Ford Falcon. Manual — part 299

412-00-4

Climate Control System — General Information

412-00-4

DIAGNOSIS AND TESTING

Climate Control System — General

Information

Acronyms and Abbreviations

NOTE: The following acronyms will be used

throughout this section.

A/C

Air Conditioning

ACC

Automatic Climate Control

ACPT

Air Conditioning Pressure Transducer

BEM

Body Electronics Module

CAN

Controller Area Network

DTC

Diagnostic Trouble Code

DZ

Dual Zone

ECU

Electronic Control Unit

EEC

Electronic Engine Control (part of

PCM)

EVT

Evaporator Vent Temperature

HIM

HVAC Integrated Module

HTR

Heater

HVAC

Heating, Ventilation & Air Conditioning

ICC

Interior Command Centre

MAX

Maximum

MCC

Manual Climate Control

MIN

Minimum

MSG

Message

N/A

Not Applicable

PCM

Powertrain Control Module

PID

Parameter Identifier

RPM

Revolutions Per Minute

SZ

Single Zone

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412-02-1

Heating and Ventilation

412-02-1

SECTION : 412-02 Heating and Ventilation

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-02-2

DESCRIPTION AND OPERATION

Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . .412-02-3

Air

Conditioning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-02-4

Dual Zone Automatic Climate Control System . . . . . . . . . . . . . . . . . 412-02-4

Distribution

Modes

. . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-02-6

Air

Filtering

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-02-8

HVAC

Ducting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..412-02-8

Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . ...412-02-9

DIAGNOSIS AND TESTING

Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . ...412-02-10

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . .412-02-10

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..412-02-10

PID

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-02-12

DTC

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..412-02-13

Pinpoint

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-02-13

REMOVAL AND INSTALLATION

Blower Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .412-02-20

HVAC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412-02-20

HVAC Case Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-02-21

Heater Core Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 412-02-22

Case Assy — Recirc Door Complete . . . . . . . . . . . . . . . . . . . . ..412-02-22

HIM Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412-02-24

Actuator — Electric Airmix (ACC only) . . . . . . . . . . . . . . . . . . . ...412-02-26

Shaft — Airmix Door DZ/SZ . . . . . . . . . . . . . . . . . . . . . . . . 412-02-27

Dual Zone Sub Harness . . . . . . . . . . . . . . . . . . . . . . . . . .412-02-28

Filter and Cover Assembly — Mesh (Standard Fitment) . . . . . . . . . . . . . 412-02-28

Filter — Particle (Optional Fitment) . . . . . . . . . . . . . . . . . . . . . 412-02-29

Vent Outlet Register — Outboard Register . . . . . . . . . . . . . . . . . . 412-02-29

Vent Outlet Register — Centre Register . . . . . . . . . . . . . . . . . . . .412-02-30

Vent Outlet Register — Floor Console Register . . . . . . . . . . . . . . . . .412-02-30

Floor Console Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . .412-02-31

412-02-2

Heating and Ventilation

412-02-2

SPECIFICATIONS

General Specifications

Description

Specification

Lubricants
HVAC Lever Cam

Dow Corning Molykote

Grease

PG 54 Silicon Grease

Engine Coolant

Do not top up the cooling

system with tap water.

Use only Ford Specified

Coolant at a Ratio of 30 -

50 %

A/C System O-Ring

PAG ND-Oil 8

Lubrication
A/C System O-Rings

Refrigerant O-Ring,

green HNBR, Evaporator

Outlet (large) - part no.

BA19S710A

Evaporator Inlet (small) -

part no. BA19S710B

Torque Specifications

Description

Nm

HVAC Mounting Upper Bolts (4)

6 - 8

HVAC Mounting Lower Nuts (2)

9 - 12

Evaporator Tube to A/C Tube

12.7 - 17.3

Clamping Bolt
HVAC Case Hi / Lo Plastic Self

1.1 - 1.5

Tapping Screws
Heater Tube Clamp Retaining Screw

1.1 - 1.5

Evaporator Plastic End Plate

1.1 - 1.5

HIM to HVAC Self Tapping Screws

1.1 - 1.5

Blower Motor to HVAC Self Tapping

1.1 - 1.5

Screws

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412-02-3

Heating and Ventilation

412-02-3

DESCRIPTION AND OPERATION

Heating and Ventilation

Manual Climate Control System

Instrument Panel

Item

Description

1

Air Conditioning Button

The airflow volume and direction can be regulated

2

Air Distribution Buttons

with the controls on the instrument panel and by

3

Air Distribution Buttons

adjusting the instrument panel.

4

Air Distribution Buttons

Instrument panel and rear console adjustable

5

Fan Speed Dial

vents

6

Recirculated Mode

The airflow can be turned on or off with the rotary

7

Rear Window Demist

controls at the side of the vents. Vents should be

either fully open (top detent position) or fully closed

8

Air Distribution Buttons

(bottom detent position).

9

Air Distribution Buttons

10

Temperature Control Dial

Blower fan speed selector
The rotary blower fan speed selector is used to adjust

the blower fan speed. At the lowest setting the fan is

off, unless A/C is selected. Outside air will still enter

the cabin if fresh air is selected, even with the blower

off.

The direction of the airflow can be adjusted

horizontally and vertically within the swivelling range

of the air vanes and vents.

NOTE: The blower fan will only operate with the

ignition in the ON position.

Temperature Control
The temperature of the air maybe adjusted using the

temperature control dial. Turn the dial clockwise to

increase heating. Turn the dial anti-clockwise to

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