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Ford F-150 1999 Workshop Manual

Climate control system
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See also: Owner's Manual
1999 F-150/250 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)
010-00725 or equivalent
New Generation Star (NGS) Tester
418-F048 (007-00500) or equivalent
R-134a Manifold Gauge Set
176-R032A or equivalent
A/C Pressure Test Adapter
412-093 (T94P-19623-E)
R-12/R-134a Air Conditioning Test Fitting Set
412-DS028 (014-00333) or equivalent
Refrigeant Leak Detector
216-00001 or equivalent
Radiator/Heater Core Pressure Tester
014-R1072 or equivalent
EEC-V 104-Pin Breakout Box
418-049 (014-00950) or equivalent
Vacuum Schematic—Manual A/C
http://www.fordtechservice.dealerconnection.com/pubs/con...
Page 1 of 30
1999 F-150/250 Workshop Manual
Procedure revision date: 07/02/2002
8/16/2010

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  • Page 1 1999 F-150/250 Workshop Manual Page 1 of 30 SECTION 412-00: Climate Control System - General Information 1999 F-150/250 Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 07/02/2002 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) 010-00725 or equivalent...
  • Page 2 1999 F-150/250 Workshop Manual Page 2 of 30 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 1999 F-150/250 Workshop Manual Page 3 of 30 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 1999 F-150/250 Workshop Manual Page 4 of 30 No operation in all the temperature settings Temperature blend door actuator control. GO to Pinpoint Test Temperature blend door. A/C electronic blend door actuator motor. Circuitry open/shorted. The blower motor does not operate Fuse.
  • Page 5 1999 F-150/250 Workshop Manual Page 5 of 30 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 1999 F-150/250 Workshop Manual Page 6 of 30 A/C Vacuum Check Valve Connect the A/C vacuum check valve to a vacuum pump with two hoses and a tee fitting. Apply 51 kPa (15 in-Hg) vacuum on the A/C vacuum check valve and observe the gauge reading. If the vacuum loss exceeds 3.37 kPa (1 in-Hg) per minute, remove the A/C vacuum check valve from the pump and plug the vacuum hoses.
  • Page 7 1999 F-150/250 Workshop Manual Page 7 of 30 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. At each function selector switch position, apply 51 kPa (15 in-Hg) of vacuum and check for a vacuum drop. Does the vacuum drop exceed 3.37 kPa (1 in-Hg) per minute? NOTE the function selector switch position where the vacuum drops.
  • Page 8 1999 F-150/250 Workshop Manual Page 8 of 30 A/C Damper Door Switch Supply Hose Connect a vacuum pump to the supply hose and try to apply vacuum. If the vacuum pump can pull vacuum, the hose is plugged. If the vacuum pump pulls partial vacuum, the hose is restricted. Is the hose plugged or restricted? REPLACE the supply hose.
  • Page 9 1999 F-150/250 Workshop Manual Page 9 of 30 GO to A15. A15 CHECK THE VACUUM HARNESS Compare the vacuum hose color in each vacuum harness to the vacuum schematic. Does the hose color agree with the schematics? GO to A16. REPLACE the vacuum harness.
  • Page 10 1999 F-150/250 Workshop Manual Page 10 of 30 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. REPLACE the vacuum control motor. TEST the system for normal operation. A20 CHECK THE VACUUM CONTROL MOTOR INSTALLATION Check the attachment of the vacuum control motor arm to the damper door.
  • Page 11 1999 F-150/250 Workshop Manual Page 11 of 30 Feel the heater core inlet hose. Is the heater core inlet hose too hot to handle? GO to B4. GO to Section 303-03A. B3 CHECK THE ENGINE COOLING SYSTEM INCLUDING RADIATOR CAP FOR LEAKS Fill the engine cooling system to specified level.
  • Page 12 1999 F-150/250 Workshop Manual Page 12 of 30 Does the PCM PID ACCS read ON? REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. GO to C2. C2 CHECK THE PID WAC WITH THE A/C OFF PCM PID WAC Does the PCM PID WAC read ON? REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
  • Page 13 1999 F-150/250 Workshop Manual Page 13 of 30 GO to C6. GO to C9. C6 CHECK THE A/C CYCLING SWITCH NOTE: The outside temperature must be over 10° C (50° F). Connect a fused jumper lead between the A/C cycling switch C139 pin 1, circuit 441 (RD/YE) and pin 4, circuit 347 (BK/YE).
  • Page 14 1999 F-150/250 Workshop Manual Page 14 of 30 Is the voltage greater than 10 volts? INSTALL a new PCM. REFER to Section 303-14. TEST the system for normal operation. REPAIR Circuit 347 (BK/YE). TEST the system for normal operation. C9 CHECK THE A/C PRESSURE CUTOFF SWITCH VOLTAGE A/C Pressure Cutoff Switch C170 Measure the voltage between the A/C pressure cutoff switch C170 pin 3, circuit 348 (VT) and ground.
  • Page 15 1999 F-150/250 Workshop Manual Page 15 of 30 Is the resistance reading greater than 10,000 ohms? INSTALL a new A/C pressure cutoff switch. TEST the system for normal operation. REPAIR Circuit 441 (RD/YE). TEST the system for normal operation. C11 CHECK CIRCUIT 348 (VT) Function Selector Switch C217 Measure the resistance between the A/C pressure cutoff switch C170 pin 3, circuit 348 (VT) and the function selector switch C217 pin 2, circuit 348 (VT).
  • Page 16 1999 F-150/250 Workshop Manual Page 16 of 30 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. Is the voltage reading greater than 10 volts? GO to C14. GO to C15.
  • Page 17 1999 F-150/250 Workshop Manual Page 17 of 30 C16 CHECK CIRCUIT 883 (PK/LB) Measure the voltage between the A/C clutch relay socket pin 3, circuit 883 (PK/LB) and ground. Is the voltage greater than 10 volts? GO to C17. REPAIR circuit 883 (PK/LB). TEST the system for normal operation. C17 CHECK WAC OUTPUT FROM THE PCM Measure the resistance between the A/C clutch relay socket pin 2, circuit 331 (PK/YE) and ground.
  • Page 18 1999 F-150/250 Workshop Manual Page 18 of 30 REPAIR circuit 331 (PK/YE). TEST the system for normal operation. C19 CHECK THE A/C COMPRESSOR CLUTCH GAP Measure the A/C compressor clutch gap at three equally spaced locations between the clutch hub and the A/C compressor clutch pulley.
  • Page 19 1999 F-150/250 Workshop Manual Page 19 of 30 Fuse Junction Panel C242 Measure the resistance between fuse junction panel C242-15, Circuit 295 (LB/PK), and ground. Is the resistance greater than 10,000 ohms? REPLACE the fuse junction panel. TEST the system for normal operation. REPAIR Circuit 295 (LB/PK).
  • Page 20 1999 F-150/250 Workshop Manual Page 20 of 30 Are the resistances less than 5 ohms? GO to D6. REPAIR the circuit(s) in question. TEST the system for normal operation. D6 CHECK THE A/C CONTROL POTENTIOMETER Measure the resistance between the blend door actuator control terminal 2 Circuit 437 (Y/LG) and terminal 3 Circuit 436 (R/LG).
  • Page 21 1999 F-150/250 Workshop Manual Page 21 of 30 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. Is the resistance greater than 10,000 ohms? REPAIR Circuit 296 (W/P) for a short.
  • Page 22 1999 F-150/250 Workshop Manual Page 22 of 30 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. Is the resistance greater than 10,000 ohms? GO to E6.
  • Page 23 1999 F-150/250 Workshop Manual Page 23 of 30 GO to E10. E8 CHECK THE BLOWER MOTOR GROUND Turn the blower motor switch to the HI position. Measure the resistance between the A/C blower motor C190-1, Circuit 261 (O/BK) and ground. Is the resistance less than 10 ohms? REPLACE the A/C blower motor.
  • Page 24 1999 F-150/250 Workshop Manual Page 24 of 30 Is the voltage 10 volts or greater? GO to E11. REPAIR Circuit 364 (BK/LG) for an open. TEST the system for normal operation. E11 CHECK THE VOLTAGE TO THE A/C BLOWER MOTOR RELAY Measure the voltage between A/C blower motor relay connector Pin 86, Circuit 181 (BR/O), and ground while selecting each mode on the function selector switch.
  • Page 25 1999 F-150/250 Workshop Manual Page 25 of 30 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). Is the resistance less than 5 ohms? REPLACE the function selector switch. TEST the system for normal operation. REPAIR Circuit 181 (BR/O) for an open.
  • Page 26 1999 F-150/250 Workshop Manual Page 26 of 30 F1 CHECK THE A/C BLOWER MOTOR OPERATION Turn the function selector switch to the FLOOR position and the blower motor switch to the LO position. Does the A/C blower motor operate properly? GO to F5.
  • Page 27 1999 F-150/250 Workshop Manual Page 27 of 30 Is the resistance less than 5 ohms? REPLACE the A/C blower motor resistor. RETEST the system for normal operation. REPAIR Circuit 261 (O/BK). TEST the system for normal operation. F5 CHECK THE BLOWER MOTOR SWITCH Turn the function selector switch to the FLOOR position and slowly rotate the blower motor switch from the LO position to the HI position and back several times.
  • Page 28 1999 F-150/250 Workshop Manual Page 28 of 30 GO to G4. G2 CHECK THE A/C BLOWER MOTOR SPEED Turn the function selector switch to the FLOOR position and the blower motor switch to the HI position. Does the A/C blower motor operate? CYCLE the blower motor switch from HI to LO several times.
  • Page 29 1999 F-150/250 Workshop Manual Page 29 of 30 follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core.
  • Page 30 1999 F-150/250 Workshop Manual Page 30 of 30 1. Discharge and recover the refrigerant. For additional information, refer to Discharging and Recovery. 2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier (19C836) attached to the core tubes. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.

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F-250 1999

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