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A7: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN CIRCUIT 1 Measure the resistance between the blowermotor, connector CH123, pin 2, circuit VH301BYE/BU, wiring ha

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SECTION 412-00 Climate Control System - General Information

VEHICLE APPLICATION: 2007.50 Transit

PAGE CONTENTS

SPECIFICATIONS

412-00-2Specifications

DIAGNOSIS AND TESTING

412-00-3Climate Control System

412-00-3Inspection and Testing

412-00-3Refrigerant Circuit - Quick Check

412-00-4Symptom chart

412-00-6System Checks

GENERAL PROCEDURES

412-00-54Spring Lock Coupling

412-00-56Air Conditioning (A/C) Clutch Air Gap Adjustment

412-00-57Fluorescent Dye Leak Detection

412-00-58Electronic Leak Detection

412-00-59Refrigerant Oil Adding

412-00-60Contaminated Refrigerant Handling

412-00-61Air Conditioning (A/C) System Recovery, Evacuation and Charging

412-00-63Vacuum Leak Detection

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Specification Item

WSH-M17B19-ARefrigerant R134a

WSH-M1C231-BRefrigerant oil

Refrigerant Capacities (When Charging)

Grams

750 ± 20A/C system

1400 ± 34A/C system with Auxiliary A/C system

Refrigerant Oil Capacities (When Charging)

millilitres

280A/C system

640A/C system with Auxiliary A/C system

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.

Air conditioning (A/C) compressor - if the quantity of refrigerant oil drained

from the faulty compressor is less than 150 ml

Drain 0 from newcompressor

Air conditioning compressor - if the amount of refrigerant oil drained from the

faulty compressor is more than 150 ml

Always, if refrigerant was drained

Clutch air gap

mm

0.35 - 0.85Compressor clutch air gap

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Climate Control System

Refer to Wiring Diagrams Section412-00,for

schematic and connector information

Inspection and Testing

1 Check customer concern

2 Visually CHECK for any obvious mechanical or

electrical damage

Visual Inspection

Electrical Mechanical

3 RECTIFY any obvious causes for a concern

found during the visual inspection before

performing any further tests CHECK the

operation of the system

4 If the concern persists after the visual

inspection, PERFORM a fault diagnosis on the

electronic engine management with WDS and

RECTIFY any displayed faults in accordancewith the displayed fault description CHECK theoperation of the system

5 For vehicles with no stored fault(s), PROCEED

in accordance with the Symptom Chartaccording to the fault symptom

6 Following checking or elimination of the faultand after completion of operations, the faultmemories of all vehicle modules must be READOUT 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).

Refrigerant circuit check

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 refrigerantcompressor to the condenser must be hot

• The refrigerant line from the A/C condenser tothe fixed orifice tube must be warm, but not sohot as the refrigerant line mentioned above

• Determine the difference in temperatureupstream and downstream of the A/C condenser

by measuring the temperatures Depending onthe ambient temperature, the temperaturedifference should be more than 20 °C If thetemperature difference is less, check thecondenser for contamination or damage to thefins as well as operation of the radiator fans

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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 do 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

After three minutes, measure the surface

temperature of the evaporator outlet line

additional air conditioning: 2 °C) or less then theair 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 aboutinsufficient cooling performance, ensure that thetemperature control is working properly

• No or poor cooling performance:

– Blockage or narrowing of a refrigerant line or

in the dehydrator: The location of theblockage or narrowing can easily be located

by temperature comparisons at therefrigerant lines and the dehydrator Theblockage or restriction is located at the pointwhere 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, checkthe corresponding component and replace itwith a new one if required

• Sudden drop in cooling performance (after theair conditioning has been switched off forapprox 5 minutes, the cooling performancereturns to normal):

– The cause is an iced-up fixed orifice tubebecause of moisture in the refrigerant circuit

In order to ensure that moisture is completelyremoved from the refrigerant circuit, thedehydrator should be renewed and theevacuation time should be extended to 2-3hours For further information

Symptom chart

Action Possible Sources

• Blower resistor assembly

• Blower relay, programmablefuel-fired booster heater

• Blower faulty/inoperative

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Action Possible Sources

Symptom

• GO to Pinpoint TestB

• Fuse(s)

• Circuit(s)

• Additional blower motor

• Additional blower switch

• Additional blower resistor

• Additional blower motor faulty

/ inoperative

• GO to Pinpoint TestC

• Fuse(s)

• Circuit(s)

• Air conditioning clutch

• Air conditioning clutch relay

• Refrigerant high pressureswitch

• Powertrain control module(PCM)

• Refrigerant low pressure switch

• Air conditioning controlassembly

• Air conditioning inoperative

• Refrigerant compressor

inoper-ative in "defrost" air distribution

setting (function of air

condi-tioning OK)

• GO to Pinpoint TestE

• Circuit(s)

• Blower relay, air conditioning

• Blower does not run

automatic-ally when the air conditioning

is switched on - vehicles with

actu-• Temperature control flap

• Air conditioning controlassembly

• Temperature control

inoper-ative - vehicles with air

condi-tioning (function of the air

• Air distribution flap actuator for

additional heater inoperative

(operation of additional blower

motor OK)

• GO to Pinpoint TestH

• Fuse(s)

• Circuit(s)

• Additional heater control valve

• Additional heater control valvemodule

• Additional heater controlassembly

• The temperature control is

inoperative when the additional

heater control assembly is

used

• GO to Pinpoint TestI

• Vacuum line(s)

• Actuator – recirculated air flap

• Climate control system controlassembly

• Recirculated air flap inoperative

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• GO to Pinpoint TestJ.

• Cooling system

• Vacuum line(s)

• Circuit(s)

• Coolant shut-off valve

• Solenoid valve, coolant shut-offvalve

• Solenoid valve switch, coolantshut-off valve

• No heating power

System Checks

PINPOINT TEST A : BLOWER FAULTY/INOPERATIVE

DETAILS/RESULTS/ACTIONS TEST CONDITIONS

A1: CHECK ALL SPEED SETTINGS OF THE BLOWER MOTOR

1 Ignition switch in position II

2 Switch the blower switch through all speedsettings

• Is the blower motor inoperative in all the switchpositions?

A2: CHECK FUSE F55

1 Ignition switch in position 0

2 CHECK Fuse F55 (standard relay box)

• Is the fuse OK?

A3: CHECK THE VOLTAGE AT FUSE F55

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3 Measure the voltage between fuse F55 andground

• Does the meter display battery voltage?

A4: CHECK VOLTAGE AT BLOWER MOTOR

2 Disconnect Connector CH123 from the blowermotor

4 Measure the voltage between the blower motor,connector CH123, pin 1, circuit CB155J

(YE/RD), wiring harness side and ground

of the system

- Vehicles with programmable fuel-firedbooster heater:

GO to A14

A5: CHECK GROUND CONNECTION OF BLOWER MOTOR

2 Set the blower switch to level 3

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3 Measure the resistance between the blowermotor, connector CH123, pin 2, circuit VH301B(YE/BU), wiring harness side and ground.

• Is a resistance of less than 2 Ohms registered?

A6: CHECK THE GROUND CONNECTION OF THE BLOWER SWITCH

1 Disconnect Connector CH101B from the blowerswitch

2 Measure the resistance between the blowerswitch, connector CH101B, pin 4, circuitGD115F (BK/RD), wiring harness side andground

A7: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN CIRCUIT

1 Measure the resistance between the blowermotor, connector CH123, pin 2, circuit VH301B(YE/BU), wiring harness side and the blowerswitch, connector CH101B, pin 2, circuitVH301A (YE/BU), wiring harness side

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A8: CHECK THE CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN CIRCUIT - LEVEL 3 INOPERATIVE

2 Disconnect Connector CH123 from the blowermotor

A9: MEASURE THE VOLTAGE AT THE BLOWER RESISTOR ASSEMBLY

2 Disconnect Connector CH403 from the blowerresistor assembly

4 Measure the resistance between the blowerresistor assembly, connector CH403, pin 1,circuit VH301C (YE/BU), wiring harness sideand ground

A10: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - LEVEL 1

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2 Set the blower switch to level 1.

3 Measure the resistance between the blowerresistor assembly, connector CH403, pin 2,circuit CH427C (BN), wiring harness side andground

A12: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - LEVEL 2

2 Measure the resistance between the blowerresistor assembly, connector CH403, pin 4,circuit CH428A (GN/WH), wiring harness sideand ground

→ Yes

INSTALL a new heater blower series resistor

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A13: CHECK THE CIRCUIT BETWEEN THE BLOWER RESISTOR ASSEMBLY AND THE BLOWER SWITCH FOR OPEN CIRCUIT - LEVEL 2

2 Measure the resistance between the blowerresistor assembly, connector CH403, pin 4,circuit CH428A (GN/WH), wiring harness sideand the blower switch, connector CH101B, pin

1, circuit CH428A (GN/WH), wiring harness side

A14: CHECK THE BLOWER MOTOR CIRCUIT

2 DisconnectBlower relay for the programmablefuel-fired booster heater from socket CH402A

3 Use a fused test cable (5 A) to bridge the blowerrelay of the programmable fuel-fired boosterheater, socket CH402A, between pin 4, circuitCB155G (BN/BU), wiring harness side and pin

1, circuit CB155F (BN/BU), wiring harness side

VFE0013150

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5 Measure the voltage between the blower motor,connector CH123, pin 1, circuit CB155A(BN/BU), wiring harness side and ground.

1 Measure the voltage between the blower relay

of the programmable fuel-fired booster heater,socket CH402A, pin 4, circuit CB154G (VT/OG)(vehicles without air conditioning: circuitCB154C (VT/OG)), wiring harness side andground

→ Yes

LOCATE and REPAIR the break in the circuitbetween the blower relay for the program-mable fuel-fired booster heater and the blowermotor with the aid of the Wiring Diagrams.CHECK the operation of the system

→ No

GO to A16

A16: CHECK THE CIRCUIT BETWEEN THE BLOWER RELAY OF THE PROGRAMMABLE FIRED BOOSTER HEATER AND THE PROGRAMMABLE FUEL-FIRED BOOSTER HEATER RELAY FOR OPEN CIRCUIT

FUEL-1 Ignition switch in position 0

2 Disconnect Relay R16

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3 Measure the resistance between the blowerrelay of the programmable fuel-fired boosterheater, socket CH402A, pin 4, circuit CB154G(VT/OG) (vehicles without air conditioning:circuit CB154C (VT/OG)), wiring harness sideand the programmable fuel-fired booster heaterrelay, pin 5, circuit CB154A (VT/OG), wiringharness side

→ Yes

CHECK and if necessary RENEW the fired booster heater relay CHECK the opera-tion of the system

fuel-→ No

LOCATE and REPAIR the break in the circuitbetween the blower relay for the program-mable fuel-fired booster heater and theprogrammable fuel-fired booster heater relayusing the Wiring Diagrams CHECK the oper-ation of the system

A17: CHECK THE VOLTAGE AT THE BLOWER RELAY OF THE PROGRAMMABLE FUEL-FIRED BOOSTER HEATER

1 Measure the voltage between the blower relay

of the programmable fuel-fired booster heater,socket CH402A, pin 3, circuit CB150P (YE/OG)(vehicles without air conditioning: circuitCB155G (BN/BU)), wiring harness side andground

connection S2B150B (vehicles without airconditioning: soldered connection S2B155)using the Wiring Diagrams CHECK the oper-ation of the system

A18: CHECK THE GROUND CONNECTION OF THE BLOWER RELAY FOR THE PROGRAMMABLE FUEL-FIRED BOOSTER HEATER

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2 Measure the resistance between the blowerrelay of the programmable fuel-fired boosterheater, socket CH402A, pin 2, circuit GD115P(BK/GY) (vehicles without air conditioning: circuitGD115D (BK/GY)), wiring harness side andground.

→ Yes

RENEW the blower relay for the mable fuel-fired booster heater CHECK theoperation of the system

program-→ No

LOCATE and RECTIFY the break in circuitGD115P (BK/RD) (vehicles without air condi-tioning: circuit GD115D (BK/GY)) between theblower relay for the programmable fuel-firedbooster heater and ground connection GP15with the aid of the Wiring Diagrams CHECKthe operation of the system

A19: CHECK GROUND CONNECTION OF BLOWER MOTOR

2 Measure the resistance between the blowermotor, connector CH123, pin 2, circuit VH301B(YE/BU), wiring harness side and ground

A20: CHECK BLOWER SWITCH

3 Set the blower switch to position 3

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4 Measure the resistance at the blower switch,connector CH101B, between pin 2 and pin 4,component side

oper-A21: CHECK BLOWER SWITCH

4 Measure the resistance at the blower switch,connector CH426B, between pin 2 and pin 4,component side

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A25: CHECK THE CIRCUIT BETWEEN THE BLOWER SWITCH AND THE AIR CONDITIONING BLOWER RELAY FOR OPEN CIRCUIT

1 Disconnect A/C blower relay from socketCH402B

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2 Measure the resistance between the blowerswitch, connector CH426B, pin 4, circuitGD115A (BK/GY), wiring harness side and theA/C blower relay, socket CH402B, pin 5, circuitGD115A (BK/GY), wiring harness side

A26: CHECK THE CIRCUIT BETWEEN THE BLOWER SWITCH AND THE AIR CONDITIONING

BLOWER RELAY FOR OPEN CIRCUIT

2 Measure the resistance between the blowerswitch, connector CH101B, pin 4, circuitGD115A (BK/GY), wiring harness side and theA/C blower relay, socket CH402B, pin 4, circuitGD115B (BK/GY), wiring harness side

A27: CHECK THE GROUND CONNECTION OF THE A/C BLOWER RELAY

1 Measure the resistance between the A/C blowerrelay, socket CH405B, pin 1, circuit GD115R(BK/RD), wiring harness side and ground

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1 Measure the resistance between the A/C blowerrelay, socket CH405B, pin 1, circuit GD115U(BK/RD), wiring harness side and ground

1 Measure the resistance between the A/C blowerrelay, socket CH402B, pin 2, circuit GD115Q(BK/RD), wiring harness side and ground

S2D115C with the aid of the Wiring Diagrams

CHECK the operation of the system

1 Measure the resistance between the A/C blowerrelay, socket CH402B, pin 2, circuit GD115Q(BK/RD), wiring harness side and ground

S2D115C with the aid of the Wiring Diagrams

A31: CHECK THE VOLTAGE AT THE AIR CONDITIONING BLOWER RELAY - PIN 1

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2 Measure the voltage between the A/C blowerrelay, socket CH402B, pin 1, circuit CB154E(VT/OG), wiring harness side and ground

A32: CHECK THE VOLTAGE AT THE AIR CONDITIONING BLOWER RELAY - PIN 1

2 Measure the voltage between the A/C blowerrelay, socket CH402B, pin 3, circuit CB155E(YE/RD), wiring harness side and ground

PINPOINT TEST B : ADDITIONAL BLOWER MOTOR FAULTY / INOPERATIVE

B1: CHECK ALL SPEED SETTINGS OF THE ADDITIONAL BLOWER MOTOR

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2 Switch the additional blower motor switchthrough all settings.

• Is the additional blower motor inoperative inall the switch positions?

→ Yes

GO to B2

→ No

- The additional blower motor is inoperative

in switch position 1, 2 and/or 3:

2 CHECK Fuse F57 (standard relay box)

• Is the fuse OK?

opera-B3: CHECK THE VOLTAGE AT FUSE F57

1 Connect Fuse F57 (standard relay box)

3 Measure the voltage between fuse F57 andground

B4: CHECK THE VOLTAGE AT THE ADDITIONAL BLOWER MOTOR

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4 Measure the voltage between the additionalblower motor, connector CH123R, pin 1, circuitCB157D (BN/GN), wiring harness side andground

B5: CHECK THE GROUND CONNECTION OF THE ADDITIONAL BLOWER MOTOR

2 Set the additional blower switch to position 4

3 Measure the resistance between the additionalblower motor, connector CH123R, pin 2, circuitCHA08A (GN/OG), wiring harness side andground

B6: CHECK THE GROUND CONNECTION OF THE ADDITIONAL BLOWER SWITCH

1 Disconnect Connector CHA05A from the tional blower switch

addi-2 Measure the resistance between the additionalblower switch, connector CHA05A, pin 1, circuitGD149H (BK/GY), wiring harness side andground

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B7: CHECK THE CIRCUIT BETWEEN THE ADDITIONAL BLOWER MOTOR AND THE ADDITIONAL BLOWER SWITCH FOR OPEN CIRCUIT

1 Measure the resistance between the additionalblower motor, connector CH123R, pin 2, circuitCHA08A (GN/OG), wiring harness side and theadditional blower switch, connector CHA05A,pin 6, circuit CHA08F (GN/OG), wiring harnessside

of the system

B8: CHECK THE CIRCUIT BETWEEN THE ADDITIONAL BLOWER MOTOR AND THE ADDITIONAL BLOWER SWITCH FOR OPEN CIRCUIT - LEVEL 4 INOPERATIVE

2 Disconnect Connector CH123R from the tional blower motor

addi-3 Disconnect Connector CHA05A from the tional blower switch

addi-4 Measure the resistance between the additionalblower motor, connector CH123R, pin 2, circuitCHA08A (GN/OG), wiring harness side and theadditional blower switch, connector CHA05A,pin 6, circuit CHA08F (GN/OG), wiring harnessside

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2 Disconnect Connector CHA04 from the additionalblower resistor

4 Measure the voltage between the additionalblower resistor, connector CHA04, pin 4, circuitCHA08B (GN/OG), wiring harness side andground

of the system

B10: CHECK THE GROUND CONNECTION OF THE ADDITIONAL BLOWER RESISTOR - LEVEL 1

2 Set the additional blower switch to level 1

3 Measure the resistance between the additionalblower resistor, connector CHA04, pin 3, circuitCHA06D (YE/VT), wiring harness side andground

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addi-2 Measure the resistance between the additionalblower switch, connector CHA05A, pin 2, circuitCHA06A (YE/VT), wiring harness side and theadditional blower resistor, connector CHA04,pin 3, circuit CHA06D (YE/VT), wiring harnessside.

2 Measure the resistance between the additionalblower resistor, connector CHA04, pin 1, circuitZA345A (OG/GY), wiring harness side andground

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addi-DETAILS/RESULTS/ACTIONS TEST CONDITIONS

2 Measure the resistance between the additionalblower switch, connector CHA05A, pin 3, circuitZA345D (OG/GY), wiring harness side and theadditional blower resistor, connector CHA04,pin 1, circuit ZA345A (OG/GY), wiring harnessside

2 Measure the resistance between the additionalblower resistor, connector CHA04, pin 2, circuitCHA07D (BU/GY), wiring harness side andground

→ Yes

E69702

RENEW the additional blower resistor

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addi-2 Measure the resistance between the additionalblower switch, connector CHA05A, pin 5, circuitCHA07A (BU/GY), wiring harness side and theadditional blower resistor, connector CHA04,pin 2, circuit CHA07D (BU/GY), wiring harnessside.

PINPOINT TEST C : AIR CONDITIONING INOPERATIVE - BLOWER FUNCTION OK

C1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

1 Ignition switch in position III

2 Run the engine at idle speed

3 Switch on the air-conditioning system

• Does the A/C clutch work, and is the A/Cindicator lamp on?

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opera-C3: CHECK THE VOLTAGE AT FUSE F36

1 Connect Fuse F36 (BJB)

3 Measure the voltage between fuse F36 (10 A)and ground

RENEW fuse F29 (5 A) CHECK the operation

of the system If the fuse blows again,LOCATE and REPAIR the short using theWiring Diagrams

C5: CHECK THE VOLTAGE AT FUSE F29

1 Connect Fuse F29 (BJB)

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3 Measure the voltage between fuse F29 (5 A)and ground.

C6: CHECK THE CONTROL VOLTAGE AT THE A/C CLUTCH RELAY

2 Disconnect A/C clutch relay from socket C1010

4 Measure the voltage between the A/C clutchrelay, socket C1010, pin 1, circuit CBB29A(WH/VT), wiring harness side and ground

C7: CHECK THE VOLTAGE AT THE A/C CLUTCH RELAY

1 Measure the voltage between the A/C clutchrelay, socket C1010, pin 3, circuit CBB36A(BU/BN), wiring harness side and ground

C8: CHECK THE CIRCUIT OF THE A/C CLUTCH

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2 Using a fused test cable ((10 A), bridge betweenthe relay of the A/C clutch, socket C1010, pin

3, circuit CBB36A (BU/BN), wiring harness sideand pin 5, circuit CH109A (WH/OG), wiringharness side

• Does the air conditioning clutch work?

→ Yes

GO to C11

→ No

GO to C9

C9: CHECK THE VOLTAGE AT THE A/C CLUTCH

2 Disconnect Connector CH302 from the A/Cclutch

3 Using a fused test cable ((10 A), bridge betweenthe relay of the A/C clutch, socket C1010, pin

3, circuit CBB36A (BU/BN), wiring harness sideand pin 5, circuit CH109A (WH/OG), wiringharness side

5 Measure the voltage between the A/C clutch,connector CH302, pin 1, circuit CH109D(WH/OG) (vehicles with a diesel engine: circuitCH109B (WH/OG)), wiring harness side andground

C10: CHECK THE GROUND CONNECTION OF THE A/C CLUTCH

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2 Measure the resistance between the A/C clutch,connector CH302, pin 2, circuit GD122Q (BK)(vehicles with a diesel engine: circuit GD122G(BK)), wiring harness side and ground.

C11: CHECK AIR CONDITIONING CLUTCH RELAY

1 Check the A/C clutch relay according to thecomponent test at the end of this section

• Is the air conditioning clutch relay OK?

→ Yes

GO to C12

→ No

RENEW the air conditioning clutch relay

C12: CHECK THE VOLTAGE AT THE REFRIGERANT HIGH PRESSURE SWITCH

2 Disconnect Connector CH433 from the gerant high pressure switch

refri-3 Ignition switch in position II

5 Measure the voltage at the refrigerant highpressure switch, between connector CH433, pin

4, circuit CH421A (GY), wiring harness side andground

→ Yes

GO to C13

→ No

GO to C18

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C13: CHECK THE A/C HIGH PRESSURE SWITCH

NOTE:Make sure that the refrigerant pressure is in the range between 3.0 and 10.5 bar (temperature

dependent) If the pressure is higher, perform a refrigerant circuit Quick Check If the pressure is lower,

check the refrigerant circuit for leaks

2 Measure the resistance at the refrigerant highpressure switch, connector CH433, between pin

1 and pin 4, component side

RENEW the refrigerant high pressure switch

C14: CHECK THE CIRCUIT BETWEEN THE POWERTRAIN CONTROL MODULE (PCM) AND THE

REFRIGERANT HIGH PRESSURE SWITCH FOR OPEN CIRCUIT - VEHICLES WITH A DIESEL

ENGINE

1 Disconnect Connector CE104B from the PCM

2 Measure the resistance between the PCM,connector CE104B, pin F2, circuit CH423A (YE),wiring harness side and the refrigerant highpressure switch, connector CH433, pin 1, circuitCH423A (YE), wiring harness side

of the Wiring Diagrams CHECK the operation

of the system

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C15: CHECK THE CIRCUIT BETWEEN THE POWERTRAIN CONTROL MODULE (PCM) AND THE A/C CLUTCH RELAY FOR OPEN CIRCUIT - VEHICLES WITH A DIESEL ENGINE

1 Measure the resistance between the PCM,connector CE104B, pin B2, circuit CH401A(VT/WH), wiring harness side and the A/C clutchrelay, socket C1010, pin 2, circuit CH401A(VT/WH), wiring harness side

Diagrams CHECK the operation of thesystem

C16: CHECK THE CIRCUIT BETWEEN THE POWERTRAIN CONTROL MODULE (PCM) AND THE REFRIGERANT HIGH PRESSURE SWITCH FOR OPEN CIRCUIT - ALL VEHICLES EXCEPT VEHICLES WITH A DIESEL ENGINE

1 Disconnect Connector CE512B from the PCM

2 Measure the resistance between the PCM,connector CE512B, pin F2, circuit CH423A (YE),wiring harness side and the refrigerant highpressure switch, connector CH433, pin 1, circuitCH423A (YE), wiring harness side

of the system

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C17: CHECK THE CIRCUIT BETWEEN THE POWERTRAIN CONTROL MODULE (PCM) AND THE A/C CLUTCH RELAY FOR OPEN CIRCUIT - ALL VEHICLES EXCEPT VEHICLES WITH A DIESEL ENGINE

1 Measure the resistance between the PCM,connector CE512B, pin B2, circuit CH401A(VT/WH), wiring harness side and the A/C clutchrelay, socket C1010, pin 2, circuit CH401A(VT/WH), wiring harness side

Diagrams CHECK the operation of thesystem

C18: CHECK THE VOLTAGE AT THE REFRIGERANT LOW PRESSURE SWITCH

2 Disconnect Connector CH421 from the gerant low pressure switch

refri-3 Ignition switch in position II

5 Measure the voltage between the refrigerantlow pressure switch, connector CH421, pin 1,circuit CH422A (VT), wiring harness side andground

→ Yes

GO to C19

→ No

GO to C20

C19: CHECK REFRIGERANT LOW PRESSURE SWITCH

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2 Measure the resistance at the refrigerant lowpressure switch, connector CH421, between pin

1 and pin 4, component side

→ Yes

LOCATE and RECTIFY the break in circuitCH421A (GY) between the refrigerant lowpressure switch and the refrigerant highpressure switch with the aid of the WiringDiagrams CHECK the operation of thesystem

2 Disconnect Connector CH101C from the A/Ccontrol assembly

3 Measure the resistance between the A/C controlassembly, connector CH101C, pin 4, circuitCH422F (VT), wiring harness side and therefrigerant low pressure switch, connectorCH421, pin 1, circuit CH422A (VT), wiringharness side

C21: CHECK THE FUNCTION OF THE DEFROST SWITCH

1 Set the air distribution to defrost

• Does the A/C clutch work, and is the A/Cindicator lamp on?

→ Yes

C24

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C22: CHECK FUSE F50

2 CHECKFuse F50 (standard relay box)

• Is the fuse OK?

opera-C23: CHECK THE VOLTAGE AT FUSE F50

1 Connect Fuse F50 (standard relay box)

3 Measure the voltage between fuse F50 (10 A)and ground

C24: CHECK THE VOLTAGE AT THE AIR CONDITIONING CONTROL PANEL

2 Disconnect Connector C101C from the A/Ccontrol assembly

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4 Measure the voltage between the A/C controlassembly, connector C101C, pin 3, circuitCB150N (YE/OG), wiring harness side andground.

PINPOINT TEST D : REFRIGERANT COMPRESSOR INOPERATIVE IN "DEFROST" AIR

DISTRIBUTION SETTING (FUNCTION OF AIR CONDITIONING OK)

NOTE:Before carrying out the check, make sure that the ambient temperature is above 4°C.

D1: MEASURE THE VOLTAGE AT THE DEFROST SWITCH

2 Disconnect Connector CH227 from the defrostswitch

4 Measure the voltage between the defrost switch,connector CH227, pin 2, circuit CB150M(YE/OG), wiring harness side and ground

D2: CHECK THE CIRCUIT BETWEEN THE DEFROST SWITCH AND THE REFRIGERANT LOW PRESSURE SWITCH FOR OPEN CIRCUIT

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3 Measure the resistance between the defrostswitch, connector CH227, pin 1, circuit CH422E(VT), wiring harness side and the refrigerant lowpressure switch, connector CH421, pin 1, circuitCH422A (VT), wiring harness side

→ Yes

TEST the mechanical actuation of the defrostswitch and REPAIR if necessary If themechanical actuation is OK, RENEW thedefrost switch CHECK the operation of thesystem

→ No

LOCATE and REPAIR the break in circuitCH422E (VT) between the defrost switch andsoldered connection S2H422 with the aid ofthe Wiring Diagrams CHECK the operation

of the system

PINPOINT TEST E : BLOWER DOES NOT RUN AUTOMATICALLY WHEN THE AIR CONDITIONING

IS SWITCHED ON - VEHICLES WITH AIR CONDITIONING

E1: CHECK THE VOLTAGE AT THE AIR CONDITIONING BLOWER RELAY (PIN 3)

5 Measure the voltage between the A/C blowerrelay, socket CH402B, pin 3, circuit CH427D(BN), wiring harness side and ground

of the system

E2: CHECK THE VOLTAGE AT THE AIR CONDITIONING BLOWER RELAY (PIN 1)

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2 Measure the voltage between the A/C blowerrelay, socket CH402B, pin 1, circuit CH422G(VT), wiring harness side and ground.

of the system

E3: CHECK THE GROUND CONNECTION OF THE A/C BLOWER RELAY (PIN 5)

2 Measure the resistance between the air tioning blower relay, socket CH402B, pin 5,circuit GD115H (BK/GY), wiring harness sideand ground

condi-• Is a resistance of less than 2 Ohms registered?

E4: CHECK THE GROUND CONNECTION OF THE A/C BLOWER RELAY (PIN 2)

1 Measure the resistance between the A/C blowerrelay, socket CH402B, pin 2, circuit GD115G(BK/GY), wiring harness side and ground

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PINPOINT TEST F : TEMPERATURE CONTROL INOPERATIVE - VEHICLES WITH AIR CONDITIONING (FUNCTION OF THE AIR CONDITIONING OK)

NOTE:Before carrying out the check, make sure that the air distribution flap is mechanically OK F1: CHECK THE VOLTAGE AT THE TEMPERATURE CONTROL FLAP ACTUATOR

2 Disconnect Connector CH232 from the ature control flap actuator

temper-3 Ignition switch in position II

4 Measure the voltage between the temperaturecontrol flap actuator, connector CH232, pin 7,circuit CB150J (YE/OG), wiring harness sideand ground

F2: CHECK THE GROUND CONNECTION OF THE TEMPERATURE CONTROL FLAP ACTUATOR

2 Measure the resistance between the ature control flap actuator, connector CH232,pin 8, circuit GD115D (BK/GY), wiring harnessside and ground

temper-• Is a resistance of less than 2 Ohms registered?

F3: CHECK THE CIRCUITS BETWEEN THE TEMPERATURE CONTROL FLAP ACTUATOR AND THE A/C CONTROL ASSEMBLY FOR OPEN CIRCUIT

1 Disconnect Connector CH101D from the A/Ccontrol assembly

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2 Measure the resistance between the ature control flap actuator, connector CH232,pin 4, circuit ZA337A (OG/GY), wiring harnessside and the A/C control assembly, connectorCH101D, pin 3, circuit ZA337A (OG/GY), wiringharness side.

temper-VFE0034302

3 Measure the resistance between the ature control flap actuator, connector CH232,pin 3, circuit ZA338A (OG/WH), wiring harnessside and the A/C control assembly, connectorCH101D, pin 2, circuit ZA338A (OG/WH), wiringharness side

temper-VFE0034301

4 Measure the resistance between the ature control flap actuator, connector CH232,pin 6, circuit ZA339A (OG/BN), wiring harnessside and the A/C control assembly, connectorCH101D, pin 1, circuit ZA339A (OG/BN), wiringharness side

temper-• Is a resistance of less than 2 Ohms measured

in all of the cases?

→ Yes

poten-tiometer CHECK the operation of the system

If the system is still inoperative, RENEW thetemperature control flap actuator

→ No

LOCATE and REPAIR the break in therelevant circuit between the temperaturecontrol flap actuator and the A/C controlassembly with the aid of the Wiring Diagrams.CHECK the operation of the system

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