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 cylinder, and manifold gauge set.

1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. For additional information, refer to «MANIFOLD GAUGE SET CONNECTION»(ref-207561-S42669147032005113000000) .
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 five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leak, and evacuate the system again.

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 cylinder, and manifold gauge set.

1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
2. Charge the system with the specified amounts of refrigerant oil and refrigerant.
3. When no more refrigerant is being drawn into the system, start the engine and select FULL COOL operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve.

Scheme 192

Refrigerant Oil Adding

Note. Installation of new components such as the A/C pressure transducer do not require additional oil.

1. Rotate the A/C compressor shaft six to eight revolutions while collecting the oil in a clean measuring device. If the amount of oil drained from the old A/C compressor is between 90-150 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. If the amount of oil that was removed from the old A/C compressor is greater than 150 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. If the amount of oil that was removed from the old A/C compressor is less than 90 ml (3 ounces), pour 90 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor.
2. For the receiver drier, drill one 12.7 mm (0.5 in) hole in the receiver drier cylinder and drain the oil into a calibrated container. Add a quantity of new oil to match that drained from the old receiver drier plus 59 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
3. For the A/C evaporator core add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the receiver drier inlet tube.
4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the receiver drier inlet tube.
5. Add 20 ml (0.75 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the receiver drier inlet tube when carrying out each of the following repairs: Installation of a new TXV Installation of a new A/C compressor pressure relief valve (19D644) Installation of a new refrigerant line Repair of an O-ring seal leak Repair of a charge port leak

Scheme 193

Contaminated Refrigerant Handling

1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. If this equipment is not available, contact an A/C repair facility in your area with the correct equipment to carry out this repair.
2. Determine and correct the cause of the customer's initial concern.
3. Remove the receiver drier. For additional information, refer to «RECEIVER DRIER»(ref-207561-S01497177412005113000000) .
4. Clean the A/C evaporator core and the A/C condenser core by flushing. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM FLUSHING»(ref-207561-S03183844542005113000000) .
5. Install the new receiver drier. For additional information, refer to «RECEIVER DRIER»(ref-207561-S01497177412005113000000) .
6. Correctly oil match the system. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
7. Evacuate and charge the system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .
8. Dispose of contaminated refrigerant according to all federal, state and local regulations.

Scheme 194

1. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the following steps. See «COMPONENTS REMOVING STEPS»(ref-207561-S34195322562005113000000) . COMPONENTS REMOVING STEPS Component Steps Driver side register 1 Passenger side register 2 Center register 3-6
2. To install, reverse the removal procedure.

Item 1-2: Driver Side and Passenger Side Register Removal Note

Scheme 195

1. Depress the inboard side tab with a flat blade tool. Pull the register rearward, depress the outboard tab and remove the register.

Item 3: Center Register Removal Note

Scheme 196

1. Insert a mini-pick in the pocket and pull the register from the instrument panel.

Scheme 197

Scheme 198

Scheme 199

1. If removing the front floor ducts, remove the instrument panel lower insulators.
2. If removing the rear seat floor ducts, remove the front seats. For additional information, refer to «SEATING»(ref-207572).
3. If removing the rear seat floor ducts, remove the lower cowl trim panels and front door sill plates to position the carpet away from the ducts.
4. If removing the fresh air inlet duct, remove the cowl panel grille. For additional information refer to «EXTERIOR TRIM»(ref-207571).
5. To remove individual components, only carry out the following steps. See «COMPONENTS REMOVING STEPS»(ref-207561-S39093619032005113000000). COMPONENTS REMOVING STEPS Component Steps LH floor duct 1-3 RH floor duct 4-6 Defroster duct 7, 11-12 Demister ducts 7, 11-12, 16-17, 20-21 Panel ducts 7-26 Floor console ducts 27-33 Rear seat floor ducts 34-36 Fresh air inlet duct 38-44
6. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 190)
7. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 191)
8. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and table. (Scheme 192)
9. To install, reverse the removal procedure.

Item 7: Instrument Panel Removal Note

1. Remove the instrument panel. For additional information, refer to «INTERIOR TRIM»(ref-207570) .

Item 8-9: LH and RH Instrument Panel Register Removal Note

1. Remove the instrument panel register. For additional information, refer to «INSTRUMENT PANEL REGISTERS»(ref-207561-S06477600572005113000000) .

Item 10: Plenum Chamber Removal Note

1. Remove the plenum chamber. For additional information, refer to «PLENUM CHAMBER, ASSEMBLY AND COMPONENTS»(ref-207561-S15934331882005113000000) .

Item 27: Floor Console Removal Note

1. Remove the floor console. For additional information, refer to «INTERIOR TRIM»(ref-207570) .

Item 30: Transmission Selector Assembly Removal Note

1. Remove the transmission selector assembly. For additional information, refer to «AUTOMATIC TRANSMISSION - 5R55S»(ref-207557) .

Scheme 200

1. Remove the instrument panel. For additional information, refer to «INTERIOR TRIM»(ref-207570) .
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.

Heater Control Valve and Heater Hoses

Note. Lubricate the coolant hoses with plain water only if needed.

Scheme 201

Scheme 202

1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «LIFTING»(ref-207545-S28498965772005113000000).
2. Remove the engine air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) or «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556).
3. If removing the heater tube assembly, remove the fresh air inlet duct. For additional information, refer to «AIR DISTRIBUTION DUCTS»(ref-207561-S01935463842005113000000).
4. If removing a heater hose or the heater tube assembly, or if equipped with a 3.9L engine, drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
5. If removing the dual coolant control valve on vehicles with a 3.0L engine, clamp off the heater hoses at the component before disconnecting.
6. If equipped with a 3.9L engine and removing a heater hose, the dual coolant control valve or the auxiliary coolant flow pump, disconnect the upper radiator hose at the engine.
7. To remove individual components, only carry out the following steps. See «INDIVIDUAL COMPONENT REMOVING STEPS»(ref-207561-S17881931902005113000000). INDIVIDUAL COMPONENT REMOVING STEPS Component Steps Heater hoses 1-7, 11-15 Heater tube assembly 5, 7, 15, 19-23 Dual coolant control valve 2, 4, 6, 8-10 Auxiliary coolant flow pump 12, 14, 16-18
8. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table. see scheme 185
9. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 193)
10. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).

Scheme 203

1. Remove the RH floor duct. For additional information, refer to «AIR DISTRIBUTION DUCTS»(ref-207561-S01935463842005113000000).
2. Remove the components in the order indicated in the following illustration and table. (Scheme 194)
3. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Note. If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested.

Note. If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle.

Note. Lubricate the coolant hoses with plain water only if needed.

Scheme 204

Scheme 205

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).
2. Partially drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207554).
3. Remove the fresh air inlet duct. For additional information, refer to «AIR DISTRIBUTION DUCTS»(ref-207561-S01935463842005113000000).
4. Remove the instrument panel. For additional information, refer to «INTERIOR TRIM»(ref-207570).
5. To remove individual components, only carry out the following steps: COMPONENTS REMOVING STEPS Component Steps Heater core and evaporator core housing 1-8 Blower motor speed control 1-13 Heater core 1-19 Evaporator core 1-18, 20-22
6. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 195)
7. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 196)
8. To install, reverse the removal procedure.
9. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000).
10. Fill the engine coolant level. For additional information, refer to «ENGINE COOLING»(ref-207554).
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).

Item 22: Thermostatic Expansion Valve Removal Note

1. Remove the thermostatic expansion valve. For additional information, refer to «THERMOSTATIC EXPANSION VALVE»(ref-207561-S16394289412005113000000) .

Scheme 206

MATERIAL SPECIFICATION

Note. If installing a new A/C compressor, the A/C clutch disc and hub (19D786), A/C compressor pulley (19D784) and A/C clutch field coil (19D798) must be inspected and transferred from the old unit to the new unit if suitable for reuse.

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 207

Scheme 208

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).
2. Remove the drive belt from the A/C compressor pulley.
3. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 198)
4. Illustration 2 of 2. Remove the component in the order indicated in the following illustration and table. (Scheme 199)
5. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
6. To install, reverse the removal procedure.
7. If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000).
8. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).

Item 6: A/C Clutch Nut Removal Note

Scheme 209

1. Remove the A/C clutch nut. Using the special tool, hold the clutch plate. Remove the nut.

Item 10: A/C Clutch Pulley Removal Note

1. Using the special tool, remove the A/C clutch pulley.

Item 12: A/C Clutch Field Coil Removal Note

1. Remove the thermal limiter. Remove the bolt and the hold-down bracket. Remove the thermal limiter.

Scheme 210

MATERIAL SPECIFICATION

Note. If installing a new A/C compressor, the A/C clutch disc and hub (19D786), A/C compressor pulley (19D784) and A/C clutch field coil (19D798) must be inspected and transferred from the old unit to the new unit if suitable for reuse.

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 211

Scheme 212

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).
2. Remove the drive belt from the A/C compressor pulley.
3. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table. (Scheme 204)
4. Illustration 2 of 2. Remove the component in the order indicated in the following illustration and table. (Scheme 205)
5. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
6. To install, reverse the removal procedure.
7. If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000).
8. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).

Item 6: A/C Clutch Nut Removal Note

1. Remove the A/C clutch nut. Using the special tool, hold the clutch plate. Remove the nut.

Item 10: A/C Clutch Pulley Removal Note

1. Using the special tool, remove the A/C clutch pulley.

Item 12: A/C Clutch Field Coil Removal Note

1. Remove the thermal limiter. Remove the bolt and the hold-down bracket. Remove the thermal limiter.

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 213

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .
2. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) or «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) .
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
6. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 214

1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «LIFTING»(ref-207545-S28498965772005113000000).
2. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).
3. Remove the center underbody deflector shield.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure. (Scheme 210)
6. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000).
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 215

Scheme 216

Scheme 217

Scheme 218

1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «LIFTING»(ref-207545-S28498965772005113000000).
2. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).
3. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) or «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556).
4. Remove the RH deflector shield.
5. Remove the screws and the splash shield.
6. Remove the air deflector. Remove the pin-type retainers. Remove the clips and the air deflector.
7. Remove the components in the order indicated in the following illustration and table. (Scheme 214)
8. To install, reverse the removal procedure.
9. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000).
10. Evacuate, leak test and charge the refrigerant system, for additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000).

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 219

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY»(ref-207561-S32152738792005113000000) , Evacuation and Charging.
2. Remove the engine air cleaner. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.0L (4V)»(ref-207555) .
3. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information refer to «LIFTING»(ref-207545-S28498965772005113000000) .
4. Remove the LH lower deflector shield.
5. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.
7. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Scheme 220

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .
2. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L»(ref-207556) .
3. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information refer to «LIFTING»(ref-207545-S28498965772005113000000) .
4. Remove the center RH and LH deflector shields.
5. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.
7. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Note. Lubricate the coolant hoses with plain water only if needed.

Scheme 221

1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «LIFTING»(ref-207545-S28498965772005113000000) .
2. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .
3. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-207554) .
4. Remove the fresh air inlet duct. For additional information, refer to «AIR DISTRIBUTION DUCTS»(ref-207561-S01935463842005113000000) .
5. Remove the RH air deflector shield.
6. Remove the components in the order indicated in the following illustration and table.
7. To install, reverse the removal procedure.
8. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C fitting that has been disconnected.

Note. Lubricate the coolant hoses with plain water only if needed.

Scheme 222

1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «LIFTING»(ref-207545-S28498965772005113000000) .
2. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .
3. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-207554) .
4. Remove the fresh air inlet duct. For additional information, refer to «AIR DISTRIBUTION DUCTS»(ref-207561-S01935463842005113000000) .
5. Remove the RH air deflector shield.
6. Remove the components in the order indicated in the following illustration and table.
7. To install, reverse the removal procedure.
8. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207561-S33012050602005113000000) .
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207561-S32152738792005113000000) .

MATERIAL SPECIFICATION

Note. Installation of a new receiver drier is not required when repairing the air conditioning system ex when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C f that has been disconnected.

Scheme 223

1. Remove the evaporator core. For additional information, refer to «HEATER CORE AND EVAPORATOR CORE HOUSING, ASSEMBLY AND COMPONENTS»(ref-207561-S13700618832005113000000) .
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.