Content .. 73 74 75 76 ..

Ford Ranger EV (2001 year). Manual - part 75

412-02-5

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

Electrical Schematic

•

DTC B2516 Blower Control Circuit Failure

Refer to Electrical and Vacuum Troubleshooting

— The interface adapter assembly (IAA) module

Manual, Cell 53, Heater or Cell 54, Air

provides the pulse width modulation (PWM)

Conditioner/Heater for schematic and connector

control signal to the variable blower controller

information.

(VBC) and monitors the VBC feedback. The
IAA module sets DTC B2516 if the blower

Inspection and Verification

motor relay is closed, the VBC control PWM

Refer to

Section 100-07

is greater than 80% duty cycle for more than
30 seconds, and the VBC feedback is greater
than the auxiliary battery voltage minus 2
volts.

Symptom Chart

Condition

Possible Sources

Action

•

DTC B1238 Over

•

Positive temperature

•

GO to

Pinpoint Test A.

Temperature Fault

coefficient (PTC) heater

overtemperature switch

harness assembly.

•

Circuit(s).

•

Interface adapter assembly

(IAA) module.

•

PTC switching module.

•

DTC B1249 Blend Door

•

Blend door actuator.

•

GO to

Pinpoint Test B.

Failure

•

Circuit(s).

•

Interface adapter assembly

(IAA) module.

•

DTC B1250 Air Temperature

•

Interface adapter assembly

•

GO to

Pinpoint Test C.

Internal Sensor Circuit Failure

(IAA) module.

•

Circuit(s).

•

In-car temperature sensor.

•

In-car temperature sensor

hose and elbow.

•

DTC B1254 Air Temperature

•

Ambient temperature sensor.

•

GO to

Pinpoint Test D.

External Sensor Circuit

•

Circuit(s).

Failure

•

Interface adapter assembly

(IAA) module.

•

DTC C1776 Heater System

•

Positive temperature

•

GO to

Pinpoint Test E.

Failure

coefficient (PTC) heater core.

•

Circuit(s).

•

PTC switching module.

•

Interface adapter assembly

(IAA) module.

•

High-voltage power

distribution box (HVPDB).

•

High-voltage PTC HTR fuse.

•

DTC C1779 Blower Switch

•

Circuit(s).

•

GO to

Pinpoint Test F.

Failure

•

Interface adapter assembly

(IAA) module.

•

Blower switch.

412-02-6

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

DTC C1780 Temperature

•

Circuit(s).

•

GO to

Pinpoint Test G.

Select Failure

•

Interface adapter assembly

(IAA) module.

•

Temperature control

potentiometer.

•

DTC B1857 Climate Control

•

Interface adapter assembly

•

GO to

Pinpoint Test H.

On/Off Switch Failure

(IAA) module.

•

A/C inverter motor controller

(IMC).

•

Circuit(s).

•

Mode select switch.

•

Recirculation vacuum

pressure sensor.

•

Blower (Fan) Runs With

•

Shorted Variable Blower

•

GO to

Pinpoint Test H.

Mode Select Switch in OFF

Controller (VBC)

Position

•

Interface Adapter Assembly

(IAA).

•

Circuit(s).

•

Recirculation vacuum

pressure sensor.

•

DTC U2015 Signal Link

•

Positive temperature

•

GO to

Pinpoint Test J.

Fault (Non SCP)

coefficient (PTC) module.

•

Circuit(s).

•

Interface adapter assembly

(IAA) module.

•

PTC heater core.

•

DTC B2513 Blower (Fan)

•

Circuit(s).

•

GO to

Pinpoint Test K.

Circuit Failure

•

Variable blower controller

(VBC).

•

Blower motor relay.

•

Blower motor.

•

Interface adapter assembly

(IAA) module.

•

DTC B2514 Blower (Fan)

•

Blower motor relay.

•

GO to

Pinpoint Test L.

Circuit Short to Vbat

•

Circuit(s).

•

Interface adapter assembly

(IAA) module.

•

DTC B2515 Heater Blower

•

Variable blower controller

•

GO to

Pinpoint Test M.

Relay Circuit Failure

(VBC).

•

Circuit(s).

•

Interface adapter assembly

(IAA) module.

•

DTC B2516 Blower Control

•

Circuit(s).

•

GO to

Pinpoint Test N.

Circuit Failure

•

Variable blower controller

(VBC).

•

Interface adapter assembly

(IAA) module.

•

No Heat/Insufficient Heat

•

Interface adapter assembly

•

GO to

Pinpoint Test P.

(IAA) module.

•

Circuit(s).

•

Positive temperature

coefficient (PTC) switching

module.

412-02-7

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

Vacuum Pump Cycles On and

•

Vacuum line(s)/connection(s).

•

GO to

Pinpoint Test Q.

Off Without Brake Pedal

•

Climate control vacuum

Activation (Climate Control

reservoir.

Vacuum System Leak

•

Vacuum jumper harness.

Test)/Incorrect Airflow

•

Heater plenum vacuum line

Through Climate Control

assembly.

Outlets

•

Mode select switch.

•

Vacuum line routing.

•

Vacuum motor(s).

•

Recirculation Function Does

•

Fresh/recirculation door

•

GO to

Pinpoint Test R.

Not Operate

vacuum motor

actuator/linkage.

•

Vacuum line.

•

Circuit(s).

•

Interface adapter assembly

(IAA) module.

•

Fresh/recirculation door

vacuum motor.

•

Fresh/recirculation select

switch.

•

Blower (Fan) Runs With

•

Incorrect climate control

•

REMOVE climate control

Mode Select Switch in OFF

assembly installed.

assembly and INSTALL

Position

correct one.

•

Pre-Heat Function Does Not

•

Positive temperature

•

GO to

Pinpoint Test E.

Operate (Postal Ranger EV

coefficient (PTC) heater core.

only) with DTC C1776.

•

Circuit(s).

•

PTC switching module.

•

Interface adapter assembly

(IAA).

•

HVPDB.

•

High-Voltage PTC HTR fuse.

•

Pre-Heat Function Does Not

•

Bulb prove out.

•

GO to

Pinpoint Test S.

Operate (Postal Ranger EV

•

Incorrect conditions.

only) without DTC C1776.

Special Tool(s)

Pinpoint Tests

Vacuum Tester 014-R1054 or equivalent

Special Tool(s)

High-Voltage Insulated Safety Gloves 100-F036 or

104-Pin Breakout Box (BOB) 418-049 (014-00950) or

equivalent

Face Shield 100-F035 or equivalent

Dial Thermometer 023-R0007 or equivalent

(Continued)

PINPOINT TEST A: DTC B1238 OVER TEMPERATURE FAULT

TEST STEP

ACTION TO TAKE

A1 CHECK POSITIVE TEMPERATURE COEFFICIENT (PTC)

HEATER OVERTEMPERATURE SWITCH STATUS

•

With key ON, monitor interface adapter assembly (IAA) module PID

Yes =

GO to A7.

HTR OT.

•

Disconnect PTC switching module C1999.

No =

GO to A2.

•

Does the HTR OT PID indicate YES?

A2 CHECK PTC HEATER OVERTEMPERATURE SWITCH

(Continued)

412-02-8

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC B1238 OVER TEMPERATURE FAULT

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect in-line C2999 and measure the resistance

Yes =

GO to A3.

between the Y/W wire and GY/W wire on C2999M.

•

Is the resistance less than 5 ohms?

No =

REPLACE the PTC heater

overtemperature switch

harness assembly.

A3 CHECK GROUND REFERENCE TO PTC HEATER

OVERTEMPERATURE SWITCH

•

With key OFF, measure the resistance between the Y/W wire on C2999F Yes =

GO to A5.

and ground.

•

Is the resistance less than 5 ohms?

No =

GO to A4.

A4 CHECK CIRCUIT 3036 (Y/W) FOR OPEN

•

Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =

REPLACE the IAA module.

module disconnected.

REFER to

Section 412-04

•

With key OFF, measure the resistance of the Y/W wire between BOB

No =

REPAIR the Y/W wire.

pin 74 and C2999F.

•

Is the resistance less than 5 ohms?

A5 CHECK CIRCUIT 3037 (GY/W) FOR OPEN

•

With key OFF, disconnect PTC switching module C1999 and measure

Yes =

GO to A6.

the resistance of the GY/W wire between pin 3 on PTC switching

module C1999 and C2999F.

•

Is the resistance less than 5 ohms?

No =

REPAIR the GY/W wire.

A6 CHECK CIRCUITS 3036 (Y/W) AND 3037 (GY/W) FOR SHORT(S)

TO POWER

•

With key OFF, disconnect IAA module C1945.

Yes =

REPAIR the wire(s) in

question.

•

With key ON, measure the voltage between pin 2 (Y/W wire), pin 3

No =

REPLACE the PTC

(GY/W wire) on PTC switching module C1999 and ground.

switching module.

•

Are any of the voltages greater than 0 volts?

A7 CHECK CIRCUIT 3834 (LG) FOR SHORT TO GROUND

•

With key OFF, disconnect IAA module C1945 and measure the

Yes =

REPLACE the IAA module.

resistance between pin 6 (LG wire) on PTC switching module C1999 and

REFER to

Section 412-04

ground.

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the LG wire.

PINPOINT TEST B: DTC B1249 BLEND DOOR FAILURE

TEST STEP

ACTION TO TAKE

B1 CHECK BLEND DOOR ACTUATOR FEEDBACK

•

Enter interface adapter assembly (IAA) module active command mode

Yes =

System OK. CHECK wiring

CONTINUOUS BLEND DOOR MOVEMENT, monitor the IAA module

for intermittent connections.

PID BLENDDR, and set the active command CONT to 10%, 50%, and

90%.

•

Is the BLENDDR PID within 3% of the active command settings?

No =

GO to B2.

B2 CHECK DRIVE VOLTAGE TO BLEND DOOR ACTUATOR

MOTOR

•

With key OFF, disconnect blend door actuator C240 and connect a

Yes =

REPLACE the blend door

voltmeter between pin 7 (BR/LG wire) and pin 8 (P wire) on blend door

actuator.

actuator C240.

•

Enter the IAA module active command mode CONTINUOUS BLEND

No =

GO to B3.

DOOR MOVEMENT and set the active command CONT to 90%.

•

Does the voltage fluctuate between 0 and

12 volts and then stabilize

at greater than 9 volts?

(Continued)

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