Ford Falcon. Manual - part 303

412-02-16 Heating 

and 

Ventilation 412-02-16

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

F1

VISUAL INSPECTION - FLOOR / CONSOLE DOOR

OPERATION

Check for door movement to Floor while pushing the ICC Button.

Yes

Check for air delivery from floor with blower operating at full speed.

System OK
Clear DTC

 NOTE:

It is usual for airflow from rear console while Floor / Heating

Perform HVAC On-Demand Self Test. Refer to

is selected.

Section 412-04.

Is the Floor mode selectable?

No

Go to F2

F2

VISUAL INSPECTION - HIM LEVER TO HVAC CAM

Remove the Glove Box. Refer to Section 501-12.

Yes

Refer to Section 412-04, Go to PinPoint Test F.

Using a mirror and a torch view the lever area between the HIM and
the HVAC to see if the HIM YELLOW lever pin is slotted into the

No

HVAC cam.

Remove the instrument panel. Refer to Section
501-12.

Was the HIM lever pin slotted into the HVAC cam?

Remove and Install the HIM ensuring that HIM
levers and HVAC cams are connected. Refer to
removal and installation instructions in this
chapter.

PINPOINT TEST G : ACTUATOR — PASSENGER AIR TEMPERATURE MIX (ACC / MCC /HTR)

 CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to

your Hand from moving parts such as blower motor, levers, etc.
NOTE: This actuator is utilized to control air temperature to both passenger and driver by the single zone (SZ)

manual climate control system. It is used to control only the passenger side air temperature for dual zone (DZ)

automatic climate control system. H (High) and L (Low) settings are not possible via the passenger

temperature rocker switch on ACC system.

NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING

Test Step

Result / Action to Take

G1

VISUAL INSPECTION - PASSENGER AIR MIX DOOR

OPERATION

Check for full door movement to full Hot and full Cold while operating

Yes

the ICC button. (For MCC, set dial control to Hot then Cold. For ACC,

System OK

select H then L by drivers temperature setting rocker switch.)

Clear DTC
Perform HVAC On-Demand Self Test. Refer to

Does the passenger air mix door move to full Hot and full Cold

Section 412-04.

positions?

No

Go to G2

G2

VISUAL INSPECTION - HIM TO TEMP DOOR SHAFT

Remove the Glove Box. Refer to Section 501-12.

Yes

Go to Section 412-04, pinpoint test E.

Using a mirror and a torch view the lever area between the HIM and
the HVAC to see if the HIM is connected to the temperature door

No

shaft.

Remove the instrument panel. Refer to Section
501-12.

Was the HIM connected to the temperature door shaft?

Remove and Install the HIM ensuring that
temperature door shaft coupling is connected to
the HIM. Refer to removal and installation
instructions in this chapter.

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412-02-17 Heating 

and 

Ventilation 412-02-17

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H : ACTUATOR — DRIVER AIR TEMPERATURE MIX (ACC)

 CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to

your Hand from moving parts such as blower motor, levers, etc.
NOTE: This actuator is utilized to control air temperature to the driver side only for dual zone (DZ) automatic

climate control system.

NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING

Test Step

Result / Action to Take

H1

VISUAL INSPECTION - DRIVER AIR MIX DOOR

OPERATION

Check for full door movement to full Cold and full Hot while operating

Yes

the ICC button. (Select C then H by the Drivers temperature setting

System OK

rocker switch.)

Clear DTC
Perform HVAC On-Demand Self Test. Refer to

Feel the face outlet temperature change temperature from Cold to Hot Section 412-04.

using your hand.

No

Does the driver temperature change from Cold to Hot?

Go to H2

H2

VISUAL INSPECTION - DRIVERS SIDE ACTUATOR TO

SHAFT

From under the Drivers side, view the Driver’s actuator shaft in

Yes

between the airmix actuator and the HVAC, for movement while

Go to H3

changing the temperature from Hot to Cold using the ICC button.

No

Did the shaft turn when Hot to Cold selected?

Refer to Section 412-04, Go to PinPoint Test G.

H3

VISUAL INSPECTION - DRIVERS SIDE SHAFT

MOVEMENT

Set the ICC to face mode.

Yes

Broken shaft, replace the HVAC Door Module.

Remove the ICC. Refer to Section 413-08.

Refer to removal and installation instructions in
this chapter.

Insert your hand through the ICC opening and try turning the
temperature door shaft.

No

Does the shaft turn?

Refer to Section 412-04, Go to PinPoint Test G.

PINPOINT TEST I : INTAKE AIR FILTER RESTRICTION (ACC / MCC / HTR)

 CAUTION: Do not use "Hot" water to clean the standard mesh Filter. Do not use any water to

clean the optional pollen filter.
NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING

Test Step

Result / Action to Take

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412-02-18 Heating 

and 

Ventilation 412-02-18

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

I1

AIR INTAKE INSPECTION

Remove the Glove Box. Refer to Section 501-12.

Yes

Standard mesh filter - using Compressed air,

Remove the Intake Air Filter, refer to section 412-01.

"blow" any contamination from the mesh Filter.
Rinse the mesh Filter under Luke warm water.

Was there Debris, Dust or Insects obstructing airflow through the

Optional Pollen Filter. If heavily contaminated -

Intake Air Filter?

Replace Filter. If mildly contaminated, use
compressed air to "blow" out any contamination.
NOTE: Cleaning rather than replacing the
optional pollen filter may degrade the air quality
and airflow quantity.

No

Air Intake Filter not the cause of the airflow
restriction.

PINPOINT TEST J : HIM LEVER TO FLOOR/CONSOLE DOOR ROD INSPECTION (ACC / MCC / HTR)

 CAUTION: Do not alter the mode position, with your hand on the rod otherwise your hand could

become jammed and cause skin damage.
NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING

Test Step

Result / Action to Take

J1

VEHICLE SETUP

Remove the Glove box. Refer to Section 501-12.

Yes

Ensure that the plastic rod retainer clip is in

Start Engine.

place at the Floor door lever end. Then refer to
chapter Section 412-04, Go to PinPoint Test F.

At the ICC select Face Mode.

Locate and follow the Rod with your hand from the HIM all the way to

No

the Floor door lever.

Reconnect rod into the Floor door lever and
secure with the retaining clip.

Is the rod connected to the Floor door lever?

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412-02-19 Heating 

and 

Ventilation 412-02-19

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST K : PASSENGER SIDE TEMPERATURE WARMER THAN THE DRIVERS SIDE (ACC /

MCC)

 CAUTION: Take all the standard safety procedures when dealing with A/C system refrigerant,

including Eye protection and Gloves.
NOTE: If the A/C suction (low side) pressure is lower than specification because of a low refrigerant charge,

the refrigerant "super heat" increases and cooling in the evaporator may be irregular, causing the passenger

side temperature to "feel’ warmer.

NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING

Test Step

Result / Action to Take

K1

VERIFICATION - VEHICLE SET-UP

Start Engine.

Yes

Go to K2

Run vehicle at operating temperature.

No

Set ICC to full Cold (Low, L) Passenger / Driver side (ACC) or Full

HVAC System Temperature "split" is to

Cold (MCC).

specification. System Okay.

Select Fresh air intake mode.

Put bonnet up.

Ensure A/C compressor is engaged (Refer 412-03).

ACC - Select manual override - Face mode.

MCC - Select Face mode.

Select the highest blower fan speed.

Insert a thermometer into the Face vent, drivers side. Allow the
temperature reading to stabilise (stay at one constant temperature)
Take a reading.

Quickly insert the thermometer into the passenger side Face vent and
allow to stabilise. Take a reading.

Is the difference in temperature between the Passenger side and
Drivers side greater than 10 Degrees?

K2

REFRIGERANT PRESSURE LOW

Connect A/C Manifold Gauge set (High & low side pressure gauges)

Yes

as per section 412-03. Conduct A/C System Performance test for low

Perform HVAC On - Demand Self Test refer to

A/C pressures as per section 412-03.

section 412-04. Go to PinPoint Test B.

Were the A/C system pressure readings to specification?

No

Refer to section 412-03. Conduct an A/C
System Leak test for possible refrigerant
leakage. Discharge, repair as required, evacuate
and recharge the A/C system.

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