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412-00-1 Climate Control System - General Information 412-00-1 SECTION 412-00 Climate Control System - General Information VEHICLE APPLICATION:2007.50 Transit CONTENTS PAGE SPECIFICATIONS Specifications 412-00-2 DIAGNOSIS AND TESTING Climate Control System Inspection and Testing Refrigerant Circuit - Quick Check Symptom chart System Checks 412-00-3 412-00-3 412-00-3 412-00-4 412-00-6 GENERAL PROCEDURES Spring Lock Coupling Air Conditioning (A/C) Clutch Air Gap Adjustment Fluorescent Dye Leak Detection Electronic Leak Detection Refrigerant Oil Adding Contaminated Refrigerant Handling Air Conditioning (A/C) System Recovery, Evacuation and Charging Vacuum Leak Detection 412-00-54 412-00-56 412-00-57 412-00-58 412-00-59 412-00-60 412-00-61 412-00-63 Climate Control System - General Information 412-00-2 412-00-2 SPECIFICATIONS Lubricants, Fluids, Sealants and Adhesives Item Specification Refrigerant R134a WSH-M17B19-A Refrigerant oil WSH-M1C231-B Refrigerant Capacities (When Charging) Grams A/C system 750 ± 20 A/C system with Auxiliary A/C system 1400 ± 34 Refrigerant Oil Capacities (When Charging) millilitres A/C system 280 A/C system with Auxiliary A/C system 640 Addition of Refrigerant Oil (When new components are installed) CAUTIONS: The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity If other A/C components are being renewed in addition to the A/C compressor, there is no need to top up with additional refrigerant oil, apart from filling the compressor millilitres When all lines and components are replaced Add 280 When all lines and components have been renewed (vehicles with additional air conditioning) Add 640 Air conditioning (A/C) compressor - if the quantity of refrigerant oil drained from the faulty compressor is less than 150 ml Drain 50 from new compressor Air conditioning compressor - if the amount of refrigerant oil drained from the faulty compressor is more than 150 ml Drain from new compressor Condenser add 30 Evaporator add 30 Accumulator/dehydrator add 90 Always, if refrigerant was drained Add the same quantity as the quantity that was collected Clutch air gap mm Compressor clutch air gap Tightening Torques Description Compressor drive plate retaining bolt 2007.50 Transit 11/2006 0.35 - 0.85 Nm lb-ft lb-in 13 10 – G509357en Climate Control System - General Information 412-00-3 412-00-3 DIAGNOSIS AND TESTING Climate Control System Refer to Wiring Diagrams Section412-00,for schematic and connector information Special Tool(s) Terminal probe kit 418-S035 29011A General Equipment Digital Multimeter (compatible with K-type thermocouple) Thermometer - Fluke 80 PK-8 (FSE number 260 4102 001 07) Worldwide Diagnostic System (WDS) Refrigerant center RECTIFY any displayed faults in accordance with the displayed fault description CHECK the operation of the system For vehicles with no stored fault(s), PROCEED in accordance with the Symptom Chart according to the fault symptom Following checking or elimination of the fault and after completion of operations, the fault memories of all vehicle modules must be READ OUT and any stored faults must be DELETED READ OUT all fault memories again following a road test Refrigerant Circuit - Quick Check WARNING:The air conditioning system is filled with R134a refrigerant Observe "Health and Safety Precautions" For further information REFER to:Health and Safety Precautions (100-00 General Information, Description and Operation) Vacuum pump Vacuum gauge Refrigerant circuit check Inspection and Testing Check customer concern Visually CHECK for any obvious mechanical or electrical damage Visual Inspection Mechanical • • • • • • • Refrigerant lines Condenser Drive belt Coolant level Coolant hoses A/C compressor Vacuum lines Electrical • Fuses • Wiring harness • Connector RECTIFY any obvious causes for a concern found during the visual inspection before performing any further tests CHECK the operation of the system If the concern persists after the visual inspection, PERFORM a fault diagnosis on the electronic engine management with WDS and 2007.50 Transit 11/2006 WARNING:Under certain circumstances, refrigerant lines and A/C components may be extremely hot or cold Exercising care, touch the refrigerant lines or A/C components in order to check this Failure to observe this instruction can lead to injury • The refrigerant line from the refrigerant compressor to the condenser must be hot • The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but not so hot as the refrigerant line mentioned above • Determine the difference in temperature upstream and downstream of the A/C condenser by measuring the temperatures Depending on the ambient temperature, the temperature difference should be more than 20 °C If the temperature difference is less, check the condenser for contamination or damage to the fins as well as operation of the radiator fans G493484en 412-00-4 Climate Control System - General Information 412-00-4 DIAGNOSIS AND TESTING • The refrigerant line between the fixed orifice tube and the evaporator must be cold from the point where the fixed orifice tube is installed Depending on the weather, the refrigerant line may also have ice on its surface • The refrigerant line between the evaporator and the A/C compressor including the dehydrator must be cold Evaporator outlet temperature test To test the power of the A/C system, the temperature of the evaporator outlet line must be measured To this, the following preconditions must be met: • Open all windows • Set the air distribution to the defrost/dashboard position and open all the ventilation nozzles • DO NOT switch on recirculated air • Select lowest blower switch setting • Select lowest temperature setting NOTE:The temperature measurement cannot be done with a thermometer which makes no contact False measurements may arise as a result of surface reflections Connect the temperature sensor (Fluke 80 PK-8) to the outlet line of the evaporator The temperature sensor must be positioned as closely as possible to the evaporator Connect the temperature sensor to the multimeter Start the engine and allow it to run at idle speed for several minutes Switch on the air-conditioning system If the measured temperature is °C (vehicles with additional air conditioning: °C) or less then the air conditioning system is OK If the temperature is higher, the A/C system may be under-filled Frequent faults and their causes If the customer expresses concern about insufficient cooling performance, ensure that the temperature control is working properly • No or poor cooling performance: – Blockage or narrowing of a refrigerant line or in the dehydrator: The location of the blockage or narrowing can easily be located by temperature comparisons at the refrigerant lines and the dehydrator The blockage or restriction is located at the point where the temperature difference is identified Note: A difference in temperature in the area of the fixed orifice tube is normal Once you have found the location of the blockage or narrowing, check the corresponding component and replace it with a new one if required • Sudden drop in cooling performance (after the air conditioning has been switched off for approx minutes, the cooling performance returns to normal): – The cause is an iced-up fixed orifice tube because of moisture in the refrigerant circuit In order to ensure that moisture is completely removed from the refrigerant circuit, the dehydrator should be renewed and the evacuation time should be extended to 2-3 hours For further information After three minutes, measure the surface temperature of the evaporator outlet line Symptom chart Symptom chart Symptom • Blower faulty/inoperative • • • • • • • 2007.50 Transit 11/2006 Possible Sources Fuse(s) Circuit(s) Blower motor Blower switch Blower resistor assembly Blower relay, programmable fuel-fired booster heater Blower relay, air conditioning Action • GO to Pinpoint Test A G493484en 412-00-5 Climate Control System - General Information 412-00-5 DIAGNOSIS AND TESTING Symptom Possible Sources • Additional blower motor faulty • Fuse(s) / inoperative • Circuit(s) • Additional blower motor • Additional blower switch • Additional blower resistor • Air conditioning inoperative blower function OK Action • GO to Pinpoint Test B • • • • • Fuse(s) • GO to Pinpoint Test C Circuit(s) Air conditioning clutch Air conditioning clutch relay Refrigerant high pressure switch • Powertrain control module (PCM) • Refrigerant low pressure switch • Air conditioning control assembly • Refrigerant compressor inoper- • Circuit(s) ative in "defrost" air distribution • Mechanical actuation of the setting (function of air condidefrost switch tioning OK) • Defrost switch • GO to Pinpoint Test D • Blower does not run automatic- • Circuit(s) ally when the air conditioning • Blower relay, air conditioning is switched on - vehicles with air conditioning • GO to Pinpoint Test E • Temperature control inoper• Circuit(s) • GO to Pinpoint Test F ative - vehicles with air condi- • Temperature control potentioning (function of the air tiometer conditioning OK) • Temperature control flap actuator • Temperature control flap • Air conditioning control assembly • Air distribution flap actuator for • Fuse(s) • GO to Pinpoint Test G additional heater inoperative • Circuit(s) (operation of additional blower • Actuator – additional heater air motor OK) distribution flap • Additional heater control assembly • The temperature control is inoperative when the additional heater control assembly is used • • • • Fuse(s) • GO to Pinpoint Test H Circuit(s) Additional heater control valve Additional heater control valve module • Additional heater control assembly • Recirculated air flap inoperative • Vacuum line(s) • GO to Pinpoint Test I • Actuator – recirculated air flap • Climate control system control assembly 2007.50 Transit 11/2006 G493484en 412-00-6 Climate Control System - General Information 412-00-6 DIAGNOSIS AND TESTING Symptom • No heating power • • • • • • Possible Sources Action Cooling system • GO to Pinpoint Test J Vacuum line(s) Circuit(s) Coolant shut-off valve Solenoid valve, coolant shut-off valve Solenoid valve switch, coolant shut-off valve System Checks PINPOINT TEST A : BLOWER FAULTY/INOPERATIVE TEST CONDITIONS DETAILS/RESULTS/ACTIONS A1: CHECK ALL SPEED SETTINGS OF THE BLOWER MOTOR Ignition switch in position II Switch the blower switch through all speed settings • Is the blower motor inoperative in all the switch positions? → Yes GO to A2 → No - The blower motor is inoperative in switch position and/or 2: GO to A9 - The blower motor is only inoperative in switch position 3: GO to A8 A2: CHECK FUSE F55 Ignition switch in position CHECK Fuse F55 (standard relay box) • Is the fuse OK? → Yes GO to A3 → No INSTALL A NEW fuse F55 (40 A) CHECK the operation of the system If the fuse blows again, LOCATE and REPAIR the short using the Wiring Diagrams A3: CHECK THE VOLTAGE AT FUSE F55 Connect Fuse F55 (standard relay box) Ignition switch in position II 2007.50 Transit 11/2006 G493484en 412-00-7 Climate Control System - General Information 412-00-7 DIAGNOSIS AND TESTING TEST CONDITIONS DETAILS/RESULTS/ACTIONS Measure the voltage between fuse F55 and ground • Does the meter display battery voltage? → Yes GO to A4 → No REPAIR the voltage supply to fuse F55 with the aid of the Wiring Diagrams CHECK the operation of the system A4: CHECK VOLTAGE AT BLOWER MOTOR Ignition switch in position Disconnect Connector CH123 from the blower motor Ignition switch in position II Measure the voltage between the blower motor, connector CH123, pin 1, circuit CB155J (YE/RD), wiring harness side and ground • Does the meter display battery voltage? → Yes E54403 - All except vehicles with programmable fuelfired booster heater: GO to A5 - Vehicles with programmable fuel-fired booster heater: GO to A19 → No - All except vehicles with programmable fuelfired booster heater: LOCATE and REPAIR the break in the circuit between the blower motor and fuse F55 using the Wiring Diagrams CHECK the operation of the system - Vehicles with programmable fuel-fired booster heater: GO to A14 A5: CHECK GROUND CONNECTION OF BLOWER MOTOR Ignition switch in position Set the blower switch to level 2007.50 Transit 11/2006 G493484en 412-00-8 Climate Control System - General Information 412-00-8 DIAGNOSIS AND TESTING TEST CONDITIONS DETAILS/RESULTS/ACTIONS Measure the resistance between the blower motor, connector CH123, pin 2, circuit VH301B (YE/BU), wiring harness side and ground • Is a resistance of less than Ohms registered? → Yes RENEW the blower motor CHECK the operation of the system E54404 → No GO to A6 A6: CHECK THE GROUND CONNECTION OF THE BLOWER SWITCH Disconnect Connector CH101B from the blower switch Measure the resistance between the blower switch, connector CH101B, pin 4, circuit GD115F (BK/RD), wiring harness side and ground • Is a resistance of less than Ohms registered? → Yes GO to A7 → No VFE0016022 LOCATE and REPAIR the break in the circuit between the blower switch and ground connection GP15 using the Wiring Diagrams CHECK the operation of the system A7: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN CIRCUIT Measure the resistance between the blower motor, connector CH123, pin 2, circuit VH301B (YE/BU), wiring harness side and the blower switch, connector CH101B, pin 2, circuit VH301A (YE/BU), wiring harness side • Is a resistance of less than Ohms registered? → Yes RENEW the blower switch CHECK the operation of the system VFE0033621 → No LOCATE and REPAIR the break in circuit VH301B (YE/BU) between the blower motor and soldered connection S2H301 using the Wiring Diagrams CHECK the operation of the system 2007.50 Transit 11/2006 G493484en 412-00-9 Climate Control System - General Information 412-00-9 DIAGNOSIS AND TESTING TEST CONDITIONS DETAILS/RESULTS/ACTIONS A8: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN CIRCUIT - LEVEL INOPERATIVE Ignition switch in position Disconnect Connector CH123 from the blower motor Disconnect Connector CH101B from the blower switch Measure the resistance between the blower motor, connector CH123, pin 2, circuit VH301B (YE/BU), wiring harness side and the blower switch, connector CH101B, pin 2, circuit VH301A (YE/BU), wiring harness side • Is a resistance of less than Ohms registered? → Yes RENEW the blower switch CHECK the operation of the system VFE0033621 → No LOCATE and REPAIR the break in circuit VH301A (YE/BU) between soldered connection S2H301 and the blower switch using the Wiring Diagrams CHECK the operation of the system A9: MEASURE THE VOLTAGE AT THE BLOWER RESISTOR ASSEMBLY Ignition switch in position Disconnect Connector CH403 from the blower resistor assembly Ignition switch in position II Measure the resistance between the blower resistor assembly, connector CH403, pin 1, circuit VH301C (YE/BU), wiring harness side and ground • Does the meter display battery voltage? → Yes INSTALL a new heater blower series resistor CHECK the operation of the system → No VFE0023419 LOCATE and REPAIR the break in circuit VH301C (YE/BU) between soldered connection S2H301 and the blower resistor assembly using the Wiring Diagrams CHECK the operation of the system A10: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - LEVEL 1 Ignition switch in position 2007.50 Transit 11/2006 G493484en 412-00-10 Climate Control System - General Information 412-00-10 DIAGNOSIS AND TESTING TEST CONDITIONS DETAILS/RESULTS/ACTIONS Set the blower switch to level Measure the resistance between the blower resistor assembly, connector CH403, pin 2, circuit CH427C (BN), wiring harness side and ground • Is a resistance of less than Ohms registered? → Yes GO to A12 → No GO to A11 VFE0008570 A11: CHECK THE CIRCUIT BETWEEN THE BLOWER RESISTOR ASSEMBLY AND THE BLOWER SWITCH FOR OPEN CIRCUIT - LEVEL 1 Disconnect Connector CH101B from the blower switch Measure the resistance between the blower resistor assembly, connector CH403, pin 2, circuit CH427C (BN), wiring harness side and the blower switch, connector CH101B, pin 3, circuit CH427B (BN), wiring harness side • Is a resistance of less than Ohms registered? → Yes RENEW the blower switch CHECK the operation of the system VFE0033622 → No LOCATE and REPAIR the break in the circuit between the blower switch and the blower resistor assembly using the Wiring Diagrams CHECK the operation of the system A12: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - LEVEL Set the blower switch to level 2 Measure the resistance between the blower resistor assembly, connector CH403, pin 4, circuit CH428A (GN/WH), wiring harness side and ground • Is a resistance of less than Ohms registered? → Yes INSTALL a new heater blower series resistor CHECK the operation of the system → No VFE0009221 2007.50 Transit 11/2006 GO to A13 G493484en Control Components 412-04-8 412-04-8 REMOVAL AND INSTALLATION Climate Control Assembly — Vehicles Without: Air Conditioning Removal Remove the audio unit Refer to:Audio Unit (415-01 Information and Entertainment System, Removal and Installation) x8 x2 E65946 E76865 1 2 2 2 2 E64668 E64667 2007.50 Transit 11/2006 G552511en Control Components 412-04-9 412-04-9 REMOVAL AND INSTALLATION E64969 E64675 10 x4 E71278 E64674 E64970 11 E67333 Installation To install, reverse the removal procedure 2007.50 Transit 11/2006 G552511en Control Components 412-04-10 412-04-10 REMOVAL AND INSTALLATION Blower Motor Resistor Removal NOTE:Removal steps in this procedure may contain installation details x8 Left-hand drive vehicles x2 x8 E77303 x2 All Vehicles E71092 E77306 E77100 Right-hand drive vehicles E64976 E77302 2007.50 Transit 11/2006 G545512en Control Components 412-04-11 412-04-11 REMOVAL AND INSTALLATION E77151 2 E65019 Installation To install, reverse the removal procedure 2007.50 Transit 11/2006 G545512en 412-04-12 Control Components 412-04-12 REMOVAL AND INSTALLATION Air Inlet Blend Door Actuator — Vehicles With: Air Conditioning Removal All Vehicles NOTE:Removal steps in this procedure may contain installation details • Pull the footwell carpet to one side • Torque: 12 Nm Refer to:Supplemental Restraint System (SRS) Health and Safety Precautions (100-00 General Information, Description and Operation) Disconnect the battery ground cable Refer to:Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures) Remove the audio unit Refer to:Audio Unit (415-01 Information and Entertainment System, Removal and Installation) Remove the left and right-hand A-pillar trim Refer to:A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation) NOTE:Make sure that the road wheels are in the straight ahead position TIE38834 E64732 Raise the vehicle Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation) CAUTION:Make sure that new bolts are installed • Detach the steering column shaft joint from the steering column shaft • Torque: 28 Nm E64678 Lower the vehicle 2007.50 Transit 11/2006 G875320en Control Components 412-04-13 412-04-13 REMOVAL AND INSTALLATION 10 12 x8 x2 E64659 E71092 11 13 x2 x8 E65946 E76865 2007.50 Transit 11/2006 G875320en 412-04-14 Control Components 412-04-14 REMOVAL AND INSTALLATION 14 17 1 E77306 15 E64663 16 E77309 2007.50 Transit 11/2006 E64665 18 E64699 19 E77151 G875320en Control Components 412-04-15 412-04-15 REMOVAL AND INSTALLATION 20 22 1 E64668 E64666 21 23 2 2 2 E64667 E64669 24 2007.50 Transit 11/2006 G875320en Control Components 412-04-16 412-04-16 REMOVAL AND INSTALLATION x4 E64670 26 Torque: Nm 25 E64673 E64672 2007.50 Transit 11/2006 G875320en Control Components 412-04-17 412-04-17 REMOVAL AND INSTALLATION Vehicles with remote control for the audio unit 30 27 E64677 E64864 31 28 E82319 E64865 All Vehicles 29 E64676 2007.50 Transit 11/2006 G875320en 412-04-18 Control Components 412-04-18 REMOVAL AND INSTALLATION 32 WARNING:Make sure that new self-locking nuts are installed Torque: 20 Nm 34 Torque: 20 Nm E64703 35 Torque: 25 Nm 1 E64704 E64700 36 Torque: 20 Nm Torque: 25 Nm 33 x4 E76864 2007.50 Transit 11/2006 E64705 G875320en Control Components 412-04-19 412-04-19 REMOVAL AND INSTALLATION 37 Loosen the bolts four turns E64706 E64732 38 Start the engine, turn the steering wheel from lock to lock Torque: 12 Nm E68978 39 E64732 x2 E78196 Installation To install reverse the removal procedure 2007.50 Transit 11/2006 G875320en Control Components 412-04-20 412-04-20 REMOVAL AND INSTALLATION Air Inlet Blend Door Actuator — Vehicles Without: Air Conditioning Removal NOTE:Removal steps in this procedure may contain installation details Left-hand drive vehicles x2 x8 E77313 Right-hand drive vehicles E65946 E77308 All Vehicles E64810 x3 E77310 E77309 Installation To install reverse the removal procedure 2007.50 Transit 11/2006 G859599en Control Components 412-04-21 412-04-21 REMOVAL AND INSTALLATION Temperature Blend Door Actuator Removal E76865 2 2 x3 2 E78327 E64667 E78328 E77309 2007.50 Transit 11/2006 G875303en 412-04-22 Control Components 412-04-22 REMOVAL AND INSTALLATION Installation To install reverse the removal procedure 2007.50 Transit 11/2006 G875303en ... Compressor clutch air gap Tightening Torques Description Compressor drive plate retaining bolt 2007.50 Transit 11/2006 0.35 - 0.85 Nm lb-ft lb-in 13 10 – G509357en Climate Control System - General Information... inspection, PERFORM a fault diagnosis on the electronic engine management with WDS and 2007.50 Transit 11/2006 WARNING:Under certain circumstances, refrigerant lines and A/C components may be... outlet line Symptom chart Symptom chart Symptom • Blower faulty/inoperative • • • • • • • 2007.50 Transit 11/2006 Possible Sources Fuse(s) Circuit(s) Blower motor Blower switch Blower resistor assembly