• HEADINGS
  • SPECIFICATIONS
  • DIAGNOSIS - EXCEPT VILLAGER
    • INSUFFICIENT OR NO A/C COOLING
    • COMPRESSOR CLUTCH CIRCUIT DIAGNOSIS
  • DIAGNOSIS - VILLAGER
    • INSUFFICIENT OR NO A/C COOLING
    • A/C SYSTEM INOPERATIVE (NO OPERATION - ALL SETTINGS)
    • FRONT BLOWER MOTOR INOPERATIVE
    • FRONT HEATER BLOWER MOTOR RUNS CONTINUOUSLY
    • OUTSIDE/RECIRCULATED AIR DOOR INOPERATIVE
    • TEMPERATURE CONTROL INOPERATIVE
    • ONE OR MORE MODES INOPERATIVE (AIR OUTLET DOES NOT CHANGE)
    • INSUFFICIENT OR NO HEAT
    • IMPROPER OR NO AIR CIRCULATION
• FIGURES
• TABLES
  • A/C SYSTEM HIGH SIDE PRESSURE SPECIFICATIONS
  • OUTSIDE/RECIRCULATED AIR DOOR ACTUATOR VOLTAGE TEST
  • TEMPERATURE BLEND DOOR ACTUATOR CIRCUIT TESTS
  • TEMPERATURE BLEND DOOR ACTUATOR VOLTAGE TEST
  • MODE DOOR ACTUATOR CIRCUIT TESTS
  • MODE DOOR ACTUATOR VOLTAGE TEST

A/C-HEATER SYSTEM - BASIC TROUBLE SHOOTING - MANUAL

MANUAL A/C-HEATER SYSTEMS Trouble Shooting - Trucks & Vans

SPECIFICATIONS

DIAGNOSIS - EXCEPT VILLAGER

INSUFFICIENT OR NO A/C COOLING

NOTE:

A continuously running A/C compressor is considered normal when ambient temperature is greater than 80°F (27°C) and high humidity conditions.

1. Check A/C Compressor Clutch
   
   If the A/C compressor clutch engages, proceed to the next step. If the A/C compressor clutch does not engage, proceed to COMPRESSOR CLUTCH CIRCUIT DIAGNOSIS.
2. Check Pressure & Compressor Clutch Cycle Rate
   
   Connect manifold gauge set. Set function control to MAX A/C. Set blower to highest speed. Set temperature control to full cool position. Close all doors and windows. Install thermometer at center discharge register. Record outside ambient temperature. Run engine at 1500 RPM with compressor clutch engaged. Stabilize A/C system with above conditions for about 10-15 minutes. Compare manifold gauge readings to normal system pressures. Low side pressure remains constant at 22-50 psi (1.5-3.5 kg/cm² ) throughout normal operating range. See A/C SYSTEM HIGH SIDE PRESSURE SPECIFICATIONS table. If clutch does not cycle rapidly (5 seconds on, 5 seconds off) and system pressure is within limits, A/C system is operating properly. If compressor cycles rapidly (5 seconds on, 5 seconds off) and low-side pressure is within limits, go to next step. If compressor cycles on at greater than 52 psi (3.7 kg/cm² ) and off at less than 21 psi (1.5 kg/cm² ), replace A/C cycling switch (also referred to as clutch cycling pressure switch). After replacing switch, verifyA/C system operation. If system still is not operating properly, reinstall original switch and go to next step.

   A/C SYSTEM HIGH SIDE PRESSURE SPECIFICATIONS
   

   Application Ambient Temp. °F (°C)		psi (kg/cm2 )
   Aerostar, Explorer & Ranger
   60 (16)		120-210 (8.4-14.8)
   70 (21)		140-220 (9.8-15.5)
   80 (27)		160-250 (11.2-17.6)
   90 (32)		180-270 (12.7-18.9)
   Bronco, "E" & "F" Series
   60 (16)		75-175 (5.3-12.3)
   70 (21)		100-200 (7.0-14.1)
   80 (27)		128-230 (8.9-16.1)
   90 (32)		150-260 (10.5-18.3)

3. Check Pressures
   
   Disconnect blower motor connector. Check low pressure gauge for pressure at which clutch cycles off. If clutch cycles off between 22-25 psi (1.5-1.8 kg/cm² ) and ambient temperature is more than 80°F (27°C), A/C system is operating properly. If clutch cycles off at less than 22 psi (1.5 kg/cm² ) or greater than 52 psi (3.7 kg/cm² ), go to next step.
4. Check For Leaks
   
   Leak test system. If leaks are found, repair as necessary. Evacuate and recharge system. Recheck A/C system for leaks. If no leaks are found, refrigerant charge is low or there is moisture in the system. Evacuate and recharge system.

COMPRESSOR CLUTCH CIRCUIT DIAGNOSIS

1. Check System Operation
   
   Ensure ambient temperature is greater than 50°F (10°C). Ensure battery voltage is greater than 12.5 volts. Start engine. Turn blower motor and A/C system on. If compressor clutch engages, circuit is operating properly. If compressor clutch does not engage, go to next step.
2. Check For Voltage
   
   Check for voltage at A/C pressure switch. If 10 volts or greater exists, go to next step. If less than 10 volts exists, go to step 10).
3. By-Pass Clutch Cycling Pressure Switch
   
   Disconnect clutch cycling pressure switch (located on accumulator-drier). Ensure engine is running and A/C control panel is set to maximum cooling position. Connect jumper wire across switch harness connector terminals. If the clutch engages, go to next step. If the clutch does not engage, go to step 7).
4. Check A/C High Pressure Cut-Off Switch
   
   Using an ohmmeter, check for continuity between A/C high pressure cut-off switch terminals. If continuity exists, go to next step. If continuity does not exist, replace A/C high pressure cut-off switch and return to step 1).
5. Check Refrigerant Pressure
   
   Connect manifold gauge set and note pressure readings. If pressure reading is less than 55 psi (3.9 kg/cm² ), check system for leaks and repair as required. After repairs, verify A/C system operation. If pressure reading is greater than 55 psi (3.9 kg/cm² ), replace clutch cycling pressure switch and verify A/C system operation.
6. Check A/C Compressor Pressure Relief Valve
   
   Inspect area surrounding A/C compressor pressure relief valve for signs of oily residue, indicating relief valve leakage. If oily residue exists, replace relief valve and return to step 1). If oily residue does not exist, inspect refrigerant system for leaks elsewhere and repair as necessary. Recharge system.
7. Check Voltage At A/C Compressor Clutch Coil
   
   Check for voltage at A/C compressor clutch coil connector. If 10 volts or greater exists, go to next step. If voltage is not 10 volts or greater, go tostep 9).
8. Check Clutch Coil Ground
   
   Connect jumper wire between ground terminal of A/C compressor clutch coil and ground. If clutch engages, repair open in ground wire. If clutch does not engage, replace A/C compressor clutch coil and return to step 1).
9. Check Fuse
   
   Check fuse for continuity. If continuity exists, go to next step. If continuity does not exist, check for short or blown fuse. Repair as necessary.
10. Check A/C Control Switch
    
    Ensure ignition switch is in RUN position and A/C system is in defrost position. Check for battery voltage at connector of A/C cycling switch. If battery voltage does not exist, go to next step. If battery voltage exists, go to step 12).
11. Check A/C Control Switch Circuit
    
    Remove connector from A/C control switch. If 10 volts or greater exists at circuit, go to next step. If voltage is less than 10 volts, check for blown fuse or open White/Purple (Brown/White wire on Bronco). Repair as necessary and return to step 1).
12. Check Function Switch
    
    Ensure function switch is in defrost position. Check A/C control switch and function switch for continuity. If there is continuity through function switch only, replace A/C control switch. If there is continuity through A/C control switch only, replace function switch. If there is continuity through both switches, repair open circuit between A/C control switch and clutch cycling pressure switch. Go to step 1).

DIAGNOSIS - VILLAGER

INSUFFICIENT OR NO A/C COOLING

1. Check A/C Compressor Clutch Operation
   
   Start engine and set A/C to maximum. If A/C compressor clutch does not engage, go to next step. If the A/C compressor clutch engages, go to step 20).
2. Check Refrigerant System Pressures
   
   Check A/C system performance. See TESTING in MANUAL A/C-HEATER SYSTEMS -VILLAGER article. If pressures are not okay, service system as necessary. If pressures are okay, go to next step.
3. Check Fuses
   
   Check RELAYS fuse (10-amp) and A/C CONT fuse (7.5-amp) in interior fuse relay block. If fuses are okay, go to step 10). If any fuse is blown, go to next step.
4. Check System
   
   Ensure ignition is off. Replace any blown fuse. Turn ignition on. Recheck fuses. If fuses are okay, go to step 11). IfA/C CONT fuse is blown, go to step 8). If RELAYS fuse is blown, go to next step.
5. Check For Short To Ground In RELAYS Fuse Circuit
   
   Ensure ignition is off. Remove RELAYS fuse from interior fuse block. Remove AIR CON relay from engine compartment right relay block. Using ohmmeter, measure resistance of Blue wire between interior fuse relay block and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Blue wire between RELAYS fuse and AIR CON relay. Resistance should be less than 5 ohms. If resistances are as specified, go to step 10). If resistances are not as specified, go to next step.
6. Check Blue Wire To AIR CON Relay
   
   Ensure ignition is off. Disconnect engine compartment fuse/relay junction connector No. 1. Remove AIR CON relay from engine compartment right fuse/relay block. Using ohmmeter, measure resistance of Blue wire between interior fuse/relay block and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Blue wire between RELAYS fuse and AIR CON relay. Resistance should be less than 5 ohms. If resistances are not as specified, repair Blue wire as necessary and retest system. If resistances are as specified, go to next step.
7. Check Junction Connector No. 1 For Continuity
   
   Ensure ignition is off. Disconnect engine compartment fuse/relay junction connector No. 1. Measure resistance of Blue wire between terminals of junction connector No. 1. If resistance is greater than 5 ohms, replace junction connector No. 1. If resistance is less than 5 ohms. repair Blue wire between RELAYS fuse (10-amp) and junction connector No. 1. Retest system.
8. Check For Short To Ground In A/C CONT Fuse Circuit
   
   Ensure ignition is off. Remove AIR CON relay from engine compartment right relay block. Disconnect front A/C control panel 12-pin connector. Replace A/C CONT fuse (7.5-amp). Turn ignition on. Turn A/C on. If fuse fails again, go to next step. If fuse does not fail repair Gray/Blue wire and retest system.
9. Check For Short To Ground Between AIR CON Relay & A/C Compressor Clutch Circuit
   
   Ensure ignition is off. Remove AIR CON relay from engine compartment left relay block. Disconnect A/C compressor clutch connector. Measure resistance of Gray/Red wire between AIR CON relay connector and A/C compressor clutch connector. Resistance should be less than 5 ohms. Measure resistance of Gray/Red wire between AIR CON relay connector and ground. Resistance should be greater than 10,000 ohms. If resistances are as specified, go to step 10). If resistances are not as specified, repair Gray/Red wire as necessary. Retest system.
10. Check A/C Compressor Clutch Signal
    
    Warm engine to normal operating temperature. Turn ignition off. Disconnect A/C compressor clutch connector. Ensure A/C is off. Measure voltage of Gray/Red wire at A/C compressor clutch. Voltage should be less than 1 volt. Turn A/C system on. Measure voltage of Gray/Red wire at A/C compressor clutch connector. Voltage should be greater than 10 volts. If voltage is not as specified, go to next step. If voltage is as specified, go to step 17).
11. Check Power Supply To AIR CON Relay
    
    Ensure ignition is off. Remove AIR CON relay from engine compartment left relay block. Turn ignition on. Measure voltage at Gray/Blue wire and Blue wire terminals of AIR CON relay connector. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair appropriate wire.
12. Check AIR CON Relay
    
    Ensure ignition is off. Remove AIR CON relay. Connect a jumper wire between Blue wire terminal of AIR CON relay and positive battery terminal. Connect a second jumper wire between Gray/Red wire terminal (circuit to PCM) of relay and negative battery terminal. Using ohmmeter, check continuity between Gray/Blue wire and Gray/Red wire terminals of relay. Ohmmeter should read less than 5 ohms, indicating continuity. Disconnect jumper wire between Gray/Red wire terminal and negative battery terminal. Check continuity between Gray/Blue wire and Gray/Red wire terminals of relay. Ohmmeter should read greater than 10,000 ohms, indicating no continuity. If continuity is as specified, go to next step. If continuity is not as specified, replace AIR CON relay.
13. Check AIR CON Relay Circuit To PCM
    
    Ensure ignition is off. Disconnect AIR CON relay connector and Powertrain Control Module (PCM) connector. Measure resistance of Gray/Red wire (Light Green wire after splice) between relay connector and PCM connector. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair open wire.
14. Check Power Supply To A/C Control Panel
    
    Ensure ignition is off. Disconnect A/C control panel 12-pin connector. Turn ignition on. Measure voltage at Gray wire terminal of A/C control panel connector. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair Gray wire between interior fuse block and A/C control panel.
15. Check A/C Pressure Cut-Off Switch
    
    Ensure ignition is off. Disconnect A/C pressure cut-off switch connector. Measure resistance between Brown wire and White/Red wire terminals of A/C pressure cut-off switch. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, replace A/C pressure cut-off switch.
16. Check Wire Between A/C Cycling Switch & A/C Pressure Cut-Off Switch
    
    Ensure ignition is off. Disconnect A/C pressure cut-off switch connector. Disconnect A/C cycling switch connector, located on accumulator-drier. Measure resistance of Brown wire between A/C pressure cut-off switch and A/C cycling switch connectors. Resistance should be less than 5 ohms. Measure resistance of Brown wire between A/C pressure cut-off switch connector and ground. Resistance should be greater than 10,000 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair Brown wire and retest system.
17. Check A/C Cycling Switch
    
    Reconnect A/C pressure cut-off switch. Run engine until normal operating temperature is reached. Turn ignition off. Disconnect A/C cycling switch connector. Connect jumper wire between Brown/White wire and Brown wire terminals of connector. Start engine, and turn A/C on. If A/C compressor clutch engages, replace A/C cycling switch. If A/C compressor clutch does not engage, go to next step.
18. Check Wire Between A/C Control Panel & A/C Cycling Switch
    
    Ensure ignition is off. Disconnect A/C cycling switch connector. Disconnect A/C control panel 12-pin connector. Measure resistance of Brown/White wire between A/C cycling switch connector and A/C control panel 12-pin connector. Resistance should be less than 5 ohms. Measure resistance between Brown/White wire terminal at A/C cycling switch connector and ground. Resistance should be greater than 10,000 ohms. Resistances are as specified, replace A/C control panel. If resistances are not as specified, repair Brown/White wire.
19. Check A/C Compressor Clutch
    
    Ensure ignition is off. Disconnect A/C compressor clutch connector. Connect a jumper between Black wire terminal of A/C compressor clutch and negative battery terminal. Connect a second jumper wire between Gray/Red wire (White/Orange wire after splice) terminal of A/C compressor clutch and positive battery terminal. Ensure clutch hub is pulled in when battery voltage is applied to A/C compressor clutch. Remove jumper wire between a/C compressor clutch and positive battery terminal. Ensure clutch hub is released when jumper wire is removed. If clutch hub functions as indicated, repair Black wire between A/C compressor clutch and ground. If clutch hub does not function as indicated, replace A/C compressor clutch.

A/C SYSTEM INOPERATIVE (NO OPERATION - ALL SETTINGS)

1. Check Fuses
   
   Check both top and bottom FRONT BLOWER MOTOR fuses (20-amp), ELECTRON BAT fuse (10-amp) and A/C CONT fuse (7.5-amp) in interior fuse block. Check IGN SW fuse(30-amp) and FRT BLWR fuse (65-amp) in engine compartment left fuse block. If any fuse is blown, go to next step. If fuses are okay, go to step 10).
2. Check System
   
   Ensure ignition is off. Replace blown fuse(s). Turn ignition on. Recheck fuses. If fuses are okay, go to step 10). If top and/or bottom FRONT BLOWER MOTOR fuses (20-amp) are blown, go to next step. If FRT BLWR fuse (65-amp) is blown, go to step 4). If ELECTRON BAT fuse (10-amp) and/or IGN SW fuse (30-amp) is blown, go to step 5). If the A/C CONT fuse (10-amp) is blown, go tostep 6).
3. Check Brown/White Wire For Short To Ground
   
   Ensure ignition is off. Remove top FRONT BLOWER MOTOR fuse (20-amp) from interior fuse block. Disconnect front blower motor relay, located behind interior fuse block. Disconnect front blower motor connector. Using ohmmeter, measure resistance of Brown/White wire between interior fuse block and ground. If resistance is less than 10,000 ohms, wire is shorted to ground. Repair as necessary. If resistance is greater than 10,000 ohms, wire is okay. Replace top FRONT BLOWER MOTOR fuse. Reconnect front blower motor relay and front blower motor connector. Go to step 10).
4. Check FRT BLWR Fuse Circuit
   
   Remove FRT BLWR fuse (65-amp) from engine compartment left fuse block. Disconnect front blower motor relay, located behind interior fuse block. Measure resistance of White/Blue wire between FRT BLWR fuse and front blower motor relay. Resistance should be less than 5 ohms. Measure resistance of White/Blue wire between FRT BLWR fuse and ground. Resistance should be greater than 10,000 ohms. If resistances are as specified, go to step 10). If resistances are not as specified, repair White/Blue wire as necessary. Retest system.
5. Check Purple Wire For Short(s) To Ground
   
   Ensure ignition is off. Remove ELECTRON BAT fuse (10-amp) from interior fuse block. Disconnect A/C control panel 16-pin connector. Measure resistance of Purple wire between left terminal of the ELECTRON BAT fuse holder and ground. If resistance is less than 5 ohms, repair wire as necessary. If resistance is greater than 5 ohms, replace ELECTRON BAT fuse. Go to step 10).
6. Check Gray Wire For Short(s) To Ground
   
   Ensure ignition is off. Remove A.C CONT fuse (7.5-amp) from interior fuse block. Disconnect A/C control panel 12-pin connector. Measure resistance of Gray wire between right terminal of METER fuse (7.5-amp) at interior fuse block and ground. If resistance is less than 5 ohms, repair wire as necessary. If resistance is greater than 5 ohms, replace A/C CONT fuse. Go to step 10).
7. Check Ignition Switch Circuit For Short To Ground
   
   Ensure ignition is off. Remove IGN SW fuse (30-amp) from engine compartment left fuse block. Disconnect front blower motor relay, located behind interior fuse block. Turn ignition on. Measure resistance of White/Purple wire between terminal nearest battery at IGN SW fuse holder and ground. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, wire is okay. Replace IGN SW fuse. Reconnect front blower motor relay. Go to step 10).
8. Check White/Purple Wire For Short To Ground
   
   Ensure ignition is off. Remove IGN SW fuse (30-amp) from engine compartment left fuse block. Disconnect ignition switch connector, located on steering column. Measure resistance of White/Purple wire between terminal nearest battery at IGN SW fuse holder and ground. If resistance is greater than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, repair White/Purple wire as necessary. Retest system.
9. Check Red/Green Wire For Short To Ground
   
   Ensure ignition is off. Disconnect ignition switch connector, located on steering column. Disconnect front blower motor relay connector. Measure resistance of Red/Green wire between ignition switch connector and ground. If resistance is greater than 10,000 ohms, replace ignition switch and retest system. If resistance is less than 10,000 ohms, repair Red/Green wire and retest system.
10. Check Power Supply To A/C Control Panel
    
    Ensure ignition is off. Remove A/C control panel. Disconnect A/C control panel 16-pin connector. Measure voltage at Purple wire of 16-pin connector. If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, repair open Purple wire between interior fuse block and A/C control panel.
11. Check Power Supply To A/C Control Panel
    
    Ensure ignition is off. Disconnect A/C control panel 12-pin connector. Turn ignition on. Measure voltage at Gray wire of 12-pin connector. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair Gray wire between interior fuse block and A/C control panel.
12. Check A/C Control Panel Grounds
    
    Ensure ignition is off. Disconnect A/C control panel 12-pin connector. Measure resistance of Black wire between 12-pin connector and ground. If resistance is less than 5 ohms, replace A/C control panel. If resistance is greater than 5 ohms, repair open Black wire.

FRONT BLOWER MOTOR INOPERATIVE

1. Check Fuses
   
   Check top and bottom FRONT BLOWER MOTOR fuses (20-amp) in interior fuse block. Check IGN SW fuse (30-amp) in engine compartment left fuse block. If fuses are okay, go to step 8). If any fuse is blown, go to next step.
2. Check System
   
   Ensure ignition is off. Replace any blown fuse. Turn ignition on. Recheck fuses. If fuses are okay, go to step 8). If FRONT BLOWER MOTOR fuse (65-amp) is blown, go to next step. If top and/or bottom FRONT BLOWER MOTOR fuse (20-amp) is blown, go to step 4). If IGN SW fuse (30-amp) is blown, go to step 5).
3. Check White/Blue Wire For Short
   
   Turn ignition off. Remove front blower motor relay, located behind interior fuse block. Remove FRONT BLOWER MOTOR fuse (65-amp). Measure resistance of White/Blue wire between FRONT BLOWER MOTOR fuse (65-amp) and blower motor relay connector. Resistance should be less than 5 ohms. Measure resistance of White/Blue wire between FRONT BLOWER MOTOR fuse (65-amp) and ground. Resistance should be greater than 10,000 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair White/Blue wire as required.
4. Check Brown/White Wire For Short To Ground
   
   Ensure ignition is off. Remove top FRONT BLOWER MOTOR fuse (20-amp) from interior fuse block. Remove front heater blower motor relay, located behind interior fuse block. Measure resistance of Brown/White wire between interior fuse block and ground. If ohmmeter indicates more than 10,000 ohms, replace top FRONT BLOWER MOTOR fuse. Reconnect front heater blower motor relay, and go to next step. If ohmmeter indicates less than 10,000 ohms, wire is shorted to ground. Repair as necessary.
5. Check Ignition Switch Circuit For Short To Ground
   
   Ensure ignition is off. Remove IGN SW fuse (30-amp) from main block. Disconnect front heater blower motor relay, located behind interior fuse block. Turn ignition on. Measure resistance of White/Purple wire at engine compartment left fuse block for short to ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, replace IGN SW fuse. Reconnect front heater blower motor relay.
6. Check White/Purple Wire For Short To Ground
   
   Ensure ignition is off. Remove IGN SW fuse (30-amp). Disconnect ignition switch connector, located on steering column. Measure resistance of White/Purple wire between fuse connector nearest battery at IGN SW fuse holder and ground. If resistance is more than 10,000 ohms, go to next step. If resistance is less than 10,000 ohms, wire is shorted to ground. Repair as necessary.
7. Check Red/Green Wire For Short To Ground
   
   Turn ignition off. Disconnect ignition switch connector. Disconnect front blower motor relay. Measure resistance of Red/Green wire between ignition switch connector and ground. If resistance is greater than 10,000 ohms, replace ignition switch and retest system. If resistance is less than 10,000 ohms, wire is shorted to ground. Repair as necessary.
8. Check Power Supply To Front Heater Blower Motor
   
   Ensure ignition is off. Disconnect front heater blower motor connector. Turn ignition on. Press any mode selection button on A/C control panel. Measure voltage at Brown/White wire of front blower motor connector. If voltage is more than 10 volts, go to step 17). If voltage is less than 10 volts, go to next step.
9. Ensure ignition is off. Disconnect front heater blower motor relay connector, located behind interior fuse block. Measure voltage at White/Blue wire at front heater blower motor relay connector. If voltage at each terminal is greater than 10 volts, go to next step. If voltage is less than 10 volts, repair White/Blue wire as necessary.
10. Check Power Supply From Ignition Switch Circuit
    
    Ensure ignition is off. Disconnect front heater blower motor relay. Turn ignition on. Measure voltage at Red/Green wire terminal of front heater blower motor relay connector. If voltage is greater than 10 volts, go to step 13). If voltage is not greater than 10 volts, go to next step.
11. Check Power Supply To Ignition Switch
    
    Ensure ignition is off. Disconnect ignition switch connector, located on steering column. Measure voltage at White/Purple wire terminal of ignition switch connector. If voltage is greater than 10 volts, go to next step. If voltage is not greater than 10 volts, repair open White/Purple wire between engine compartment left fuse block and ignition switch.
12. Check Red/Green Wire For Continuity
    
    Ensure ignition is off. Disconnect ignition switch connector, located on steering column. Disconnect front heater blower motor relay. Measure resistance of Red/Green wire between ignition switch connector and front heater blower motor relay connector. If resistance is less than 5 ohms, wire is okay. Replace ignition switch. If resistance is more than 5 ohms, repair open Red/Green wire.
13. Check Yellow/Red Wire
    
    Ensure ignition is off. Disconnect front heater blower motor relay. Disconnect A/C control panel 12-pin connector. Measure resistance of Yellow/Red wire between front heater blower motor relay and ground. Ohmmeter should indicate more than 10,000 ohms. Check continuity of Yellow/Red wire between front heater blower motor relay and A/C control panel. Ohmmeter should indicate less than 5 ohms. If resistances are not as specified, repair Yellow/Red wire. If resistances are as specified, reconnect relay and A/C control panel connectors. Go to next step.
14. Check Front Blower System
    
    Ensure ignition is off. Disconnect A/C control panel 12-pin connector. Connect jumper wire between Yellow/Red wire terminal of 12-pin connector and ground. Turn ignition on. If front heater blower motor operates, replace A/C control panel. If front heater blower motor does not operate, test blower motor relay. Replace relay if necessary. If relay is okay, go to next step.
15. Check Blower Motor Relay
    
    To check blower motor relay, see MANUAL A/C-HEATER SYSTEMS - VILLAGER article. If relay is okay, go to next step. If relay is faulty, replace relay and retest system.
16. Check Brown/White Wires
    
    Ensure ignition is off. Disconnect front heater blower motor relay and front heater blower motor connector. Blower motor connector is located behind right instrument panel lower cover. Measure resistance of Brown/White wire between front heater blower motor relay connector and ground. Resistance should be more than 10,000 ohms. Measure resistance of Brown/White wires between front heater blower motor relay connector and front heater blower motor connector. Resistance should be less than 5 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair Brown/White wire(s).
17. Check Heater Blower Motor Operation
    
    Ensure ignition is off. Disconnect front heater blower motor connector. Using jumper wire, connect Brown/White wire terminal of front heater blower motor to positive battery terminal. Connect a second jumper wire between Green wire terminal of front heater blower motor and ground. Replace front heater blower motor if it does not operate. If front heater blower motor operates, go to next step.
18. Check Front Blower Motor Switch
    
    To test front heater blower motor switch, see MANUAL A/C-HEATER SYSTEMS - VILLAGER article. If switch is okay, go to next step. If switch is faulty, replace switch and retest system.
19. Check Front Blower Motor Resistor
    
    To test front heater blower motor resistor, see MANUAL A/C-HEATER SYSTEMS - VILLAGER article. If resistor is faulty, replace resistor and retest system. If resistor is okay, go to next step.
20. Check Front Blower System Grounds
    
    Ensure ignition is off. Disconnect front heater blower motor switch connector. Disconnect front heater blower motor resistor connector. Measure resistance of Black wire between front heater blower motor switch connector and ground. Measure resistance of Black wire between front heater blower motor resistor connector and ground. If resistance is less than 5 ohms, repair open Green wire. If ohmmeter indicates more than 5 ohms, repair appropriate Black wire.

FRONT HEATER BLOWER MOTOR RUNS CONTINUOUSLY

1. Check Blower Motor Relay
   
   Test front heater blower motor relay. See MANUAL A/C-HEATER SYSTEMS - VILLAGER article. Replace relay if necessary. If relay is okay, go to next step.
2. Check Yellow/Red Wire For Short To Ground
   
   Ensure ignition is off. Remove front heater blower motor relay. Disconnect A/C control panel 12-pin connector. Measure resistance of Yellow/Red wire between front heater blower motor relay and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Yellow/Red wire between front heater blower motor relay and A/C control panel 12-pin connector. Resistance should be less than 5 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair Yellow/Red wire.
3. Check Green Wire For Short To Ground
   
   Ensure ignition is off. Disconnect front heater blower motor, front heater blower motor switch, and front heater blower motor resistor connectors. Measure resistance of Green wire between front heater blower motor connector and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Green wires between front heater blower motor connector, front heater blower motor switch, and front heater blower motor resistor connectors. Resistance should be less than 5 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair appropriate Green wire(s).
4. Check Light Green/Red Wire For Short To Ground
   
   Ensure ignition is off. Disconnect front heater blower motor switch and front heater blower motor resistor connectors. Measure resistance of Light Green/Red wire between front heater blower motor switch connector and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Light Green/Red wire between front heater blower motor switch connector and front heater blower motor resistor connector. Resistance should be less than 5 ohms. If resistance are as specified, go to next step. If resistances are not as specified, repair Light Green/Red wire.
5. Check Yellow/Black Wire For Short To Ground
   
   Ensure ignition is off. Disconnect front heater blower motor switch and front heater blower motor resistor connectors. Measure resistance of Yellow/Black wire between front heater blower motor switch connector and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Yellow/Black wire between front heater blower motor switch connector and front heater blower motor resistor connector. Resistance should be less than 5 ohms. If resistances are as specified, replace A/C control panel. If resistances are not as specified, repair Yellow/Black wire.

OUTSIDE/RECIRCULATED AIR DOOR INOPERATIVE

1. Check Voltage To Outside/Recirculated Air Door Actuator
   
   Ensure ignition is off. Disconnect outside/recirculated air door actuator connector, located behind passenger-side instrument panel lower cover. Turn ignition on. Measure voltage at indicated wire of outside/recirculated air door actuator connector. See OUTSIDE/RECIRCULATED AIR DOOR ACTUATOR VOLTAGE TEST table. If voltage is not as specified, go to next step. If voltage is as specified, replace outside/recirculated air door actuator.

   OUTSIDE/RECIRCULATED AIR DOOR ACTUATOR VOLTAGE TEST
   

   Air Selector Button Position	Wire Color	Volts
   Fresh Air	Yellow/Black	0
   Fresh Air	White	12
   Recirculated Air	Yellow/Black	12
   Recirculated Air	White	0

2. Check Yellow/Black Wire
   
   Ensure ignition is off. Disconnect outside/recirculated air door actuator connector. Disconnect A/C control panel 12-pin connector. Measure resistance of Yellow/Black wire between outside/recirculated air door actuator connector and ground. Resistance should be greater than 10,000 ohms. Measure resistance of Yellow/Black wire between outside/recirculated air door actuator connector and A/C control panel 12-pin connector. Resistance should be less than 5 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair Yellow/Black wire.
3. Check White Wire
   
   Ensure ignition is off. Disconnect outside/recirculated air door actuator connector and A/C control panel 12-pin connector. Measure resistance of White wire between outside/recirculated air door actuator connector and ground. Resistance should be greater than 10,000 ohms. Measure resistance of White wire between outside/recirculated air door actuator connector and A/C control panel 12-pin connector. Resistance should be less than 5 ohms. If resistances are as specified, replace A/C control panel. If resistances are not as specified, repair White wire.

TEMPERATURE CONTROL INOPERATIVE

1. Check Wires To Temperature Blend Door Actuator
   
   Turn ignition off. Disconnect A/C control panel 16-pin connector. Disconnect temperature blend door actuator connector, located behind passenger-side instrument panel lower cover. Using ohmmeter, measure resistance of indicated wires between 16-pin connector and ground. See TEMPERATURE BLEND DOOR ACTUATOR CIRCUIT TESTS table. Measure resistance of indicated wires between 16-pin connector and temperature blend door actuator connector. See TEMPERATURE BLEND DOOR ACTUATOR CIRCUIT TESTS table. If results are not as specified, repair appropriate wire(s). If results are as specified, reconnect 16-pin connector, and go to next step.

   TEMPERATURE BLEND DOOR ACTUATOR CIRCUIT TESTS
   

   Test & Wire Color		Ohms
   Short To Ground Check (1)
   Blue/Black Wire		More Than 10,000
   Orange Wire		More Than 10,000
   Blue/Red Wire		More Than 10,000
   Red/White Wire		More Than 10,000
   Red/Black Wire		More Than 10,000
   Continuity Check (2)
   Blue/Black Wire		Less Than 5
   Orange Wire		Less Than 5
   Blue/Red Wire		Less Than 5
   Red/White Wire		Less Than 5
   Red/Black Wire		Less Than 5
   (1) Check between indicated wire and ground. (2) Check indicated wire between 16-pin connector and temperature blend door actuator connector.

2. Check Output From A/C Control Panel
   
   Ensure ignition is off. Disconnect temperature blend door actuator connector. Turn ignition on. Press any mode button on A/C control panel. Move temperature control knob between full WARM and full COOL settings, and measure voltage at indicated terminal of temperature blend door actuator connector. See TEMPERATURE BLEND DOOR ACTUATOR VOLTAGE TEST table. If voltage is not as specified, replace A/C control panel. If voltage is as specified, go to next step.

   TEMPERATURE BLEND DOOR ACTUATOR VOLTAGE TEST
   

   Wire Color	Volts
   Orange Wire	Varies Between .25 (Full COOL) 9.25 (Full WARM)
   Blue/Red Wire	Approximately 0
   Blue/Black Wire	Approximately 7.75

3. Check Temperature Blend Door Actuator Operation
   
   Ensure ignition is off. Disconnect A/C control panel 16-pin connector.

CAUTION:

DO NOT apply battery voltage to actuator for an extended period, as temperature blend door mechanism and/or actuator may be damaged.

Connect a jumper wire between positive battery terminal and Red/White wire terminal of 16-pin connector. Connect a second jumper wire between Red/Black wire terminal of 16-pin connector and ground. Ensure actuator rotates toward full cool position (counterclockwise). Reverse polarity, and ensure actuator rotates toward full warm position (clockwise). If actuator functions as indicated, replace A/C control panel. If actuator does not function as indicated, replace temperature blend door actuator.

ONE OR MORE MODES INOPERATIVE (AIR OUTLET DOES NOT CHANGE)

1. Check Mode Door Actuator Signal Return Wire
   
   Turn ignition off. Disconnect A/C control panel 12-pin connector. Disconnect mode door actuator connector, located behind driver-side instrument panel lower cover. Using ohmmeter, measure resistance of Black/Red wire between 12-pin connector and ground. Resistance should be more than 10,000 ohms. Measure resistance of Black/Red wire between 12-pin connector and mode door actuator connector. Resistance should be less than 5 ohms. If resistances are as specified, go to next step. If resistances are not as specified, repair Black/Red wire.
2. Check Wires To Mode Door Actuator
   
   Ensure ignition is off. Disconnect A/C control panel 12-pin and 16-pin connectors. Disconnect mode door actuator connector. Using ohmmeter, measure resistance of indicated wires between connector and ground. See MODE DOOR ACTUATOR CIRCUIT TESTS table. Measure resistance of indicated wires between A/C control panel connectors and mode door actuator connector. See MODE DOOR ACTUATOR CIRCUIT TESTS table. If results are not as specified, repair appropriate wire(s). If results are as specified, reconnect A/C control panel connectors and go to next step.

   MODE DOOR ACTUATOR CIRCUIT TESTS
   

   Test & Wire Color		Ohms
   Short To Ground Check (1)
   Light Green Wire		More Than 10,000
   Light Green/Red Wire		More Than 10,000
   Light Blue Wire		More Than 10,000
   Brown Wire		More Than 10,000
   Brown/Yellow Wire		More Than 10,000
   Blue/White Wire		More Than 10,000
   Continuity Check (2)
   Light Green Wire		Less Than 5
   Light Green/Red Wire		Less Than 5
   Light Blue Wire		Less Than 5
   Brown Wire		Less Than 5
   Brown/Yellow Wire		Less Than 5
   Blue/White Wire		Less Than 5
   (1) Check between indicated wire and ground. (2) Check indicated wire between A/C control panel connectors (12-pin and 16-pin) and mode door actuator connector.

3. Check Output From A/C Control Panel
   
   Ensure ignition is off. Disconnect mode door actuator connector. Turn ignition on. Press any mode button on A/C control panel. Press each mode button on A/C control panel, and measure voltage at indicated terminal of mode door actuator connector. See MODE DOOR ACTUATOR VOLTAGE TEST table. If voltage is not as specified, replace A/C control panel. If voltage is as specified, go to next step.

   MODE DOOR ACTUATOR VOLTAGE TEST
   

   Wire Color	Volts
   Light Green Wire	5
   Light Green/Red Wire	5
   Light Blue Wire	5
   Brown Wire	5
   Brown/Yellow Wire	5
   Blue/White Wire	5

4. Check Wires To Mode Door Actuator Motor
   
   Ensure ignition is off. Disconnect A/C control panel 16-pin connector. Disconnect mode door actuator connector. Measure resistance of Green wire and Green/Yellow wire between 16-pin connector and ground. Resistance should be greater than 10,000 ohms for each wire. Measure resistance of Green wire and Green/Yellow wire between 16-pin connector and mode door actuator connector. Resistance should be less than 5 ohms for each wire. If resistances are as specified, reconnect mode door actuator connector, and go to next step. If resistances are not as specified, repair appropriate wire(s).
5. Check Mode Door Actuator Motor Operation
   
   Ensure ignition is off. Disconnect A/C control panel 16-pin connector.

CAUTION:

DO NOT apply battery voltage to actuator for an extended period, as mode door actuator mechanism and/or actuator may be damaged.

Connect a jumper wire between positive battery terminal and Green wire terminal of 16-pin connector. Connect a second jumper wire between Green/Yellow wire terminal of 16-pin connector and ground. Ensure actuator rotates toward vent position (counterclockwise).

Reverse polarity, and ensure actuator rotates toward defrost position (clockwise). If actuator functions as indicated, replace A/C control panel. If actuator does not function as indicated, replace mode door actuator.

INSUFFICIENT OR NO HEAT

Check cooling system and repair if necessary. If cooling system is okay, check heater control valve, rod and linkage for binding or sticking operation. Repair if necessary. If heater control valve, rod and linkage are okay, check for plugged heater core. Replace if necessary. If heater core is okay, no problem is indicated at this time.

IMPROPER OR NO AIR CIRCULATION

Inspect outside/recirculated air door, temperature blend door, panel/floor/defrost mode door, and the respective linkages for binding or sticking operation. Repair if necessary. If doors and linkages are okay, inspect cowl vent ducts for blockage. Repair if necessary. If ducts are okay, no problem is indicated at this time.