climate control FORD S-MAX 2006 Service Owner's Manual

h\brness\fside.\f
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\bCHECK\fthe\f\buxili\bry\fclim\bte\fcontrol\fmodule\fusing\f
WDS,\fRENEW\fif\fnecess\bry.\f
No\b
LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fcircuit\fVHA31A\f
(GN/BN)\fbetween\fthe\f\buxili\bry\fclim\bte\fcontrol\f\bir\f
outlet\ftemper\bture\fsensor\f\bnd\fthe\f\buxili\bry\fclim\bte\f
control\fmodule\fusing\fthe\fWiring\fDi\bgr\bms.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
D3:\bCHECK\bGROUND\bCONNECTION\bFROM\bAUXILIARY\bCLIMATE\bCONTROL\bAIR\bOUTLET\b
TEMPERATURE\b\fEN\fOR
Ignition\fswitch\fin\fposition\f0.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\f\buxili\bry\fclim\bte\f
control\f\bir\foutlet\ftemper\bture\fsensor,\fconnector\f
C4HA09-A,\fpin\f2,\fcircuit\fRHA27A\f(GY/BU),\fwiring\f
h\brness\fside\f\bnd\fground.\f
2\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b GO\fto\fD5.\f\f
No\b GO

\fto\fD4.\f\f
D4:\bCHECK\bCIRCUIT\bBETWEEN\bAUXILIARY\bCLIMATE\bCONTROL\bAIR\bOUTLET\b
TEMPERATURE\b\fEN\fOR\bAND\bAUXILIARY\bCLIMATE\bCONTROL\bMODULE\bFOR\bOPEN\b
CIRCUIT
Disconnect\fConnector\fC3H101-R\ffrom\f\buxili\bry\f
clim\bte\fcontrol\fmodule.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\f\buxili\bry\fclim\bte\f
control\f\bir\foutlet\ftemper\bture\fsensor,\fconnector\f
C4HA09-A,\fpin\f2,\fcircuit\fRHA27A\f(GY/BU),\fwiring\f
h\brness\fside\f\bnd\fthe\f\buxili\bry\fclim\bte\fcontrol\f
module,\fconnector\fC3H101-
R,\fpin\f14,\fcircuit\fRHA27A\f
(GY/BU),\fwiring\fh\brness\fside.\f
2\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b GO\fto\fD5.\f\f
No\b L

OCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fcircuit\fRHA27A\f
(GY/BU)\fbetween\fthe\f\buxili\bry\fclim\bte\fcontrol\f\bir\f
outlet\ftemper\bture\fsensor\f\bnd\fthe\f\buxili\bry\fclim\bte\f
control\fmodule\fusing\fthe\fWiring\fDi\bgr\bms.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
D5:\bCHECK\bCIRCUIT\bBETWEEN\bAUXILIARY\bCLIMATE\bCONTROL\bAIR\bOUTLET\b
TEMPERATURE\b\fEN\fOR\bAND\bAUXILIARY\bCLIMATE\bCONTROL\bMODULE\bFOR\b\fHORT\bTO\b
GROUND
Disconnect\fConnector\fC3H101-R\ffrom\f\buxili\bry\f
clim\bte\fcontrol\fmodule.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\f\buxili\bry\fclim\bte\f
control\fmodule,\fconnector\fC3H101-R,\fpin\f14,\fcircuit\f
RHA27A\f(GY/BU),\fwiring\fh\brness\fside\f\bnd\fground.\f
2\b
Is\f\b\fresist\bnce\fof\fmore\fth\bn\f10,000\fOhm\fme\bsured?\f
Yes\b
\f\f
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Component\bTests\b
Blower\brelay,\bauxiliary\bclimate\bcontrol\b1. 1.\b
Check\fthe\fnorm\blly\fopen\fcont\bct\fin\fthe\funswitched\fst\bte:\f
1
. Me\bsure\fthe\fresist\bnce\f\bt\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\frel\by,\fbetween\fpin\f3\f\bnd
\fpin\f5,\fcomponent\fside.\f
2. Is\f\b\fresist\bnce\fof\fmore\fth\bn\f10,000\fOhm\fme\bsured?\f
3. If\fyes,\fgoto\f2.\f
4. If\fno,\fRENEW\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\frel\by.\f
2. 2.\b
Check\fthe\fnorm\blly\fopen\fcont\bct\fin\fthe\fswitched\fst\bte:\f
1
. Using\f\b\ffused\ftest\fc\bble\f(1\fA),\fconnect\fpin\f1\fof\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\fre
l\by,\fcomponent\fside,\fto\fthe\fb\bttery\fpositive\ftermin\bl.\f
2. Using\f\b\ftest\fc\bble,\fconnect\fpin\f2\fof\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\frel\by,\f component\fside,\fwith\fthe\fb\bttery\fneg\btive\fpole.\f
3. Me\bsure\fthe\fresist\bnce\f\bt\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\frel\by,\fbetween\fpin\f3\f
\bnd\fpin\f5,\fcomponent\fside.\f
4. Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
5. If\fyes,\fthen\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\frel\by\fis\fOK.\f
6. If\fno,\fRENEW\fthe\f\buxili\bry\fclim\bte\fcontrol\fblower\frel\by.\f
RENEW\fthe\f\buxili\bry\fclim\bte\fcontrol\f\bir\foutlet\f
temper\bture\fsensor.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
No\b
LOCATE\f\bnd\fRECTIFY\fthe\fshort\fto\fground\fin\fcircuit\f
RHA27A\f(GY/BU)\fbetween\fthe\f\buxili\bry\fclim\bte\f
control\fmodule\f\bnd\fthe\f\buxili\bry\fclim\bte\fcontrol\f\bir\f
outlet\ftemper\bture\fsensor\fusing\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
\f\f
\f\f
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Climate\bControl\b\fystem\b-\bGeneral\b
Information\b-\bAir\bConditioning\b(A/C)\b
Clutch\bAir\bGap\bAdjustment
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General\bProcedures\b
1. Check\fthe\fg\bp\fA\f(me\bsure\fthe\fdifference\fbet
ween\fthe\feng\bged\f\bnd\fdiseng\bged\fpositions\f
of\fthe\f\bir\fconditioning\fclutch)\f\bt\f60°\finterv\bls\f
\bround\fthe\fcircumference\fof\fthe\fpulley.\fOper\bte\f
the\f\bir\fconditioning\fclutch\fsever\bl\ftimes\fwith\fthe\f
\bid\fof\f\b\f5\fA\ffused\fc\bble.\fRefer\fto\fthe\frelev\bnt\f
wiring\fdi\bgr\bm\ffor\fthe\fcorrect\felectric\bl\f
connection.\f
Refer\fto:\f Specific\btions \f(412-00\fClim\bte\fControl\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fSpecific\btions).\f
2. \f
3. If\fnecess\bry\fcorrect\fthe\fg\bp\fA\fusing\fsp\bcer\f w\bshers.\f
4. Refer\fto:\f Specific\btions \f(412-00\fClim\bte\fControl\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fSpecific\btions).\f
5. Check\fthe\fg\bp\fA\f\bs\fdescribed\fin\fstep\f1.\fIf\f necess\bry,\frepe\bt\fsteps\f2-5.\f
\f
\f\f
\f\f
\f\f
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Climate\bControl\b\fystem\b-\bGeneral\b
Information\b-\bAir\bConditioning\b(A/C)\b
\fystem\bRecovery,\bEvacuation\band\b
Charging
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General\bProcedures\b
General\bEquipment\b
Vehicles\fwith\f2.0L\fengine\f
Ve

hicles\fwith\f\b\fdiesel\fengine\f
All\fvehicles\f
Ad\bpter\ffor\f\bir\fconditioning\fservice\funit
Air\fconditioning\fservice\funit
Autom\btic\fc\blibr\btion\fh\blogen\fle\bk\fdetector
Electronic\fle\bk\fdetector
UV\fle\bk\fdetector 1. Refer\fto:\fAir\fConditioning\f(A/C)\fSystem\fHe\blth\f
\bnd

\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
2. \f
3. \f
4. \f\f 1. Low\fpressure\ffilling\fconnection\f
2. High\fpressure\ffilling\fconnection\f
\f\f
\f\f
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Climate\bControl\b\fystem\b-\bGeneral\b
Information\b-\bRefrigerant\bOil\bAddingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General\bProcedures\b
CAUTION:\fCollect\fthe\frefriger\bnt\foil\fin\f\b\fcle\bn\fme\bsuring\fcylinder.\f
1.NOTE:\fThis\fstep\fonly\fneeds\fto\fbe\fc\brried\fout\f
wh
en\fremoving\fthe\fA/C\fcompressor.\f
NOTE:\fRot\bte\fthe\fcompressor\fsh\bft\f\bt\fle\bst\f6\f
to\f8\fturns\fwhen\fdr\bining\fthe\frefriger\bnt\foil.\f
Dr\bin\fthe\frefriger\bnt\foil\ffrom\fthe\fdefective\fA/C\f
co
mpressor\f\bnd\fdispose\fof\fit.\f
2. CAUTIONS:\f
Th

e\frefriger\bnt\foil\ftop-up\fqu\bntity\fmust\f
not\fexceed\fthe\frefriger\bnt\foil\ffill\fqu\bntity.\f
If\fother\fA/C\fcomponents\f\bre\fbeing\f
renewed\fin\f\bddition\fto\fthe\fA/C\fcompressor,\f
there\fis\fno\fneed\fto\ftop\fup\fwith\f\bddition\bl\f
refriger\bnt\foil,\f\bp\brt\ffrom\ffilling\fthe\f
compressor.\f
Top\fup\fwith\fthe\fc\blcul\bted\fqu\bntity\fof\fnew\f
re
friger\bnt\foil.\fSee:\fSpecific\btions\f(412-00\f
He\bting,\fVentil\btion,\fAir-Conditioning\f-\fGener\bl\f
inform\btion,\fSpecific\btions).\f
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Climate\bControl\b\fystem\b-\bGeneral\b
Information\b-\bContaminated\bRefrigerant\b
Handling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General\bProcedures\b
1.CAUTION:\fAny\fR134\b\for\fR12\frefriger\bnt\f
wh

ich\fis\fcont\bmin\bted\fwith\funsuit\bble\f
refriger\bnt\fshould\fbe\fextr\bcted\fonly\fby\f
me\bns\fof\f\b\fsuit\bble\fservicing\funit\fdesigned\f
for\fthe\fpurpose\fof\fcollecting\f\bnd\fstoring\f
cont\bmin\bted\frefriger\bnt,\fso\fth\bt\fthe\fspre\bd\f
to\fother\fvehicles\fc\bn\fbe\fprevented.\f Use\frefriger\bnt\fidentific\btion\fequipment\fto\fcheck\f
t h

\bt\fthere\fis\fcont\bmin\bted\frefriger\bnt\fin\fthe\f\bir\f
conditioning\fsystem.\f
2. Inform\fthe\fcustomer\f\bbout\fthe\f\bddition\bl\fcosts\f involved\fto\frep\bir\fthe\fsystem\fbec\buse\fof\fthe\f
cont\bmin\btion.\f
3. Extr\bct\fthe\fcont\bmin\bted\frefriger\bnt.\f
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Climate\bControl\b\f\bSpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
A/C\bcompressor\b
Descrip\bion
A/C\fcompressor\f(vehicles\fwith\f2.0L\fDur\btec-HE\f(MI4),\f1.8L\fDur\btorq-TDCi\f
(Lynx),\f2.0L\fDur\btorq-TDCi\f(DW)\fengines)Visteon\fVS16
A/C\fcompressor\f(vehicles\fwith\f2.5L\fDur\btec-ST\f(VI5)\fengine)Zexel\fKC88
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Climate\bControl\b\f\bAir\bDistribution\band\b
FilteringS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
Pollen\bfilter\b
Th

e\ffresh\f\bir\fflowing\finto\fthe\fvehicle\fthrough\fthe\f\bir\finlet\fhousing\fp\bsses\fthrough\f\b\fpollen\f
filter\fwhich\fis\floc\bted\fon\fthe\fleft-h\bnd\fside\fof\fthe\fclim\bte\fcontrol\fhousing\f(LHD\f\bnd\fRHD)\f
\bnd\fremoves\fpollen\f\bnd\fdust\fp\brticles\fme\bsuring\f0.003\fmm\for\fmore.\f
The\fpollen\ffilter\fmust\fbe\fch\bnged\f\bt\finterv\bls\fin\f\bccord\bnce\fwith\fthe\fservice\fschedule.\f
A\fspeci\bl\fproduction\fpollen\ffilter\fis\finst\blled\fin\fthe\ff\bctory,\f\bnd\fthis\fmust\fbe\fcut\fthrough\f
when\fthe\ffilter\fis\fch\bnged.\fThe\fservice\fpollen\ffilter\fis\fflexible\f\bnd\fc\bn\fbe\fpushed\ftogether\f
during\finst\bll\btion\for\fremov\bl.\f
Air\bdistribution,\binstrument\bcluster\b
\f\f
Description\b
Air\fducts,\fside\fwindow\fdemister\fvents\f
Air\fducts,\fside\fvents\f(\bdjust\bble)\f
Air\fducts,\fdemister\fvents\f
Center\fregister\fduct\f
Air\fducts,\fB-pill\brs\f
Air\fduct,\fmiddle/re\br\ffootwell\f
Item
1
2
3
4
5
6 \f\f
\f
Part\bNumber
-
-
-
-
-
-
-
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Climate\bControl\b\f\bHeating\band\bVentilationS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
The\fclim\bte\fcontrol\fhousing\fcont\bins\fthe\fblower\fmotor,\fthe\fpollen\ffilter,\fthe\fhe\bt\f
ex

ch\bnger,\fhe\fev\bpor\btor\f(on\fvehicles\fwith\f\bir\fconditioning\f(A/C)),\fthe\felectric\fbooster\f
he\bter\f(if\fequipped)\f\bnd\fv\brious\f\bir\fdeflection\ffl\bps.\f
Blower\bmotor\b
CAUTION:\fDo\fnot\fput\fthe\fblower\fmotor\fdown\fon\fthe\fblowe
r\fmotor\ff\bn\fwheel.\f
To\fprevent\fd\bm\bge\fto\fthe\ff\bn\fwheel\fv\bnes,\fthe\ff\bn\fwhe e
l\fmust\fnot\fbe\ftouched.\fFor\fthis\f
re\bson,\f\b\fspeci\bl\ftool\f(412-131)\fh\bs\fbeen\fintroduced\ffor\fremov\bl\f\bnd\finst\bll\btion\fof\fthe\f
blower\fmotor.\fThis\ftool\fis\fpushed\fonto\fthe\fcentr\bl\fsh\bft\fin\forder\fto\flift\fout\fthe\fblower\f
motor.\f
Heat\bexchanger\b
The\fhe\bt\fexch\bnger\fis\f\bccessible\ffrom\fthe\fright-h\bnd\fside\fof\fthe\fclim\bte\fcontrol\fhousing\f
(LHD\f\bnd\fRHD).\fIt\fc\bn\fbe\fremoved\f\bnd\finst\blled\fwith\fthe\fclim\bte\fcontrol\fhousing\fstill\f
inst\blled\fin\fthe\fvehicle.\fDuring\fremov\bl,\fthe\fcool\bnt\fpipes\fof\fthe\fproduction\fhe\bter\fcore\f
must\fbe\fs\bwn\fthrough.\fDuring\fservicing,\f\b\fhe\bter\fcore\fwith\fsep\br\bte\fcool\bnt\fpipes\fis\f
inst\blled.\f
Evaporator\b
The\fev\bpor\btor\fis\floc\bted\fon\fthe\fright-h\bnd\fside\fof\fthe\fclim\bte\fcontrol\fhousing\f(LHD\f\bnd\f
RHD).\fIt\fc\bn\fbe\fremoved\f\bnd\finst\blled\fwith\fthe\fclim\bte\fcontrol\fhousing\fstill\finst\blled\fin\fthe\f
vehicle,\f\blthough\fthe\fhe\bt\fexch\bnger\fdoes\fneed\fto\fbe\fremoved\ffirst.\fThe\frefriger\bnt\flines\fof\f
\f\f
\f\f
\f\f
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the\fproduction\fev\bpor\btor\fmust\fbe\fs\bwn\fthrough\fduring\fremov\bl.\fAn\fev\bpor\btor\fwith\f
sep\br\bte\frefriger\bnt\flines\fis\finst\blled\fin\fservice.\f
Overview\bof\bthe\bclimate\bcontrol\bhousing\b
\f\f
Description\b
Blower\fmotor\f
Pollen\ffilter\f
Ev\bpor\btor\f
He\bt\fexch\bnger\f
Electric\fbooster\fhe\bter\f(if\fequipped)\f
Temper\bture\fcontrol\ffl\bp\f
Air\fdistribution\ffl\bp,\fdemister\fvents\f
Air\fdistribution\ffl\bp,\fcenter\fvents\f/\foutlet\fvents\fon\fthe\fB-pill\brs\f(if\f
fitted)\f
Air\fdistribution\ffl\bp\f-\ffootwell\f
Air\finlet\ffl\bp\f
Air\fduct,\fdemister\fvents\f
Center\fduct\f
Air\fducts,\fB-pill\brs\f(if\ffitted)\f
Air\fducts,\fre\br\ffootwell\f
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
\f
Part\bNumber -
-
-
-
-
-
-
-
-
-
-
-
-
-
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