HVAC - Automatic: Other Saab 9-7X I

Sensor Resistance Table

Sensor Resistance Table

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

A/C Compressor Clutch Assembly Connector Parts Information

A/C Compressor Clutch Assembly Connector Terminal Identification

Scheme 39

A/C Low Pressure Switch Connector Parts Information

A/C Low Pressure Switch Connector Terminal Identification

Scheme 40

A/C Refrigerant Pressure Sensor Connector Parts Identification

A/C Refrigerant Pressure Sensor Connector Terminal Identification

Scheme 41

Air Temperature Actuator - Left Connector Parts Information

Air Temperature Actuator - Left Connector Terminal Identification

Air Temperature Actuator - Right

Air Temperature Actuator - Right Connector Parts Information

Air Temperature Actuator - Right Connector Terminal Identification

Scheme 42

Air Temperature Sensor - Lower Left Connector Parts Information

Air Temperature Sensor - Lower Left Connector Terminal Identification

Air Temperature Sensor - Lower Right

Air Temperature Sensor - Lower Right Connector Parts Information

Air Temperature Sensor - Lower Right Connector Terminal Identification

Air Temperature Sensor - Upper Left

Air Temperature Sensor - Upper Left Connector Parts Information

Air Temperature Sensor - Upper Left Connector Terminal Identification

Air Temperature Sensor - Upper Right

Air Temperature Sensor - Upper Right Connector Parts Information

Air Temperature Sensor - Upper Right Connector Terminal Identification

Scheme 43

Air Temperature Sensor Assembly - Inside Connector Parts Information

Air Temperature Sensor Assembly - Inside Connector Terminal Identification

Scheme 44

Ambient Air Temperature Sensor Connector Parts Information

Ambient Air Temperature Sensor Connector Terminal Identification

Scheme 45

Ambient Light/Sunload Sensor Assembly Connector Parts Information

Ambient Light/Sunload Sensor Assembly Connector Terminal Identification

Scheme 46

Blower Motor Connector Parts Information

Blower Motor Connector Terminal Identification

Scheme 47

Blower Motor Control Module Connector Parts Information

Blower Motor Control Module Connector Terminal Identification

Scheme 48

Console Mode Actuator - Auxiliary Connector Parts Information

Console Mode Actuator - Auxiliary Connector Terminal Identification

Defrost Actuator

Defrost Actuator Connector Parts Information

Defrost Actuator Connector Terminal Identification

Scheme 49

HVAC Control Module C1 Connector Parts Information

HVAC Control Module C1 Connector Terminal Identification

Scheme 50

HVAC Control Module C2 Connector Parts Information

HVAC Control Module C2 Connector Terminal Identification

Scheme 51

HVAC Control Module - Auxiliary Connector Parts Information

HVAC Control Module - Auxiliary Connector Terminal Identification

Mode Actuator

Mode Actuator Connector Parts Information

Mode Actuator Connector Terminal Identification

Scheme 52

Rear Blower Motor Connector Parts Information

Rear Blower Motor Connector Terminal Identification

Scheme 53

Rear Blower Resistor Connector Parts Information

Rear Blower Resistor Connector Terminal Identification

Recirculation Actuator

Recirculation Actuator Connector Parts Information

Recirculation Actuator Connector Terminal Identification

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections .

Blower Motor Always On

Blower Motor Always On

Blower Motor Inoperative

Blower Motor Inoperative

Auxiliary Blower Motor Always On (Body Type VIN 3)

Auxiliary Blower Motor Always On (Body Type VIN 3)

Auxiliary Blower Motor Malfunction

Auxiliary Blower Motor Malfunction

Air Delivery Improper - Auxiliary

Air Delivery Improper - Auxiliary

Ambient Air Temperature Display Updating

The HVAC control module will not request compressor clutch engagement when the ambient air temperature display is less than 5°C (40°F). In order to inspect compressor clutch operation during cold weather conditions, the vehicle must be brought inside and the ambient air temperature display must be updated. To update the ambient air temperature display on the HVAC control module, perform the following procedure

1. Turn ON the ignition.
2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches.

Re-Calibrating Actuators (Primary)

When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC control module be sure to perform the following

1. Place the ignition switch to the OFF position.
2. Disconnect the scan tool.
3. Install the HVAC control module.
4. Connect all previously disconnected components.
5. Start the vehicle.
6. Wait 40 seconds for the HVAC control module to self-calibrate.
7. Verify that no DTCs have set as current DTCs.

When replacing the HVAC actuator it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC actuator be sure to perform one of the following

Preferred Method (w/ Scan Tool)

1. Clear all DTCs.
2. Place the ignition switch in the OFF position.
3. Install the HVAC actuator.
4. Connect all previously disconnected components.
5. Start the vehicle.
6. With the scan tool, initiate the Motor Re-calibration feature of the Heating and Air Conditioning Special Functions menu.
7. Verify that no DTCs have set as current DTCs.

Alternate Method (w/o Scan Tool)

1. Clear all DTCs.
2. Place the ignition switch to the OFF position.
3. Install the HVAC actuator.
4. Connect all previously disconnected components.
5. Remove the HVAC B fuse for a minimum of 10 seconds.
6. Install the HVAC B fuse.
7. Start the vehicle.
8. Wait 40 seconds for the HVAC control module to self-calibrate.
9. Verify that no DTCs have set as current DTCs.

Scheme 54

1. Remove the instrument panel (I/P) accessory trim plate. Refer to «Instrument Panel Accessory Trim Plate Replacement»(ref-268082-S22048371982007101800000) .
2. Remove the HVAC control module screws.
3. Remove the HVAC control module from the I/P.
4. Disconnect the electrical connectors from the HVAC control module.

HVAC Control Module

The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the following features

Air Delivery Description and Operation

Auxiliary HVAC Control Module - VIN 6

The auxiliary HVAC control module is a class 2 device that interfaces between the rear seat occupants and the auxiliary HVAC system to maintain auxiliary air temperature and auxiliary air distribution settings. The battery positive voltage circuit provides power that the control module uses for KAM. If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The auxiliary HVAC control module will perform a recalibration of the electric actuators when commanded with a scan tool or if KAM is lost. This will ensure the actuators are moving with in the calibrated range. During this calibration process the auxiliary blower motor will be disabled for up to 3 minutes.

The defrost actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts.

The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts.

The mode actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts.

The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts.

Auxiliary Mode Actuator - VIN 6

The auxiliary mode actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5-volt reference, position signal, and 2 control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to coordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts.

The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits.

Auxiliary Console Mode Actuator

The auxiliary console mode actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5-volt reference, position signal, and 2 control circuits enable the actuator to operate. The control circuits use either a 0 or 12 volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts.

The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits.

Blower Motor Control Processor

The blower motor control processor controls the speed of the blower motor by increasing or decreasing the voltage drop on the ground side of the blower motor. The HVAC control module provides a low side pulse width modulated signal to the blower motor control processor over the blower motor speed control circuit. As the requested blower speed increases, the HVAC control module increases the amount of time that the speed signal is modulated to ground. As the requested blower speed decreases, the HVAC control module decreases the amount of time that the signal is modulated to ground.

Air Speed - Front Control

The blower control switch is integrated into the HVAC control module. The 2 rocker type switches provide the vehicle operator the ability to select several blower speeds. The HVAC control module uses a bar graph type display to indicate the selected blower speed. The HVAC control module provides a pulse width modulated (PWM) signal to the blower motor through the blower motor speed control circuit. The blower motor changes speed based on the received PWM signal from the HVAC control module. Power and ground are provided to the blower motor through the battery positive voltage and ground circuits. When the HVAC control module is operating in AUTO mode, the system automatically controls the blower speed. Power and ground are provided to the HVAC control module by the ignition 3 voltage and the ground circuits.

Air Speed - Auxiliary - VIN 6

There are 2 separate controls for the auxiliary HVAC system. There is the front auxiliary blower motor switch and the auxiliary HVAC control module. If the front auxiliary blower motor switch is in any other position than OFF or REAR, then the auxiliary air temperature actuator mimics the set passenger temperature. The auxiliary mode will mimic the primary mode. If the front auxiliary blower motor switch is in the REAR position, then the system will only function with inputs to the auxiliary HVAC control module. If the front auxiliary blower motor switch is in the OFF position, then the auxiliary HVAC control module does not respond to input. The auxiliary HVAC control module can not request A/C operation from the PCM. The 2 rocker type switches on the auxiliary HVAC control module provide the operator the ability to select several blower speeds. The auxiliary HVAC control module uses a bar graph type display to indicate the selected blower speed. The auxiliary HVAC control module provides a pulse width modulated (PWM) signal to the auxiliary blower motor through the auxiliary blower motor speed control circuit. The auxiliary blower motor changes speed based on the received PWM signal from the auxiliary HVAC control module. Power and ground are provided to the auxiliary blower motor through the battery positive voltage and ground circuits. Power and ground are provided to the auxiliary HVAC control module by the ignition 3 voltage and the ground circuits.

Air Speed - Auxiliary - VIN 3

The auxiliary HVAC system uses an LED display for air speed. When one LED is illuminated on the auxiliary HVAC control module the air flow through the center console to the rear is provided by the primary blower motor. The air speed will vary depending on the front blower motor setting. When 2 LED's are illuminated the auxiliary blower motor is set to medium speed. When 3 LED's are illuminated the auxiliary blower motor is set to high speed. When the operator selects medium blower speed, power is delivered to the auxiliary blower motor through the auxiliary blower motor medium speed control circuit. When the operator selects high blower speed, power is delivered to the auxiliary blower motor through the auxiliary blower motor high speed control circuit. Ground is provided to the blower motor through the ground circuit. Power and ground are provided to the auxiliary HVAC control module through the ignition 3 voltage and ground circuits.

OFF Mode

Press the OFF switch to turn off the HVAC control module. When the vehicle is moving, air flowing over the vehicle increases the air pressure just ahead of the windshield. This forces air into the outside air inlet, into the HVAC module and out through the floor and windshield outlets. Since the A/C compressor is not running, the incoming air may be warmed but not cooled.

Air Distribution

The HVAC control module controls the distribution of air by the use of a defrost actuator and a mode actuator. The modes that may be selected are

1. Defrost
2. Defog
3. Panel
4. Bi-Level
5. Floor

The mode and defrost actuators are connected to the mode and defrost doors by a cam type linkage system. Depending on the position of the door, air is directed through the HVAC module and distributed through various ducts leading to the outlets in the dash. If the HVAC control module detects a fault with the mode or defrost doors the HVAC control module will try to drive the actuator for a predetermined amount of time, to defrost, which is the defaulted position for the mode and defrost door actuators. When the mode switch is placed in the defrost or defog positions the A/C is commanded on and the recirculation door is moved to the outside air position to help reduce window fogging. A/C is available in all modes and recirculation is only available in the panel and bi-level modes.

The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position.

The defrost actuator operates the same as the mode actuator. The HVAC control module sends signals to the mode door actuator through the defrost door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the defrost actuator. When you select a defrost setting, logic determines the value of the defrost actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the defrost door position signal circuit. The motor moves the defrost door to the desired position.

Front Defrost

When defrost is selected, the A/C compressor is activated. The A/C compressor clutch will engage when ambient temperatures are above 3°C (38°F). The blower motor will be activated, regardless of the coolant temperature. The HVAC control module will override the auxiliary HVAC control module so a high volume of air is delivered to the front defrost vents. The rear window defogger does not affect the HVAC system.

Air Distribution - Auxiliary Control VIN 3

The auxiliary HVAC system provides ventilation for the rear seat occupants. The rear seat occupants will exercise control of the auxiliary air delivery modes and air speed, while the HVAC control module will maintain control of the air temperature setting. The HVAC control module's blower motor must be ON in order for the auxiliary HVAC system to receive heated or cooled air. The HVAC control module will have the authority to override the auxiliary HVAC system and place it in the OFF mode when the primary HVAC system is placed in the front window DEFROST position. To override the auxiliary HVAC control module, a signal is delivered from the HVAC control module through the class 2 serial data circuit, to the auxiliary HVAC control module. This pause in operation will be indicated by the flashing the text OFF.

When the auxiliary mode switch is toggled, a signal is sent to the auxiliary mode actuator through the auxiliary mode door control circuit. Power and ground are supplied to the auxiliary mode actuator through the ignition 3 voltage and ground circuits.

When the HVAC control module is ON, the air that is delivered to the auxiliary HVAC system is the low auxiliary blower speed. When the operator selects medium blower speed, power is delivered to the auxiliary blower motor through the auxiliary blower motor medium speed control circuit. When the operator selects high blower speed, power is delivered to the auxiliary blower motor through the auxiliary blower motor high speed control circuit. Ground is provided to the blower motor through the ground circuit. Power and ground are provided to the auxiliary HVAC control module through the ignition 3 voltage and ground circuits.

Air Distribution - Auxiliary Control VIN 6

The auxiliary HVAC system provides ventilation for the rear seat occupants.

The auxiliary mode actuator shares a control circuit with the auxiliary air temperature actuator. If change of position is required for both actuators, then the module positions the auxiliary air temperature actuator first. All control circuits for the auxiliary actuators are at a low voltage potential until a change of position is required. The module then applies a high voltage potential to the appropriate control circuit, which will rotate the actuator.

The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the following features

Air Temperature Description and Operation

The auxiliary HVAC control module is a class 2 device that interfaces between the rear seat occupants and the auxiliary HVAC system to maintain auxiliary air temperature and auxiliary air distribution settings. The battery positive voltage circuit provides power that the control module uses for KAM. If the battery positive voltage circuit loses power, all auxiliary HVAC DTCs and settings will be erased from KAM. The auxiliary HVAC control module will perform a recalibration of the electric actuators when commanded with a scan tool or if KAM is lost. This will ensure the actuators are moving with in the calibrated range.

Air Temperature Actuator

The air temperature actuators are a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference, and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5, or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts.

The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates, the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts.

Auxiliary Air Temperature Actuator - VIN 6

The auxiliary air temperature actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Low reference, 5-volt reference, position signal, and 2 control circuits enable the actuator to operate. The control circuits use either a 0 or 12-volt value to coordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the auxiliary HVAC control module grounds one of the control circuits while providing the other with 12 volts. The control module reverses the polarity of the control circuits to move the actuator in the opposite direction. When the actuator shaft rotates, the potentiometers adjustable contact changes the door position signal between 0-5 volts.

The auxiliary HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, one of the control circuits is grounded. As the actuator shaft rotates, the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module grounds both control circuits.

Air Temperature Sensors

The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors

1. Ambient air temperature sensor
2. Inside air temperature sensor assembly
3. Upper left air temperature sensor
4. Upper right air temperature sensor
5. Lower left air temperature sensor
6. Lower right air temperature sensor

A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40 to +101°C (-40 to +215°F). The sensor signal varies between 0-5 volts.

The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease.

If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected.

The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions

A new outside temperature reading will be displayed if the vehicle has been off for more than three hours. If the vehicle has been off for less than three hours, the old temperature reading may be displayed because underhood heat is affecting the true outside temperature. Since underhood heat can also affect the outside temperature while the engine is running, it may take several minutes of driving before the display updates to the actual outside temperature.

Air Temperature Description and Operation

The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST, and REAR DEFROST switches.

1. Turn ON the ignition.
2. Simultaneously press the MODE, FRONT DEFROST, and REAR DEFROST switches.

Sunload Sensor

The sunload sensor is a 2-wire photo diode. The vehicle uses left and right sunload sensors. The 2 sensors are integrated into the sunload sensor assembly. Low reference and signal circuits enable the sensor to operate. As the light shining upon the sensor gets brighter, the sensor resistance increases. The sensor signal decreases as the resistance increases. The sensor operates within an intensity range between completely dark and bright. The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between 0-255 counts.

The sunload sensor provides the HVAC control module a measurement of the amount of light shining on the vehicle. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system compensates for the increased temperature by diverting additional cool air into the vehicle.

If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted sunload value. This value will not be displayed on the scan tool. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is fixed. The scan tool parameter for the sunload sensor is the actual state of the signal circuit.

A/C Refrigerant Pressure Sensor

The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts. When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is high, the signal value is near 5 volts. The powertrain control module (PCM) converts the voltage signal to a pressure value.

The A/C refrigerant pressure sensor protects the A/C system from operating when an excessively high pressure condition exists. The PCM disables the compressor clutch if the A/C pressure is more than 2413 kPa (350 psi). The clutch will be enabled after the pressure decreases to less than 1578 kPa (229 psi).

A/C Low Pressure Switch

The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 137-165 kPa (20-24 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON.

The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit.

Coolant Bypass Valve

The coolant bypass valve controls coolant flow to the auxiliary heater core. Integral to the coolant bypass valve is an electric solenoid that controls vacuum flow to open and close the valve. When the HVAC control module applies 12 volts to the integral solenoid, the solenoid applies vacuum to a diaphragm that closes the water valve. This action restricts coolant flow to the auxiliary heater core. The coolant bypass valve is a normally open valve. If there is a concern with control of the valve or with its vacuum source the valve will still be able to supply heated coolant to the auxiliary heater core.

Steering Wheel Controls

The steering wheel controls for the HVAC system include air temperature and blower motor speed adjustments. Pressing the up arrow on the air temperature switch increases the outlet air temperature. Pressing the down arrow on the air temperature switch decreases the outlet air temperature. The body control module (BCM) receives the input from the steering wheel controls. Pressing one of the steering wheel switches enables an in line resistor to drop voltage on the remote radio control signal circuit. The BCM then interprets this voltage signal and sends a class 2 message to the HVAC control module for the desired change.

Engine Coolant

Engine coolant is the essential element of the heating system. The thermostat controls the normal engine operating coolant temperature. The thermostat also creates a restriction for the cooling system that promotes a positive coolant flow and helps prevent cavitation.

Coolant enters the heater core through the inlet heater hose, in a pressurized state. The heater core is located inside the HVAC module. The ambient air drawn through the HVAC module absorbs the heat of the coolant flowing through the heater core. Heated air is distributed to the passenger compartment, through the HVAC module, for passenger comfort. Opening or closing the air temperature door controls the amount of heat delivered to the passenger compartment. The coolant exits the heater core through the return heater hose and recirculated back through the engine cooling system.

A/C Cycle

Refrigerant is the key element in an air conditioning system. R-134a is presently the only EPA approved refrigerant for automotive use. R-134a is an very low temperature gas that can transfer the undesirable heat and moisture from the passenger compartment to the outside air.

The A/C compressor is belt driven and operates when the magnetic clutch is engaged. The compressor builds pressure on the vapor refrigerant. Compressing the refrigerant also adds heat to the refrigerant. The refrigerant is discharged from the compressor, through the discharge hose, and forced to flow to the condenser and then through the balance of the A/C system. The A/C system is mechanically protected with the use of a high pressure relief valve. If the A/C refrigerant pressure sensor were to fail or if the refrigerant system becomes restricted and refrigerant pressure continued to rise, the high pressure relief will pop open and release refrigerant from the system.

Compressed refrigerant enters the condenser in a high temperature, high pressure vapor state. As the refrigerant flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid state.

The condenser is located in front of the radiator for maximum heat transfer. The condenser is made of aluminum tubing and aluminum cooling fins, which allows rapid heat transfer for the refrigerant. The semi-cooled liquid refrigerant exits the condenser and flows through the liquid line, to the orifice tube.

The orifice tube is located in the liquid line between the condenser and the evaporator. The orifice tube is the dividing point for the high and the low pressure sides of the A/C system. As the refrigerant passes through the orifice tube, the pressure on the refrigerant is lowered. Due to the pressure differential on the liquid refrigerant, the refrigerant will begin to vaporize at the orifice tube. The orifice tube also meters the amount of liquid refrigerant that can flow into the evaporator.

Refrigerant exiting the orifice tube flows into the evaporator core in a low pressure, liquid state. Ambient air is drawn through the HVAC module and passes through the evaporator core. Warm and moist air will cause the liquid refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and draws moisture onto the evaporator. The refrigerant exits the evaporator through the suction line and back to the compressor, in a vapor state, and completing the A/C cycle of heat removal. At the compressor, the refrigerant is compressed again and the cycle of heat removal is repeated.

The conditioned air is distributed through the HVAC module for passenger comfort. The heat and moisture removed from the passenger compartment will also change form, or condense, and is discharged from the HVAC module as water.

A/C Cycle with Auxiliary

The auxiliary A/C system operates from the vehicles primary A/C system. The front or primary A/C system must be ON to allow the rear A/C system to function.

Refrigerant is the key element in an air conditioning system. R-134a is presently the only EPA approved refrigerant for automotive use. R-134a is an very low temperature gas that can transfer the undesirable heat and moisture from the passenger compartment to the outside air.

The A/C system used on this vehicle is a non cycling system. Non cycling A/C systems use a high pressure switch to protect the A/C system from excessive pressure. The high pressure switch will OPEN the electrical signal, to the compressor clutch, in the event that the refrigerant pressure becomes excessive. After the high and low side of the A/C system pressure equalize, the high pressure switch will CLOSE. Closing the high pressure switch will complete the electrical circuit to the compressor clutch. The A/C system is also mechanically protected with the use of a high pressure relief valve. If the high pressure switch were to fail or if the refrigerant system becomes restricted and refrigerant pressure continued to rise, the high pressure relief will pop open and release refrigerant from the system.

The A/C compressor is belt driven and operates when the magnetic clutch is engaged. The compressor builds pressure on the vapor refrigerant. Compressing the refrigerant also adds heat to the refrigerant. The refrigerant is discharged from the compressor, through the discharge hose, and forced to flow to the condenser and then through the balance of the A/C system.

Compressed refrigerant enters the condenser in a high temperature, high pressure vapor state. As the refrigerant flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid state.

The condenser is located in front of the radiator for maximum heat transfer. The condenser is made of aluminum tubing and aluminum cooling fins, which allows rapid heat transfer for the refrigerant. The semi-cooled liquid refrigerant exits the condenser and flows through the liquid line. The liquid line flow is split and the liquid refrigerant flows to both the front or primary A/C system, and to the liquid line for the rear A/C system.

The liquid refrigerant, flowing to the rear A/C system, flows into the rear thermal expansion valve (TXV). The rear TXV is located at the rear evaporator inlet. The TXV is the dividing point for the high and the low pressure sides of the rear A/C system. As the refrigerant passes through the TXV, the pressure on the refrigerant is lowered. Due to the pressure differential on the liquid refrigerant, the refrigerant will begin to boil at the expansion device. The TXV also meters the amount of liquid refrigerant that can flow into the evaporator.

Refrigerant exiting the TXV flows into the evaporator core in a low pressure, liquid state. Ambient air is drawn through the rear A/C module and passes through the evaporator core. Warm and moist air will cause the liquid refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and draws moisture onto the evaporator. The refrigerant exits the evaporator through the suction line and back to the primary A/C systems suction line. Refrigerant in the primary A/C system suction line flows back to the compressor, in a vapor state, and completes the A/C cycle of heat removal. At the compressor, the refrigerant is compressed again and the cycle of heat removal is repeated.

The conditioned air is distributed through the rear A/C module for passenger comfort. The heat and moisture removed from the rear passenger compartment will also change form, or condense, and is discharged from the rear A/C module as water.