Ford Ranger EV (2001 year). Manual — part 80

412-02-25

412-02-25

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST P: NO HEAT/INSUFFICIENT HEAT

TEST STEP

ACTION TO TAKE

P1 CHECK POSITIVE TEMPERATURE COEFFICIENT (PTC)

HEATER CORE CONTROL SIGNALS

•

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

Yes =

GO to P3.

(IAA) module and IAA module C1945.

•

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

No =

If voltage equals 0 volts,

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

REPLACE the IAA module.

IAA module PIDs CORE A and CORE B.

REFER to

Section 412-04

.

•

Note which PID indicates ON.

•

If CORE A PID indicates ON, measure the voltage between BOB pin

If voltage is greater than 4.5

33 and ground (BOB pin 80).

volts, GO to P2.

•

If CORE B PID indicates ON, measure the voltage between BOB pin

34 and ground (BOB pin 80).

•

Is the voltage between 2 and 3 volts?

P2 CHECK CIRCUIT 3260 (O/W) FOR OPEN

•

With key OFF, disconnect PTC switching module C1999 and measure

Yes =

REPLACE the PTC

the resistance of the O/W wire between pin 4 on PTC switching module

switching module.

C1999 and BOB pin 33.

•

Is the resistance less than 5 ohms?

No =

REPAIR the O/W wire.

P3 CHECK PTC HEATER CORE CONTROL SIGNALS AFTER

CYCLING IGNITION KEY

•

Turn the ignition key to the OFF position and then to the ON position.

Yes =

System OK. CHECK wiring

for intermittent connections.

•

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

No =

If voltage equals 0 volts,

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

REPLACE the IAA module.

IAA module PIDs CORE A and CORE B.

REFER to

Section 412-04

.

•

Note which PID indicates ON.

•

If CORE A PID indicates ON, measure the voltage between BOB pin

If voltage is greater than 4.5

33 and ground (BOB pin 80).

volts, GO to P4.

•

If CORE B PID indicates ON, measure the voltage between BOB pin

34 and ground (BOB pin 80).

•

Is the voltage between 2 and 3 volts?

P4 CHECK CIRCUIT 3261 (PK/Y) FOR OPEN

•

With key OFF, disconnect PTC switching module C1999 and measure

Yes =

REPLACE the PTC

the resistance of the PK/Y wire between pin 5 on PTC switching module

switching module.

C1999 and BOB pin 34.

•

Is the resistance less than 5 ohms?

No =

REPAIR the PK/Y wire.

PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION
(CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE
CONTROL OUTLETS

TEST STEP

ACTION TO TAKE

Q1 CHECK SYSTEM AIRFLOW

•

With key ON, set the blower control knob to the HIGH position and

Yes =

System OK. If vacuum

rotate the mode select knob through all mode positions.

pump cycles on and off

continuously without brake

pedal activation, GO to Q4.

•

Check the airflow through the climate control outlets for all mode

No =

If air flows through

positions.

defroster outlets for all

•

Does air flow through the correct outlets for all mode positions?

mode positions, GO to Q2.
If air flows through

incorrect outlets, GO to

Q10.

(Continued)

412-02-26

412-02-26

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION
(CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE
CONTROL OUTLETS

TEST STEP

ACTION TO TAKE

Q2 CHECK CLIMATE CONTROL VACUUM RESERVOIR SUPPLY

LINE CONNECTION

•

Check the vacuum supply line to the climate control vacuum reservoir

Yes =

GO to Q3.

for a secure connection.

•

Is the vacuum supply line securely connected?

No =

RECONNECT the vacuum

supply line.

Q3 CHECK VACUUM RESERVOIR CHECK VALVE

•

Disconnect the vacuum lines from the vacuum reservoir.

Yes =

RECONNECT the vacuum

lines. GO to Q4.

NOTE: Vacuum should remain constant when applied to the vacuum

No =

REPLACE the climate

reservoir port for the vacuum line leading to the passenger compartment

control vacuum reservoir.

and there should be no vacuum when applied to the port for the vacuum

line leading to the vacuum tee assembly. Airflow through the check valve

should be in the direction towards the vacuum pump.

•

Use Vacuum Tester to apply 103 kPa (15 psi) of vacuum to both ports

on the vacuum reservoir.

•

Is the vacuum reservoir check valve OK?

Q4 CHECK CLIMATE CONTROL VACUUM RESERVOIR FOR

VACUUM LEAK

•

With key ON, disconnect the vacuum line leading to the passenger

Yes =

RECONNECT the vacuum

compartment from the climate control vacuum reservoir and plug the port

line to the vacuum reservoir.

on the vacuum reservoir.

GO to Q5.

•

Monitor interface adapter assembly (IAA) module PID VACPRES for a

No =

REPLACE the climate

change in vacuum pressure after the vacuum pump shuts off.

control vacuum reservoir.

•

Does the vacuum level remain constant?

Q5 CHECK VACUUM LINE TO PASSENGER COMPARTMENT

•

With key ON, disconnect the vacuum line in the passenger compartment

Yes =

RECONNECT the vacuum

located on the right side of the bulkhead and plug the port on the

line to the bulkhead port.

bulkhead.

GO to Q6.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the vacuum line

after the vacuum pump shuts off.

between the climate control

•

Does the vacuum level remain constant?

vacuum reservoir and

bulkhead.

Q6 CHECK BLACK VACUUM LINE TO MODE SELECT SWITCH

•

With key ON, disconnect the vacuum connector from the mode select

Yes =

RECONNECT the vacuum

switch and plug the black vacuum line on the vacuum connector.

connector to the mode select

switch. GO to Q8.

•

Monitor IAA module PID module VACPRES for a change in vacuum

No =

GO to Q7.

pressure after the vacuum pump shuts off.

•

Does the vacuum level remain constant?

Q7 CHECK BLACK VACUUM LINE IN VACUUM JUMPER

HARNESS

•

With key ON, disconnect the vacuum jumper harness leading to the

Yes =

REPLACE the vacuum

heater plenum and plug the black vacuum line port on the heater plenum

jumper harness.

vacuum connector.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the heater

after the vacuum pump shuts off.

plenum vacuum line

•

Does the vacuum level remain constant?

assembly.

Q8 CHECK MODE SELECT SWITCH

(Continued)

412-02-27

412-02-27

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION
(CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE
CONTROL OUTLETS

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect the vacuum jumper harness leading to the

Yes =

RECONNECT the vacuum

heater plenum and plug all ports on the blue vacuum jumper harness

jumper harness. GO to Q10.

connector except for the black vacuum line port.

•

Use Vacuum Tester to apply 103 kPa (15 psi) of vacuum to the black

No =

GO to Q9.

vacuum line port on the blue vacuum jumper harness connector and

rotate the mode select knob through all mode positions.

•

Does the vacuum level remain constant for all mode positions?

Q9 CHECK VACUUM JUMPER HARNESS

•

With key OFF, disconnect the vacuum jumper harness from the mode

Yes =

REPLACE the mode select

select switch.

switch.

•

Use Vacuum Tester to apply 103 kPa (15 psi) to each individual vacuum

No =

REPLACE the vacuum

line with the other end of the vacuum line plugged.

jumper harness.

•

Do all vacuum lines hold vacuum?

Q10 VERIFY VACUUM LINE ROUTING

•

Compare vacuum line colors in each harness to the vacuum schematic.

Yes =

GO to Q11.

Refer to Electrical and Vacuum Troubleshooting Manual (EVTM),

Cell 53, Heater or Cell 54, Air Conditioner/Heater.

•

Is the vacuum line routing correct?

No =

CORRECT the vacuum line

routing.

Q11 CHECK VACUUM LINES/CONNECTIONS

•

Check each vacuum line for a secure connection. Also check for blocked, Yes =

GO to Q12.

pinched, kinked, or damaged vacuum lines.

•

Are the vacuum lines OK?

No =

REPAIR as necessary.

Q12 CHECK VACUUM MOTORS

•

Disconnect the vacuum line from each vacuum motor and use Vacuum

Yes =

GO to Q13.

Tester to apply 103 kPa (15 psi) of vacuum to each vacuum motor.

•

Do the vacuum motors hold vacuum?

No =

REPLACE the vacuum

motor(s) in question.

Q13 CHECK WHITE VACUUM LINE TO FRESH/RECIRCULATION

DOOR VACUUM MOTOR

•

With key ON, remove the white vacuum line from the fresh/recirculation

Yes =

RECONNECT the white

door vacuum motor and plug the vacuum line.

vacuum line to the

fresh/recirculation door

vacuum motor. GO to Q14.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the heater

after the vacuum pump shuts off.

plenum vacuum line

•

Does the vacuum level remain constant?

assembly.

Q14 CHECK YELLOW VACUUM LINE TO FLOOR/DEFROST

DOOR VACUUM MOTOR

•

With key ON, remove the yellow vacuum line from the floor/defrost

Yes =

RECONNECT the yellow

door vacuum motor and plug the hose.

vacuum line to the

floor/defrost door vacuum

motor. GO to Q15.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the heater

after the vacuum pump shuts off.

plenum vacuum line

•

Does the vacuum level remain constant?

assembly.

Q15 CHECK BLUE VACUUM LINE TO FLOOR/DEFROST DOOR

VACUUM MOTOR

(Continued)

412-02-28

412-02-28

Heating and Ventilation

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION
(CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE
CONTROL OUTLETS

TEST STEP

ACTION TO TAKE

•

With key ON, remove the blue vacuum line from the floor/defrost door

Yes =

RECONNECT the blue

vacuum motor and plug the vacuum line.

vacuum line to the

floor/defrost door vacuum

motor. GO to Q16.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the heater

after the vacuum pump shuts off.

plenum vacuum line

•

Does the vacuum level remain constant?

assembly.

Q16 CHECK RED VACUUM LINE TO PANEL/DEFROST DOOR

VACUUM MOTOR

•

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

Yes =

RECONNECT the red

remove the red vacuum line from the panel/defrost door vacuum motor

vacuum line to the

and plug the vacuum line.

panel/defrost door vacuum

motor. GO to Q17.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the heater

after the vacuum pump shuts off.

plenum vacuum line

•

Does the vacuum level remain constant?

assembly.

Q17 CHECK GREEN VACUUM LINE TO RECIRCULATION

VACUUM SOLENOID

•

With key ON, set the mode select knob to the OFF position, disconnect

Yes =

System OK. CHECK for

the green vacuum line from the recirculation vacuum solenoid, and plug

intermittent vacuum line

the vacuum line.

connections.

•

Monitor IAA module PID VACPRES for a change in vacuum pressure

No =

REPLACE the heater

after the vacuum pump shuts off.

plenum vacuum line

•

Does the vacuum level remain constant?

assembly.

PINPOINT TEST R: RECIRCULATION FUNCTION DOES NOT OPERATE

TEST STEP

ACTION TO TAKE

R1 CHECK RECIRCULATION FUNCTION (FRESH POSITION)

•

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

Yes =

GO to R3.

and check the position of the outside/recirculation door.

•

Is the outside/recirculation door in the fresh position?

No =

GO to R2.

R2 CHECK FRESH/RECIRCULATION DOOR VACUUM MOTOR

ACTUATOR

•

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

Yes =

GO to R3.

disconnect the white vacuum line from the fresh/recirculation door

vacuum motor, and check the position of the outside/recirculation door.

•

Is the outside/recirculation door in the fresh position?

No =

CHECK for binding

actuator/linkage. If OK,

CHECK for stuck

recirculation vacuum

solenoid. REPAIR as

necessary.

R3 CHECK RECIRCULATION FUNCTION (RECIRCULATION

POSITION)

NOTE: If the LED on the fresh/recirculation select switch does not

Yes =

System OK. CHECK

illuminate when the fresh/recirculation select switch is depressed, GO to

wiring/vacuum lines for

R17.

intermittent connections.

•

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

depress the fresh/recirculation select switch, and check the position of the

outside/recirculation door.

(Continued)