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Ford F-150 2001 Climate Control System Workshop Manual

Climate control system
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2001 F-150 Workshop Manual
SECTION 412-00: Climate Control System - General Information
DIAGNOSIS AND TESTING
Climate Control System
Refer to Wiring Diagrams Cell 54, Air Conditioner/Heater for schematic and connector information.
Special Tool(s)
Alternator, Regulator, Battery and Starter Tester (ARBST)
010-00735 or equivalent
Worldwide Diagnostic System (WDS)
418-F224,
New Generation STAR (NGS) Tester
418-F052, or equivalent scan tool
Fluke 77 III Automotive Meter
105-R0056 or equivalent
R-134a Manifold Gauge Set
176-R032A or equivalent
Connector, Refrigerant Pressure Line
412-093 (T94P-19623-E)
Set, A/C Fittings
412-DS028 (014-00333, D93L-19703-B) or equivalent
Refrigerant Leak Detector
216-00001 or equivalent
Pressure Test Kit
014-R1072 or equivalent
Breakout Box, EEC V Control System
418-049 (014-00950, T94L-50-EEC-V)
Vacuum Schematic—Manual A/C
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS11/~MUS~LEN/18/...
31
2001 F-150 Workshop Manual
Procedure revision date: 08/05/2002
12/14/2010

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Summary of Contents for Ford F-150 2001 Climate Control System

  • Page 1 2001 F-150 Workshop Manual SECTION 412-00: Climate Control System - General Information 2001 F-150 Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 08/05/2002 Climate Control System Refer to Wiring Diagrams Cell 54, Air Conditioner/Heater for schematic and connector information. Special Tool(s) Alternator, Regulator, Battery and Starter Tester (ARBST) 010-00735 or equivalent Worldwide Diagnostic System (WDS)
  • Page 2 2001 F-150 Workshop Manual Item Part Number Description 18A318 Vacuum control motor, panel/defrost door 18A478 Panel/defrost door (full vacuum position) — Defrost airflow — Side window demister airflow 18B545 Temperature blend door (full heat position) 19860 A/C evaporator core 19A813 Air inlet duct door (full vacuum position) —...

  • Page 3: Symptom Chart

    2001 F-150 Workshop Manual Yellow Floor/panel door Black Vacuum source — Not used Blue Floor/panel door Panel/defrost door VACUUM APPLICATION CHART—MANUAL A/C Function Selector Switch Position Switch Port Color Function MAX A/C A/C PNL/ VENT OFF FLR/ PNL FLOOR FLR/ DEF DEF White Recirc/fresh Yellow Floor/panel Black Vacuum source...
  • Page 4 2001 F-150 Workshop Manual Insufficient, erratic, or no heat Low engine coolant level. GO to Pinpoint Test Engine overheating. Plugged or partially plugged heater core. Temperature blend door binding/stuck. A/C electronic blend door actuator. The A/C does not operate/does not operate correctly Fuse.
  • Page 5 2001 F-150 Workshop Manual Is the hose connected? GO to A3. RECONNECT the hose. TEST the system for normal operation. A3 LEAK CHECK THE VACUUM SUPPLY HOSE Vacuum Supply Hose Plug one end of the hose and connect the vacuum pump to the other end. Apply vacuum and observe the gauge reading.
  • Page 6 2001 F-150 Workshop Manual Inspect the A/C vacuum check valve for an obstruction and/or correct operation. Airflow through the A/C vacuum check valve should be in the direction toward the engine (engine connection site is marked "VAC"). Is the A/C vacuum check valve plugged or obstructed? INSTALL a new A/C vacuum check valve.
  • Page 7 2001 F-150 Workshop Manual Does the function selector switch supply hose leak? REPAIR or INSTALL a new function selector switch supply hose. TEST the system for normal operation. RECONNECT the function selector switch supply hose. GO to A9 CHECK THE CONTROL ASSEMBLY Inline Vacuum Harness Connect a vacuum tester to the black hose and plug the other hoses.
  • Page 8 2001 F-150 Workshop Manual Does the vacuum drop exceed 1.68 kPa (1/2 in-Hg) per minute? INSTALL a new function selector switch. TEST the system for normal operation. RECONNECT the function selector switch vacuum connector. GO to A11 CHECK THE SUPPLY HOSE FOR OBSTRUCTIONS A/C Damper Door Switch Supply Hose Connect a vacuum pump to the supply hose and try to apply vacuum.
  • Page 9 2001 F-150 Workshop Manual GO to A14. A14 CHECK THE VACUUM HOSES TO DAMPER DOORS Connect a vacuum pump to each hose and try to pull a vacuum. If the vacuum pump can pull a vacuum, the hose is plugged. If the vacuum pump pulls a partial vacuum, the hose is restricted. Is a hose plugged or restricted? INSTALL a new vacuum hose.
  • Page 10 2001 F-150 Workshop Manual Does the vacuum hose leak? REPAIR or INSTALL a new hose. TEST the system for normal operation. GO to A19. A19 CHECK THE VACUUM CONTROL MOTOR Vacuum Control Motor Check the vacuum control motor for leaks with a vacuum pump. Does the vacuum control motor hold a vacuum? GO to A20.
  • Page 11 2001 F-150 Workshop Manual Is the engine coolant at the correct level (hot/cold) as indicated on the engine coolant recovery reservoir? GO to B2. GO to B3. B2 CHECK FOR HOT WATER TO THE HEATER CORE INLET HOSE WARNING: The heater core inlet hose will become too hot to handle and may cause serious burns if the system is working correctly. NOTE: Be sure that the inlet hose flow restrictor is in place and is undamaged.
  • Page 12 2001 F-150 Workshop Manual Is the heater core outlet hose cool or cold? TEST the heater core for a plugged or partially plugged condition. GO to Pinpoint Test PINPOINT TEST C: THE A/C DOES NOT OPERATE OR DOES NOT OPERATE CORRECTLY CONDITIONS DETAILS/RESULTS/ACTIONS C1 CHECK THE PID ACCS WITH THE A/C OFF...
  • Page 13 2001 F-150 Workshop Manual PCM PID WAC Does the PCM PID WAC read ON? GO to C13. REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. C5 CHECK THE A/C CYCLING SWITCH VOLTAGE A/C Cycling Switch C139 Measure the voltage between the A/C cycling switch C139 pin 1, circuit 441 (RD/YE) and ground. Is the voltage greater than 10 volts? GO to C6.
  • Page 14 2001 F-150 Workshop Manual Is the pressure reading between 345 kPa (50 psi) and 1724 kPa (250 psi)? INSTALL a new A/C cycling switch. TEST the system for normal operation. CHECK for refrigerant leaks. REFER to Electronic Leak Detection Tracer Dye Leak Detection in this section.
  • Page 15 2001 F-150 Workshop Manual C10 CHECK THE A/C PRESSURE CUTOFF SWITCH Connect a fused jumper lead between the A/C pressure cutoff switch C170 pin 1, circuit 441 (RD/YE) and pin 3, circuit 348 (VT). Measure the voltage between the A/C cycling switch C139 pin 1, circuit 441 (RD/YE) and ground. Is the voltage reading greater than 10 volts? INSTALL a new A/C pressure cutoff switch.
  • Page 16 2001 F-150 Workshop Manual Is the voltage greater than 10 volts? INSTALL a new function selector switch. TEST the system for normal operation. REPAIR circuit 295 (LB/PK). TEST the system for normal operation. C13 CHECK THE VOLTAGE AT THE A/C COMPRESSOR CLUTCH FIELD COIL A/C Compressor Clutch Field Coil C106 Measure the voltage between the A/C compressor clutch field coil C106, circuit 321 (GY/WH) and ground.
  • Page 17 2001 F-150 Workshop Manual A/C Clutch Relay Measure the resistance between the A/C clutch relay socket pin 5, circuit 321 (GY/WH) and the A/C compressor clutch field coil C106, circuit 321 (GY/WH). Is the resistance less than 5 ohms? GO to C16. REPAIR Circuit 321(GY/WH).
  • Page 18 2001 F-150 Workshop Manual PCM C174 Connect the EEC-V 104-Pin Breakout Box to the PCM C174. Do not connect the breakout box to the PCM. Measure the resistance between the A/C clutch relay socket pin 2, circuit 331 (PK/YE) and the breakout box pin Is the resistance less than 5 ohms? INSTALL a new PCM.
  • Page 19 2001 F-150 Workshop Manual Fuse 5 (15A) Is the fuse OK? GO to D4. REPLACE Fuse 5 (15A). TEST the system for normal operation. If the fuse opens again, GO to D3 CHECK CIRCUIT 295 (LB/PK) FOR A SHORT TO GROUND A/C Electronic Blend Door Actuator Motor C229 Function Selector Switch C217 Fuse Junction Panel C242...
  • Page 20 2001 F-150 Workshop Manual REPAIR Circuit 295 (LB/PK). TEST the system for normal operation. D5 CHECK CIRCUITS 436 (R/LG), 437 (Y/LG) AND 438 (R/W) Blend Door Actuator Control C220 Measure the resistance between the following pins: Blend Door Actuator Control C220 A/C Electronic Blend Door Actuator Motor C229 Circuit Pin 3 Pin 4...
  • Page 21 2001 F-150 Workshop Manual E1 CHECK FUSE 22 (10A) Fuse 22 (10A) Is the fuse OK? GO to E3. GO to E2. E2 CHECK CIRCUIT 181 (BR/O) FOR A SHORT TO GROUND A/C Blower Motor Relay Function Selector Switch C217 Measure the resistance between function selector switch C217-1, Circuit 181 (BR/O), and ground.
  • Page 22 2001 F-150 Workshop Manual Is the resistance greater than 10,000 ohms in all function selector switch positions except OFF? INSTALL a new A/C blower motor. TEST the system for normal operation. GO to E5. E5 CHECK CIRCUIT 399 (BR/Y) FOR A SHORT TO GROUND A/C Blower Motor Relay Measure the resistance between the A/C blower motor C190-2, Circuit 399 (BR/Y), and ground.
  • Page 23 2001 F-150 Workshop Manual Measure the voltage between A/C blower motor C190-2, Circuit 399 (BR/Y), and ground while selecting each mode on the function selector switch. Is the voltage greater than 10 volts in all function selector switch positions except OFF? GO to E8.
  • Page 24 2001 F-150 Workshop Manual normal operation. REPAIR Circuit 261 (O/BK) for an open. TEST the system for normal operation. E10 CHECK CIRCUIT 364 (BK/LG) FOR AN OPEN A/C Blower Motor Relay Measure the voltage between A/C blower motor relay connector Pin 87, Circuit 364 (BK/LG) and ground. Is the voltage 10 volts or greater? GO to E11.
  • Page 25 2001 F-150 Workshop Manual Is the voltage 10 volts or greater? GO to E13. REPAIR Circuit 296 (W/P) for an open. TEST the system for normal operation. E13 CHECK CIRCUIT 181 (BR/O) Measure the resistance between function selector switch C217-1, Circuit 181 (BR/O), and A/C blower motor relay connector Pin 86, Circuit 181 (BR/O).
  • Page 26 2001 F-150 Workshop Manual Is the resistance less than 5 ohms? INSTALL a new A/C blower motor relay (19E703). TEST the system for normal operation. REPAIR Circuit 399 (BR/Y) for an open. TEST the system for normal operation. PINPOINT TEST F: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY CONDITIONS DETAILS/RESULTS/ACTIONS F1 CHECK THE A/C BLOWER MOTOR OPERATION...
  • Page 27 2001 F-150 Workshop Manual REPAIR Circuit 57 (BK). TEST the system for normal operation. F4 CHECK THE CIRCUIT RESISTANCE A/C Blower Motor Resistor A/C Blower Motor Measure the resistance between A/C blower motor resistor C191-2, Circuit 261 (O/BK), and the A/C blower motor C190-1, Circuit 261 (O/BK).
  • Page 28 2001 F-150 Workshop Manual INSTALL a new blower motor switch. TEST the system for normal operation. PINPOINT TEST G: NO OPERATION IN HIGH BLOWER SETTING CONDITIONS DETAILS/RESULTS/ACTIONS G1 CHECK THE A/C BLOWER MOTOR OPERATION Turn the function selector switch to the FLOOR position and the blower motor switch to the position next to the HI position.
  • Page 29 2001 F-150 Workshop Manual Check to ensure the connector is correctly and securely connected to the blower motor switch. Is the connector correctly attached to the blower motor switch? INSTALL a new blower motor switch. RETEST the system for normal operation. RECONNECT and CHECK the A/C blower motor operation.
  • Page 30 2001 F-150 Workshop Manual 1. Remove the heater core from the vehicle. For additional information, refer to Section 412-02. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the Radiator/Heater Core Pressure Tester to the adapter. 4.
  • Page 31 2001 F-150 Workshop Manual http://www.fordtechservice.dealerconnection.com/pubs/content/~WS11/~MUS~LEN/18/... 12/14/2010...