Ford Ranger EV (2001 year). Manual — part 75
412-02-5
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
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
Symptom Chart
Condition
Possible Sources
Action
•
DTC B1238 Over
•
Positive temperature
•
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.
Failure
•
Circuit(s).
•
Interface adapter assembly
(IAA) module.
•
DTC B1250 Air Temperature
•
Interface adapter assembly
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.
External Sensor Circuit
•
Circuit(s).
Failure
•
Interface adapter assembly
(IAA) module.
•
DTC C1776 Heater System
•
Positive temperature
•
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).
Failure
•
Interface adapter assembly
(IAA) module.
•
Blower switch.
412-02-6
412-02-6
Heating and Ventilation
DIAGNOSIS AND TESTING (Continued)
Symptom Chart (Continued)
Condition
Possible Sources
Action
•
DTC C1780 Temperature
•
Circuit(s).
Select Failure
•
Interface adapter assembly
(IAA) module.
•
Temperature control
potentiometer.
•
DTC B1857 Climate Control
•
Interface adapter assembly
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
Mode Select Switch in OFF
Controller (VBC)
Position
•
Interface Adapter Assembly
(IAA).
•
Circuit(s).
•
Recirculation vacuum
pressure sensor.
•
DTC U2015 Signal Link
•
Fault (Non SCP)
coefficient (PTC) module.
•
Circuit(s).
•
Interface adapter assembly
(IAA) module.
•
PTC heater core.
•
DTC B2513 Blower (Fan)
•
Circuit(s).
Circuit Failure
•
Variable blower controller
(VBC).
•
Blower motor relay.
•
Blower motor.
•
Interface adapter assembly
(IAA) module.
•
DTC B2514 Blower (Fan)
•
Blower motor relay.
Circuit Short to Vbat
•
Circuit(s).
•
Interface adapter assembly
(IAA) module.
•
DTC B2515 Heater Blower
•
Relay Circuit Failure
(VBC).
•
Circuit(s).
•
Interface adapter assembly
(IAA) module.
•
DTC B2516 Blower Control
•
Circuit(s).
Circuit Failure
•
Variable blower controller
(VBC).
•
Interface adapter assembly
(IAA) module.
•
No Heat/Insufficient Heat
•
Interface adapter assembly
(IAA) module.
•
Circuit(s).
•
Positive temperature
coefficient (PTC) switching
module.
412-02-7
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).
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
•
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
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.
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
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 =
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
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.
•
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
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 =
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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