Auxiliary Climate Control - Diagnosis and Testing

Diagnostic Trouble Code Index: Heating, Ventilation and Air Conditioning (HVAC) Module

The diagnostics in this manual assume a certain level of skill and knowledge of Ford-specific diagnostic techniques. For information on these techniques,
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

DTC Chart: Instrument Panel Cluster (IPC)

The diagnostics in this manual assume a certain level of skill and knowledge of Ford-specific diagnostic techniques. For information on these techniques,
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Network Diagnostic Trouble Codes (DTCs) (U-codes) are often the result of intermittent conditions, such as damaged wiring or low battery voltage events. In addition, vehicle repair procedures, such as module reprogramming, often set network Diagnostic Trouble Codes (DTCs). Replacing a module to correct a network DTC is unlikely to correct the concern. To prevent repeat network DTC concerns, inspect all network wiring, especially the connectors. Check the vehicle battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).

Symptom Chart

Symptom Chart: Electric Auxiliary Heater

The diagnostics in this manual assume a certain level of skill and knowledge of Ford-specific diagnostic techniques. For information on these techniques,
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Pinpoint Tests

The diagnostics in this manual assume a certain level of skill and knowledge of Ford-specific diagnostic techniques. For information on these techniques,
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Electric Auxiliary Heater Does Not Operate/Does Not Operate Correctly

Refer to Wiring Diagrams Cell 54 for schematic and connector information. Refer to Wiring Diagrams Cell 55 for schematic and connector information.

Normal Operation and Fault Symptoms

Electric Auxiliary Heater,
Refer to: Auxiliary Climate Control - System Operation and Component Description (412-02 Auxiliary Climate Control, Description and Operation).

DTC Fault Trigger Conditions

Possible Sources

• Wiring, Terminals or Connectors
• Electric Auxiliary Heater Relay 1 and 2
• Supplemental Electric Heater
• HVAC Module
• PCM

Visual Inspection and Preliminary Diagnosis

• Inspect fuse 2 in the CJB (7.5A).
• Inspect high-current fuse 4 in the BJB Mega fuse (70A) and Mega fuse 5 (50A).
• Inspect the electric auxiliary heater relay for loose mounting or corrosion.

NOTICE: Use the correct probe adapter(s) when making measurements. Using incorrect probe adapter(s) may damage the connector.

NOTE: Before continuing with this pinpoint test, diagnose and repair all HVAC MODULE DIAGNOSTIC TROUBLE CODES (DTCS).

NOTE: Make sure the operating conditions for the electric heaters are met. To activate the electric auxiliary heater request, turn the temperature control knob to the full heat position. To deactivate the electric auxiliary heater request, turn the temperature control knob to the cooling position.

A1 CHECK THE ELECTRIC AUXILIARY HEATER RELAY

Ignition OFF. Perform the component test for the Relay - High Current ISO. Refer to Wiring Diagrams Cell 149 for schematic and connector information. Do the electric auxiliary heater relays pass the component test? Yes GO to A2 No INSTALL new relays as necessary.

A2 CHECK THE IPC (INSTRUMENT PANEL CLUSTER) FOR DIAGNOSTIC TROUBLE CODES (DTCS)

The ignition is on. Using the diagnostic scan tool, perform the IPC self-test. Are DTCs B10EA:00 or B10EA:01 retrieved? Yes For B10EA:00, go to A5. For B10EA:01, GO to Pinpoint Test B. No GO to A3

A3 CHECK THE ELECTRIC AUXILIARY HEATER RELAY SUPPLY VOLTAGE

Ignition OFF. Disconnect the electric auxiliary heater relay 1. Disconnect the electric auxiliary heater relay 2. The ignition is on. Action: Click to display the connectors Positive lead Measurement/Action Negative lead Electric Auxiliary Heater Relay 1, Cavity 1 Ground Electric Auxiliary Heater Relay 2, Cavity 1 Ground Is the voltage greater than 11 volts? Yes GO to A4 No CHECK CJB fuse 2 (7.5A) is OK. If OK, REPAIR the faulty circuit. If not OK, REFER to the Wiring Diagrams to determine the possible causes of the short circuit.

A4 CHECK THE ELECTRIC AUXILIARY HEATER SWITCHED VOLTAGE RELAY SUPPLY CIRCUITS

Action: Click to display the connectors Positive lead Measurement/Action Negative lead Electric Auxiliary Heater Relay, Heater Relay 1 Cavity 3 Ground Electric Auxiliary Heater Relay, Heater Relay 2 Cavity 3 Ground Is the voltage greater than 11 volts? Yes GO to A5 No CHECK high-current BJB Mega fuse 4 (70A) and Mega fuse 5 (50A) are OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to determine the possible causes of the short circuit.

A5 CHECK THE ELECTRIC AUXILIARY HEATER RELAY COIL CONTROL CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF. Disconnect the instrument panel cluster C220A. The ignition is on. Action: Click to display the connectors Positive lead Measurement/Action Negative lead Electric Auxiliary Heater Relay, Heater Relay 1 Cavity 2 Ground Electric Auxiliary Heater Relay, Heater Relay 2 Cavity 2 Ground Is there voltage present? Yes REPAIR the faulty circuit. No GO to A6

A6 CHECK THE ELECTRIC AUXILIARY HEATER CIRCUITS FOR A SHORT TO GROUND

Ignition OFF. Disconnect the electric auxiliary heater. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2603-1 Ground C2603-2 Ground Is the resistance greater than 10000 ohms? Yes GO to A7 No REPAIR the faulty circuit.

A7 CHECK THE ELECTRIC AUXILIARY HEATER CIRCUITS FOR AN OPEN

Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2603-1 Electric Auxiliary Heater Relay 1, Cavity 5 C2603-2 Electric Auxiliary Heater Relay 2, Cavity 5 Is the resistance less than 3 ohms? Yes GO to A8 No REPAIR the faulty circuit.

A8 CHECK THE ELECTRIC AUXILIARY HEATER CIRCUITS FOR A SHORT CIRCUIT

Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2603-1 C2603-2 Is the resistance greater than 10000 Ohms? Yes GO to A9 No REPAIR the faulty circuit.

A9 CHECK THE ELECTRIC AUXILIARY HEATER GROUND

Disconnect and inspect the electric auxiliary heater ground. Repair: corrosion (replace the connector or terminals - clean the module contacts) Reconnect the electric auxiliary heater ground. Operate the system and verify that the concern is still present. Is the concern still present? Yes GO to A10 No At this time the system is operating correctly. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or terminal problems.

A10 CHECK THE ELECTRIC AUXILIARY HEATER CONNECTIONS

Disconnect and inspect the electric auxiliary heater connector. Repair: corrosion (replace the connector or terminals - clean the module contacts) damaged or bent contacts - replace the terminals/contacts pushed-out pins - replace the pins as necessary Reconnect the electric auxiliary heater connector. Make sure it is properly seated and latched. Operate the system and verify that the concern is still present. Is the concern still present? Yes INSTALL a new electric auxiliary heater. Refer to: Electric Auxiliary Heater (412-02 Auxiliary Climate Control, Removal and Installation). If the concern is not resolved, GO to A11. No At this time the system is operating correctly. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or terminal problems.

A11 CHECK THE HVAC (HEATING, VENTILATION AND AIR CONDITIONING) MODULE FOR PROPER OPERATION

Ignition OFF. Disconnect and inspect all HVAC module connectors. Repair: corrosion (install new connector or terminals - clean module pins) damaged or bent pins - install new terminals/pins backed-out pins - install new pins as necessary Connect the HVAC module connector(s). Make sure they are installed and fully seated. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK the On-Line Automotive Service Information System (OASIS) for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, STOP this test and FOLLOW the TSB instructions. If no TSBs apply to this concern, INSTALL a new HVAC control module. REFER TO: Heating, Ventilation and Air Conditioning (HVAC) Control Module (412-00 Climate Control System - General Information, Removal and Installation). If the concern is not resolved, GO to A12. No The system is currently operating correctly. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

A12 CHECK INSTRUMENT PANEL CLUSTER (IPC) OPERATION

Ignition OFF. Disconnect and inspect the IPC connector. Repair: corrosion (replace the connector or terminals - clean the module contacts) damaged or bent contacts - replace the terminals/contacts pushed-out pins - replace the pins as necessary Reconnect the IPC connector. Make sure it is properly seated and latched. Operate the system and verify that the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, STOP this test and FOLLOW the TSB instructions. If no TSBs apply to this concern, Click here to access the guided procedure (IPC). No The system is currently operating correctly. The concern may have been caused by module connections. ADDRESS the root cause of any connector or terminal issues.

DTC B10EA:01 or 5-5

For circuit and connector information, refer to Wiring Diagrams Cell 54.

Normal Operation and Fault Symptoms

Electric Auxiliary Heater, Electric Auxiliary Heater,
Refer to: Auxiliary Climate Control - System Operation and Component Description (412-02 Auxiliary Climate Control, Description and Operation).

DTC Fault Trigger Conditions

Possible Sources

• Wiring, Terminals or Connectors
• HVAC control module
• PCM

NOTICE: Use the correct probe adapter(s) when making measurements. Using incorrect probe adapter(s) may damage the connector.

B1 CHECK THE HVAC (HEATING, VENTILATION AND AIR CONDITIONING) CONTROL MODULE FOR DIAGNOSTIC TROUBLE CODES (DTCS)

The ignition is on. Using Self-Test - Retrieving and Clearing Heating, Ventilation and Air Conditioning (HVAC) Control Module Diagnostic Trouble Codes, perform the HVAC control module self-test. REFER TO: Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control System - General Information, Diagnosis and Testing). Was DTC 5-5 retrieved? Yes GO to B3 No GO to B2

B2 CHECK THE IPC (INSTRUMENT PANEL CLUSTER) FOR DIAGNOSTIC TROUBLE CODES (DTCS)

The ignition is on. Using the diagnostic scan tool, perform the IPC self-test. Are DTCs B10EA:00 or B10EA:01 retrieved? Yes For B10EA:00, GO to Pinpoint Test A. For B10EA:01, GO to B3. No For all other IPC diagnostic trouble codes (DTCs): Refer to: Instrument Cluster, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).

B3 CHECK THE ELECTRIC AUXILIARY HEATER REQUEST CIRCUIT FOR A SHORT TO BATTERY VOLTAGE

Ignition OFF. Disconnect the instrument panel cluster C220A. Disconnect the Heating, Ventilation and Air Conditioning (HVAC) control module C2357A. The ignition is on. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2357A-20 Ground Is there voltage present? Yes REPAIR the faulty circuit. No GO to B4

B4 CHECK THE ELECTRIC AUXILIARY HEATER REQUEST CIRCUIT FOR A SHORT TO GROUND

Ignition OFF. Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2357A-20 Ground Is the resistance greater than 10000 ohms? Yes GO to B5 No REPAIR the faulty circuit.

B5 CHECK THE ELECTRIC AUXILIARY HEATER REQUEST CIRCUIT FOR AN OPEN

Action: Click to display the connectors Positive lead Measurement/Action Negative lead C2357A-20 C220A-21 Is the resistance less than 3 ohms? Yes GO to B6 No REPAIR the circuit.

B6 CHECK THE HVAC (HEATING, VENTILATION AND AIR CONDITIONING) CONTROL MODULE OPERATION

Ignition OFF. Disconnect and inspect all HVAC module connectors. Repair: corrosion (install new connector or terminals - clean module pins) damaged or bent pins - install new terminals/pins backed-out pins - install new pins as necessary Connect the HVAC module connectors. Make sure they are fully seated and locked. Reconnect the IPC connector. Make sure it is properly seated and latched. Operate the system and determine if the concern is still present. Is the concern still present? Yes CHECK the On-Line Automotive Service Information System (OASIS) for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, STOP this test and FOLLOW the TSB instructions. If no TSBs apply to this concern, INSTALL a new HVAC control module. REFER TO: Heating, Ventilation and Air Conditioning (HVAC) Control Module (412-00 Climate Control System - General Information, Removal and Installation). If the concern is not resolved, GO to B7. No The system is currently operating correctly. The concern may have been caused by a loose or corroded connector. ADDRESS the root cause of any connector or pin issues.

B7 CHECK INSTRUMENT PANEL CLUSTER (IPC) OPERATION

Ignition OFF. Disconnect and inspect the IPC connector. Repair: corrosion (replace the connector or terminals - clean the module contacts) damaged or bent contacts - replace the terminals/contacts pushed-out pins - replace the pins as necessary Reconnect the IPC connector. Make sure it is properly seated and latched. Operate the system and verify that the concern is still present. Is the concern still present? Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, STOP this test and FOLLOW the TSB instructions. If no TSBs apply to this concern, Click here to access the guided procedure (IPC). No The system is currently operating correctly. The concern may have been caused by module connections. ADDRESS the root cause of any connector or terminal issues.