Ford Falcon. Manual — part 322

412-04-1 Control

Components 412-04-1

SECTION : 412-04 Control Components

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-04-2

DESCRIPTION AND OPERATION

Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .412-04-3

HVAC Integrated Module (“HIM” Module) . . . . . . . . . . . . . . . . . . . 412-04-3

Climate Control Sensors . . . . . . . . . . . . . . . . . . . . . . . . . ..412-04-3

Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . ...412-04-3

CAN Bus Information . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-04-5

HIM Feature and Benefit Summary . . . . . . . . . . . . . . . . . . . . . ..412-04-6

DIAGNOSIS AND TESTING

HIM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-04-7

Module

Configuration

. . . . . . . . . . . . . . . . . . . . . . . . . . ...412-04-7

HIM Calibration File Down Load . . . . . . . . . . . . . . . . . . . . . . ..412-04-7

Cabin Temperature Sensor Calibration Factor . . . . . . . . . . . . . . . . . 412-04-7

HVAC On-Demand Self Test . . . . . . . . . . . . . . . . . . . . . . . ...412-04-7

DTC

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-04-8

PID

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-04-11

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..412-04-12

Connector Circuit Reference . . . . . . . . . . . . . . . . . . . . . . . ..412-04-12

Air Conditioning & HVAC Relay and Fuses . . . . . . . . . . . . . . . . . ...412-03-14

Pinpoint

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-04-14

REMOVAL AND INSTALLATION

Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-04-30

Cabin Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . .412-04-30

Sunload sensor/Twilight sensor . . . . . . . . . . . . . . . . . . . . . . ...412-04-30

Ambient Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . .412-04-30

Evaporator Temperature Sensor (Evaporator Thermistor) . . . . . . . . . . . . .412-04-30

412-04-2 Control

Components 412-04-2

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 Hi / Lo Plastic Self Tapping

1.1 - 1.5

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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412-04-3 Control

Components 412-04-3

DESCRIPTION AND OPERATION

The Cabin temperature sensor is located in the ICC

Control Components

facia behind a small grille immediately to the right of

the ICC display screen and is wired directly to the

HVAC Integrated Module (“HIM” Module)

BEM. It is used by the ACC climate control system

The introduction of the Ford BA Falcon vehicle brings only. The CTS takes temperature readings via a DC

with it a new concept in Heating, Ventilation and Air

operated fan motor drawing air from the car interior

Conditioning control. This new technology is known as through the grill and across a thermistor. When there

the HVAC Integrated Module (“HIM”).

is a change in temperature, the value of resistance

changes giving a change in voltage output. This

The HIM is a self-contained electronic control module

change is read by the BEM where is translated into a

attached to the passenger side of the HVAC unit. This

CAN message that is read by the HIM. The CTS is

new generation device contains electric motors, gear

not a serviceable item. If the CTS is faulty, the

drive mechanisms and a PCB Board which electrically

complete ICC should be replaced after prior approval

and mechanically control the HVAC system.

gained. Refer to section 413-08 for ICC replacement.

The HIM incorporates air delivery damper control,

Whenever the ICC or BEM is replaced, the CTS

variable blower fan speed control and high speed

calibration factor needs to be retaught to the BEM.

serial data communication interconnected to and

The combined Twilight and Sun Load sensor is

exchanging data with many other electrical vehicle

located in the top of the instrument panel between the

sub systems.

passenger and driver screen air duct. The sensor is

When climate control buttons or knobs are operated,

wired directly to the BEM. The Sun load sensor is

the ICC module sends a CAN message to the HIM.

used by the ACC climate control system only, to

The HIM executes the selected function and sends a

adjust the ACC for different sun intensity levels. The

message back to the ICC module to update the

Twilight Sensor provides information about low light

display screen as required for that function.

conditions for automatic headlight operation.

The HIM is fitted to all three variants of climate control

The Ambient temperature sensor is located in the

systems available in the FORD BA Falcon vehicle

passenger side external mirror housing and is wired

range. The climate control variants are:

directly to the HIM. It is used by the ACC climate

ACC

Automatic Climate Control with Dual

control system only. The Ambient Temperature sensor

Zone capabilities

is not a serviceable item. If the sensor is faulty, the

complete LH external mirror assembly should be

MCC

Standard Heating and Air Conditioning

replaced.

(Manual Climate Control)

The BEM is located within the ICC assembly. Refer to

HTR

Heating system only

Section 413-08 for ICC functions and specifications,

The HIM module is a common component fitted to all

and refer to Section 419-10 for BEM functions and

three variants, however, in the event of a service

specifications.

replacement, the HIM requires configuration during

the installation in to a vehicle. Refer to HIM Module

Acronyms and Abbreviations

Configuration further in this section.

The following acronyms will be used throughout this

The HIM receives and sends data to various vehicle

section.

sub systems via the CAN bus, including the ICC, BEM

and PCM.

A/C

Air Conditioning

NOTE: The climate system will operate with the

ACC

Automatic Climate

ignition key set to RUN position only. Also, the HIM

Control

will only respond to diagnostic commands and

ACPT

A/C Pressure Transducer

services from the WDS test tool while the ignition key

BEM

Body Electronic Module

set to RUN position only.

(GEM)

CAN

Controller Area Network

Climate Control Sensors

DTC

Diagnostic Trouble Code

The climate control system relies on various sensors

DZ

Dual Zone

located in specific positions throughout the vehicle.

The sensor data is used to control the various HVAC

EATC

Electronic Air

subsystems such as air distribution, blower fan speed

Temperature Control

control, air conditioning and heating.

EEC

Electronic Engine Control

Some of the sensor data used by the HVAC system is

(part of PCM)

retrieved through the serial CAN bus data system.

EVT

Evaporator Vent

The Evaporator temperature sensor is located in the

Temperature

HVAC air conditioning core and is wired directly to the FCSD

Ford Customer Service

HIM. It is used by the ACC and MCC climate systems

Division

only.

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412-04-4 Control

Components 412-04-4

DESCRIPTION AND OPERATION (Continued)

NVM

Electronic Automatic

Temperature Control

PCM

Powertrain Control

Module

ECU

Electronic Control Unit

HIM

HVAC Integrated Module

HTR

Heater

HVAC

Heating, Ventilation & Air

Conditioning

ICC

Interior Command Center

MAX

Maximum

MCC

Manual Climate Control

MIN

Minimum

MSG

Message

N/A

Not Applicable

PID

Parameter Identifier

WDS

Worldwide Diagnostic

System

RAM

Random Aces Memory

(Loss of data when

power removed)

ROM

Read Only Memory

RPM

Revolutions Per Minute

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