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Ford Ranger EV (2001 year). Manual - part 78

412-02-17

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H: DTC B1857 CLIMATE CONTROL ON/OFF SWITCH FAILURE

TEST STEP

ACTION TO TAKE

H4 CARRY OUT ON-DEMAND SELF-TEST IN PANEL/FLOOR

MODE

•

With key ON, set the mode select knob to the PANEL/FLOOR position

Yes =

GO to H11.

and carry out the on-demand self-test for the IAA module.

•

Does DTC B1857 Climate Control On/Off Switch Failure occur?

No =

System OK. CHECK wiring

for intermittent connections.

H5 CHECK A/C PRESENT SIGNAL STATUS

•

With key ON, monitor IAA module PID AC PRST.

Yes =

GO to H8.

•

Does the AC PRST PID indicate YES?

No =

GO to H6.

H6 CHECK A/C PRESENT SIGNAL FROM A/C INVERTER MOTOR

CONTROLLER (IMC)

•

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 between BOB pin 93 and ground

No =

GO to H7.

(BOB pin 80).

•

Is the resistance less than 5 ohms?

H7 CHECK CIRCUIT 3024 (DB/LG) FOR OPEN

•

With key OFF, measure the resistance of the DB/LG wire between pin 3

Yes =

REPLACE the A/C IMC.

on A/C IMC C1947 and BOB pin 93.

REFER to

Section 412-03

•

Is the resistance less than 5 ohms?

No =

REPAIR the DB/LG wire.

H8 CHECK MODE SELECT SWITCH

•

With key OFF, disconnect mode select switch C234.

Yes =

GO to H9.

•

Measure the resistance between terminals 1 and 2 on the mode select

No =

REPLACE the mode select

switch with the mode select knob in the A/C and MAX A/C positions.

switch.

•

Are the resistances less than 5 ohms?

H9 CHECK GROUND TO MODE SELECT SWITCH

•

With key OFF, measure the resistance between pin 1 (BK wire) on mode Yes =

GO to H10.

select switch C234 and ground.

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

H10 CHECK CIRCUIT 3055 (BR/LG) FOR OPEN

•

Connect 104-Pin Breakout Box (BOB) to interface adapter assembly

Yes =

REPLACE the IAA module.

(IAA) module C1945; leave IAA module disconnected.

REFER to

Section 412-04

•

With key OFF, measure the resistance of the BR/LG wire between pin 2

No =

REPAIR the BR/LG wire.

on mode select switch C234 and BOB pin 59.

•

Is the resistance less than 5 ohms?

H11 CHECK RECIRCULATION VACUUM PRESSURE SENSOR

SIGNAL

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

Yes =

GO to H18.

module C1945.

•

With key ON, set the mode select knob to the OFF position and measure No =

If voltage is less than 0.25

the voltage between BOB pin 94 and ground.

volts, GO to H12.

•

Is the voltage between 0.25 and 3 volts?

If voltage is greater than 3

volts, GO to H16.

H12 CHECK RECIRCULATION VACUUM PRESSURE SENSOR

VOLTAGE REFERENCE

•

With key ON, measure the voltage between BOB pin 103 and ground

Yes =

GO to H14.

(BOB pin 80).

•

Is the voltage greater than 4.5 volts?

No =

GO to H13.

H13 CHECK CIRCUIT 3066 (O/Y) FOR SHORT TO GROUND

(Continued)

412-02-18

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H: DTC B1857 CLIMATE CONTROL ON/OFF SWITCH FAILURE

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect BOB from the IAA module; leave BOB

Yes =

REPLACE the IAA module.

connected to IAA module C1945.

REFER to

Section 412-04

•

With key OFF, disconnect recirculation vacuum pressure sensor C2993

No =

REPAIR the O/Y wire.

and measure the resistance between BOB pin 103 and ground (BOB pin

80).

•

Is the resistance greater than 10,000 ohms?

H14 CHECK CIRCUITS 3066 (O/Y) AND 3067 (LB/R) FOR OPEN(S)

•

With key OFF, disconnect recirculation vacuum pressure sensor C2993

Yes =

GO to H15.

and measure the resistance of the O/Y wire between recirculation vacuum

pressure sensor C2993 and BOB pin 103.

•

With key OFF, measure the resistance of the LB/R wire between

No =

REPAIR the wire(s) in

recirculation vacuum pressure sensor C2993 and BOB pin 94.

question.

•

Are the resistances less than 5 ohms?

H15 CHECK CIRCUIT 3067 (LB/R) FOR SHORT TO GROUND

•

With key OFF, disconnect BOB from the IAA module; leave BOB

Yes =

REPLACE the recirculation

connected to IAA module C1945.

vacuum pressure sensor.

•

With key OFF, measure the resistance between BOB pin 94 and ground

No =

REPAIR the LB/R wire.

(BOB pin 80).

•

Is the resistance greater than 10,000 ohms?

H16 CHECK RECIRCULATION VACUUM PRESSURE SENSOR

GROUND REFERENCE

•

With key OFF, measure the resistance between BOB pin 90 and ground

Yes =

GO to H17.

(BOB pin 80).

•

Is the resistance less than 5 ohms?

No =

REPLACE the IAA module.

REFER to

Section 412-04

H17 CHECK CIRCUIT 3068 (BR/PK) FOR OPEN

•

With key OFF, disconnect BOB from the IAA module; leave BOB

Yes =

REPLACE the recirculation

connected to IAA module C1945.

vacuum pressure sensor.

•

With key OFF, disconnect recirculation vacuum pressure sensor C2993

No =

REPAIR the BR/PK wire.

and measure the resistance of the BR/PK wire recirculation vacuum

pressure sensor C2993 and BOB pin 90.

•

Is the resistance less than 5 ohms?

H18 CHECK MODE SELECT SWITCH

•

With key OFF, disconnect mode select switch C234.

Yes =

GO to H19.

•

Measure the resistance between terminals 3 and 4 on the mode select

No =

REPLACE the mode select

switch with the mode select knob in the PANEL, PANEL/FLOOR,

switch.

FLOOR, FLOOR/DEFROST, DEFROST, and A/C (if equipped)

positions.

•

Are the resistances less than 5 ohms?

H19 CHECK GROUND TO MODE SELECT SWITCH

•

With key OFF, measure the resistance between pin 4 (BK wire) on mode Yes =

GO to H20.

select switch C234 and ground.

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

H20 CHECK CIRCUIT 3056 (T/LG) FOR OPEN

•

With key OFF, measure the resistance of the T/LG wire between pin 3

Yes =

REPLACE the IAA module.

on mode select switch C234 and BOB pin 58.

REFER to

Section 412-04

•

Is the resistance less than 5 ohms?

No =

REPAIR the T/LG wire.

412-02-19

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST J: DTC U2015 SIGNAL LINK FAULT (NON SCP)

TEST STEP

ACTION TO TAKE

J1 CHECK HEATER CORE OVERTEMPERATURE STATUS

NOTE: Diagnostic trouble code (DTC) U2015 Signal Link Fault (Non Yes = GO to

Pinpoint Test A.

SCP) occurs with other vehicle faults. Do NOT proceed with the following

test steps unless the heating system is inoperative (no heat condition).

•

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

HTR OT.

•

Does the HTR OT PID indicate YES?

No =

GO to J2.

J2 CHECK SWITCHED POWER STATUS TO POSITIVE

TEMPERATURE COEFFICIENT (PTC) SWITCHING MODULE

NOTE: The HTR PWR PID may fluctuate between ENABLE and

Yes =

GO to J7.

DISABLE when the key is turned to the ON position. If this occurs, you

must wait 30 seconds for the final result.

•

With key ON, monitor IAA module PID HTR PWR for 30 seconds.

•

Does the HTR PWR PID indicate ENABLE?

No =

GO to J3.

J3 CHECK SWITCHED POWER TO PTC SWITCHING MODULE

•

With key OFF, disconnect PTC switching module C1999.

Yes =

REPLACE the PTC

switching module.

•

With key ON, measure the voltage between pin 1 (LG/O wire) and pin 2

No =

GO to J4.

(Y/W wire) on PTC switching module C1999.

•

Is the voltage greater than 10 volts?

J4 CHECK GROUND REFERENCE TO PTC SWITCHING MODULE

•

With key OFF, measure the resistance between pin 2 (Y/W wire) on

Yes =

GO to J6.

PTC switching module C1999 and ground.

•

Is the resistance less than 5 ohms?

No =

GO to J5.

J5 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 pin 2 on No =

REPAIR the Y/W wire.

PTC switching module C1999 and BOB pin 74.

•

Is the resistance less than 5 ohms?

J6 CHECK CIRCUIT 3035 (LG/O) 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 LG/O wire between pin 1

No =

REPAIR the LG/O wire.

on PTC switching module C1999 and BOB pin 37.

•

Is the resistance less than 5 ohms?

J7 CHECK STATUS OF PTC HEATER CORES

NOTE: Turn the key to the OFF position and clear continuous IAA

Yes =

GO to J8.

module diagnostic trouble codes (DTCs) before proceeding. If PIDs

CORE A and CORE B indicate RETRY and PIDs HTR CAR and

HTR CBR indicate YES after 45 seconds, wait approximately 4 minutes

for the results. If CORE A or CORE B does not indicate FAULT, cycle

the ignition key OFF/ON and repeat.

•

With key ON, set the mode select knob to the PANEL/FLOOR position

and the temperature control knob to the full warm position, and monitor

IAA module PIDs CORE A, CORE B, HTR CAR, HTR CBR, and

HTR SHT for 45 seconds.

NOTE: If CORE A and CORE B PIDs both indicate OFF and the

No =

GO to J10.

HTR SHT PID indicates YES, GO to J14.

•

Does the CORE A or the CORE B PID indicate FAULT?

(Continued)

412-02-20

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST J: DTC U2015 SIGNAL LINK FAULT (NON SCP)

TEST STEP

ACTION TO TAKE

J8 CHECK PTC HEATER CORES

•

Disconnect the 12-volt auxiliary battery negative cable.

Yes =

GO to J9.

•

Remove the high-voltage power distribution box (HVPDB) cover and

No =

REPLACE the PTC heater

disconnect PTC switching module high-voltage C1912 .

core.

•

If CORE A PID indicated FAULT, measure the resistance between the

DB wire and DG wire on PTC switching module C1912M.

•

If CORE B PID indicated FAULT, measure the resistance between the

R wire and W wire on PTC switching module C1912M.

•

Is the resistance between 65 and 140 ohms?

J9 INSPECT PTC HEATER CORES

•

Remove the PTC heater core and check for contaminants (excessive

Yes =

REPLACE the PTC

moisture and/or debris) on the heater core.

switching module.

•

Is the heater core clear of contaminants?

No =

REMOVE the contaminants.

If necessary, REPLACE the

PTC heater core.

J10 CHECK STATUS OF PTC POWER ON SELF-TEST (POST) LINE

TO PTC SWITCHING MODULE

•

With key OFF, disconnect PTC switching module C1999.

Yes =

GO to J12.

•

With key ON, measure the voltage between pin 6 (LG wire) on PTC

No =

GO to J11.

switching module C1999 and ground.

•

Is the voltage greater than 9.5 volts?

J11 CHECK CIRCUIT 3834 (LG) FOR OPEN

•

Connect 104-Pin Breakout Box (BOB) to interface adapter assembly

Yes =

REPLACE the IAA module.

(IAA) module C1945; leave IAA module disconnected.

REFER to

Section 412-04

•

With key OFF, measure the resistance of the LG wire between pin 6 on

No =

REPAIR the LG wire.

PTC switching module C1999 and BOB pin 65.

•

Is the resistance less than 5 ohms?

J12 CHECK CIRCUIT 3834 (LG) FOR SHORT TO POWER

•

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

REPAIR the LG wire.

module disconnected.

•

With key ON, measure the voltage between BOB pin 65 and ground

No =

GO to J13.

(BOB pin 80).

•

Is the voltage greater than 0 volts?

J13 CHECK STATUS OF PTC POST LINE TO IAA MODULE

•

With key OFF, reconnect PTC switching module C1999.

Yes =

System OK. CHECK wiring

for intermittent connections.

•

With key ON, measure the voltage between BOB pin 65 and ground

No =

REPLACE the PTC

(BOB pin 80).

switching module.

•

Is the voltage greater than 10 volts?

J14 CHECK PTC SWITCHING MODULE FOR SHORT

•

With key ON, monitor IAA module PID HTR SHT.

Yes =

GO to J15.

•

Disconnect PTC switching module C1999.

No =

REPLACE the PTC

•

Does the HTR SHT PID indicate YES?

switching module.

J15 CHECK CIRCUIT 3038 (O) FOR SHORT TO GROUND

•

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 between BOB pin 53 and ground

No =

REPAIR the O wire.

(BOB pin 80).

•

Is the resistance greater than 10,000 ohms?

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