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Ford Taurus 2003 Workshop Manual
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Ford Taurus 2003 Workshop Manual

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2003 Taurus/Sable Workshop Manual
SECTION 412-00: Climate Control System - General Information
DIAGNOSIS AND TESTING
Climate Control System
Printable View (1000 KB)
Refer to Wiring Diagrams Cell
54
for schematic and connector information.
Refer to Wiring Diagrams Cell
55
for schematic and connector information.
Special Tool(s)
Worldwide Diagnostic System (WDS)
418-F224,
New Generation STAR (NGS) Tester
418-F052, or equivalent scan tool
Rotunda 73 III Automotive Meter
105-R0057 or equivalent
R134a Manifold Gauge Set
176-R032A or equivalent
Vacuum Pump Kit
416-D002 (D95L-7559-A) or equivalent
Connector, Refrigerant Pressure Line
412-093 (T94P-19623-E)
Set, A/C Fittings
412-DS028 (014-00333, D93L-19703-B) or equivalent
Refrigerant Leak Detector
216-00001 or equivalent
Pressure Test Kit
014-R1072 or equivalent
Breakout Box, EEC V Control System
418-049 (014-00950, T94L-50-EEC-V)
Starter, Alternator, Battery, Regulator Electrical Tester (S.A.B.R.E.)
010-00736 or equivalent
Manual Climate Control Vacuum Schematic
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS3H/~MUS~LEN/19/...
Page 1 of 47
2003 Taurus/Sable Workshop Manual
Procedure revision date: 02/16/2006
11/22/2011

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Summary of Contents for Ford Taurus 2003

  • Page 1 2003 Taurus/Sable Workshop Manual Page 1 of 47 SECTION 412-00: Climate Control System - General Information 2003 Taurus/Sable Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 02/16/2006 Climate Control System Printable View (1000 KB) Refer to Wiring Diagrams Cell for schematic and connector information. Refer to Wiring Diagrams Cell for schematic and connector information.
  • Page 2 2003 Taurus/Sable Workshop Manual Page 2 of 47 Item Part Number Description — Panel airflow — Floor console door, full vacuum position (floor console equipped only) 18A318 Vacuum control motor—defrost door — Defrost door, full vacuum position — Defrost airflow —...
  • Page 3 2003 Taurus/Sable Workshop Manual Page 3 of 47 Port Number Line Color Function White Air inlet door floor door Black Source vacuum — Not used Blue floor door Yellow Defrost door Also controls the floor console door, if equipped. MANUAL CLIMATE CONTROL VACUUM APPLICATION CHART Function Selector Switch Position Port Number Line Color Function...
  • Page 4 2003 Taurus/Sable Workshop Manual Page 4 of 47 — Defrost door, full vacuum position — Defrost airflow — Side window demister airflow — Supplemental temperature blend door, full heat position — Recirculation air inlet 18731 Supplemental recirculation air inlet door, full vacuum position 18731 Air inlet door, full vacuum position —...
  • Page 5 2003 Taurus/Sable Workshop Manual Page 5 of 47 Mechanical Electrical Loose, missing or damaged A/C compressor drive belt Open fuses Loose or disconnected A/C clutch Blower motor inoperative Loose, misrouted or damaged vacuum lines A/C compressor inoperative Circuitry open/shorted Broken or leaking vacuum control motor Disconnected, loose fitting, or incorrectly installed electrical connectors and pins Discharged A/C system Broken or leaking refrigerant lines...
  • Page 6 2003 Taurus/Sable Workshop Manual Page 6 of 47 To exit the self-test and clear all DTCs, press the front defrost button. All RCC module DTCs will be cleared. Always exit the self-test before powering the system down (system turned off). Intermittent DTCs will be deleted after 80 ignition switch ON cycles after the intermittent condition occurs.
  • Page 7 2003 Taurus/Sable Workshop Manual Page 7 of 47 8. Compare the Average Center Vent Temperature to the A/C performance chart for the ambient conditions at the time of testing. If the Average Center Vent Temperature is less than the temperature in the A/C performance chart, no further diagnosis is required. If the Average Center Vent Temperature is greater than the temperature in the A/C performance chart, refer to the Symptom Chart.
  • Page 8 2003 Taurus/Sable Workshop Manual Page 8 of 47 Temperature blend door binding/stuck. The blower motor does not operate— Open fuse. GO to Pinpoint Test manual climate control Circuit open/short. Blower motor (19805). Function selector switch (19B888). Blower motor relay (14B192). The blower motor is inoperative—EATC Open fuse.
  • Page 9 2003 Taurus/Sable Workshop Manual Page 9 of 47 condition is found, INSTALL a new door actuator. REFER Connect a fused jumper wire between RCC module C228 pin 21, circuit 249 (DB/LG) and RCC module C228 pin Section 412-04. TEST the system for normal operation. 11, circuit 729 (RD/WH).
  • Page 10 2003 Taurus/Sable Workshop Manual Page 10 of 47 Are the resistances less than 5 ohms? A8 CHECK CIRCUIT 250 (OG) AND 249 (DB/LG) FOR A SHORT TOGETHER Measure the resistance between RCC module C228 pin 22, circuit 250 (OG) and RCC module C228 pin 21, circuit 249 (DB/LG).
  • Page 11 2003 Taurus/Sable Workshop Manual Page 11 of 47 A12 CHECK POTENTIOMETER LOW SIDE RESISTANCE Drive the actuator to the full clockwise position. Refer to A1. GO to A15. Measure the resistance between RCC module C228 pin 9, circuit 437 (YE/LG) and RCC module C228 pin 20, circuit 438 (RD/WH).
  • Page 12 2003 Taurus/Sable Workshop Manual Page 12 of 47 Is the resistance greater than 10,000 ohms? A17 CHECK CIRCUITS 436 (RD/LG) AND 437 (YE/LG) FOR A SHORT TO GROUND Disconnect: Temperature Blend Door Actuator C289. Measure the resistance between RCC module C228 pin 5, circuit 436 (RD/LG) and ground. Measure the GO to A18.
  • Page 13 2003 Taurus/Sable Workshop Manual Page 13 of 47 Is the voltage between 4.7 and 5.1 volts? B3 CHECK CIRCUIT 790 (WH/OG) FOR AN OPEN Ignition OFF. Disconnect: RCC Module C228. GO to B4. Measure the resistance between the RCC module C228 pin 23, circuit 790 (WH/OG) and the in-vehicle temperature sensor C233, circuit 790 (WH/OG).
  • Page 14 2003 Taurus/Sable Workshop Manual Page 14 of 47 PINPOINT TEST C: DTC B1255 OR DTC B1257 — AMBIENT TEMPERATURE SENSOR OPEN CIRCUIT OR SHORT TO GROUND Test Step Result / Action to Take C1 CHECK THE AMBIENT TEMPERATURE SENSOR RESISTANCE Ignition OFF.
  • Page 15 2003 Taurus/Sable Workshop Manual Page 15 of 47 Is the resistance greater than 10,000 ohms? C6 CHECK CIRCUIT 788 (RD/OG) FOR A SHORT TO GROUND Ignition OFF. Measure the resistance between the RCC module C228 pin 7, circuit 788 (RD/OG) and ground. INSTALL a new RCC module.
  • Page 16 2003 Taurus/Sable Workshop Manual Page 16 of 47 Is the resistance less than 5 ohms? D4 CHECK CIRCUIT 398 (BK/YE) FOR AN OPEN Measure the resistance between the solar radiation sensor C287 pin 5, circuit 398 (BK/YE). INSTALL a new RCC module. TEST the system for normal operation.
  • Page 17 2003 Taurus/Sable Workshop Manual Page 17 of 47 Is the resistance greater than 10,000 ohms? E2 CHECK CIRCUIT 833 (TN) FOR SHORT TO VOLTAGE Ignition ON. Measure the voltage between the ICP C2009 pin 14, circuit 833 (TN) and ground. REPAIR circuit 833 (TN).
  • Page 18 2003 Taurus/Sable Workshop Manual Page 18 of 47 Is voltage present? E6 CHECK CIRCUIT 832 (LB/PK) FOR AN OPEN Ignition OFF. Measure the resistance between the ICP C2009 pin 13, circuit 832 (LB/PK) and the RCC module C228 pin 1, INSTALL a new integrated control panel (18C858).
  • Page 19 2003 Taurus/Sable Workshop Manual Page 19 of 47 Ignition ON. REFER to Section 418-00 to diagnose the network concern. Measure the voltage between the RCC module pin 10, circuit 298 (VT/OG) and ground. REPAIR circuit 298 (VT/OG). TEST the system for normal operation. Is the voltage greater than 10 volts? PINPOINT TEST G: THE EATC SYSTEM IS INOPERATIVE, INTERMITTENT OR INCORRECT OPERATION Test Step...
  • Page 20 2003 Taurus/Sable Workshop Manual Page 20 of 47 GO to Pinpoint Test G11 CHECK THE RCC MODULE FUNCTIONS Press each function button and observe the display. Does the RCC perform and display any functions? INSTALL a new RCC module. TEST the system for normal operation.
  • Page 21 2003 Taurus/Sable Workshop Manual Page 21 of 47 Check for manifold vacuum at the open port on the vacuum check valve. Is manifold vacuum present at the open port on the vacuum check valve? H4 CHECK THE VACUUM CHECK VALVE Ignition OFF.
  • Page 22 2003 Taurus/Sable Workshop Manual Page 22 of 47 selector switch vacuum source line. TEST the system for normal operation. GO to H9. Can a vacuum be pulled on the function selector switch vacuum source line? H9 CHECK THE FUNCTION SELECTOR SWITCH VACUUM SOURCE LINE FOR LEAKS Plug the function selector switch vacuum source line at the function selector switch connection.
  • Page 23 2003 Taurus/Sable Workshop Manual Page 23 of 47 Does the vacuum in any hose drop exceed 3.37 kPa (1 in-Hg) per minute? H13 CHECK THE VACUUM CONTROL MOTOR Disconnect: Vacuum Control Motor. Connect a vacuum pump to the affected vacuum control motor. Apply 51 kPa (15 in-Hg) of vacuum. INSTALL a new vacuum control motor (18A318).
  • Page 24 2003 Taurus/Sable Workshop Manual Page 24 of 47 Is manifold vacuum present at the check valve vacuum source line? I3 CHECK THE VACUUM CHECK VALVE FOR BLOCKAGE Reconnect the vacuum source line to the vacuum check valve. Disconnect the vacuum reservoir line and the EATC module vacuum line from the GO to I4.
  • Page 25 2003 Taurus/Sable Workshop Manual Page 25 of 47 I7 CHECK THE VACUUM RESERVOIR FOR A LEAK Connect the vacuum pump reservoir line to the vacuum reservoir. INSTALL a new vacuum reservoir. TEST the system for normal operation. With the vacuum pump connected to the vacuum reservoir line, leak test the vacuum reservoir.
  • Page 26 2003 Taurus/Sable Workshop Manual Page 26 of 47 I11 CHECK THE VACUUM CONTROL MOTOR LINE FOR LEAKS Plug the vacuum control motor line at the vacuum control motor connection. REPAIR or INSTALL a new vacuum harness. TEST the system for normal Leak test the vacuum control motor line using the vacuum pump.
  • Page 27 2003 Taurus/Sable Workshop Manual Page 27 of 47 Does the air inlet door vacuum control motor operate and hold a vacuum? I17 INSPECT THE AIR INLET DOOR LINKAGE AND MOVEMENT Inspect the air inlet door linkage and verify correct movement of the door. Is the air inlet door or air inlet door linkage broken, binding or otherwise REPAIR the air inlet door or air inlet door linkage as needed.
  • Page 28 2003 Taurus/Sable Workshop Manual Page 28 of 47 Test Step Result / Action to Take K1 CHECK THE A/C PRESSURE PCM PID Ignition ON. GO to K2. Enter the following diagnostic mode on the scan tool: A/C Pressure PCM PID. With the manifold gauge set connected, compare the pressure readings of the manifold gauge set and the A/C pressure PID.
  • Page 29 2003 Taurus/Sable Workshop Manual Page 29 of 47 Is the resistance less than 21 ohms? K10 CHECK THE VOLTAGE AT THE FUNCTION SELECTOR SWITCH Ignition OFF. Remove the climate control assembly. Refer to Section 412-04. GO to K11. Disconnect: Function Selector Switch C294b. Ignition ON.
  • Page 30 2003 Taurus/Sable Workshop Manual Page 30 of 47 Start the engine. Does the A/C compressor operate? K15 CHECK CIRCUIT 879 (DG/WH) Ignition OFF. Remove the fused jumper lead from the A/C pressure cutoff switch C1062. INSTALL a new PCM. REFER to Section 303-14.
  • Page 31 2003 Taurus/Sable Workshop Manual Page 31 of 47 Is the voltage greater than 10 volts? K19 CHECK CIRCUIT 347 (BK/YE) Measure the resistance between the A/C control relay socket pin 5, circuit 347 (BK/YE) and the A/C compressor clutch field coil C100, circuit 347 (BK/YE). GO to K21.
  • Page 32 2003 Taurus/Sable Workshop Manual Page 32 of 47 PINPOINT TEST L: THE A/C IS ALWAYS ON Test Step Result / Action to Take L1 CHECK PID WACF WITH THE A/C OFF Ignition ON. REPAIR circuit 331 (PK/YE). TEST the system for normal operation. Place the function selector switch to the OFF position or press the OFF manual override button .
  • Page 33 2003 Taurus/Sable Workshop Manual Page 33 of 47 Is the voltage greater than 10 volts? L7 CHECK FOR VOLTAGE TO THE A/C COMPRESSOR CLUTCH FIELD COIL Ignition OFF. Disconnect: A/C Compressor Clutch Field Coil C100. GO to L8. Ignition ON. Measure the voltage between the A/C compressor clutch field coil C100, circuit 347 (BK/YE) GO to L9.
  • Page 34 2003 Taurus/Sable Workshop Manual Page 34 of 47 Is the voltage greater than 10 volts? M2 CHECK THE GROUND TO THE BLEND DOOR ACTUATOR Ignition OFF. Measure the resistance between the blend door actuator C289 pin 8, circuit 57 (BK) and ground. GO to M3.
  • Page 35 2003 Taurus/Sable Workshop Manual Page 35 of 47 Measure the resistance between temperature blend door actuator C289 pin 6, circuit 436 (RD/LG) and pin 3, circuit 437 (YE/LG) GO to M9. while rotating the temperature control potentiometer from full WARM to full COOL. GO to M7.
  • Page 36 2003 Taurus/Sable Workshop Manual Page 36 of 47 Is voltage present? M11 CHECK FOR A BINDING, STUCK OR BROKEN BLEND DOOR Ignition OFF. Remove the actuator. Refer to Section 412-04. REPAIR the blend door/linkage. REFER Inspect for a binding, stuck or broken blend door or linkage. Section 412-04.
  • Page 37 2003 Taurus/Sable Workshop Manual Page 37 of 47 socket pin 30, circuit 371 (PK/WH). REPAIR circuit 371 (PK/WH). TEST the system for normal operation. Is the resistance less than 5 ohms? N5 CHECK THE BLOWER MOTOR RELAY GROUND Measure the resistance between the blower motor relay C2017 socket pin 86, circuit 275 (YE) and ground. GO to N8.
  • Page 38 2003 Taurus/Sable Workshop Manual Page 38 of 47 system for normal operation. REPAIR circuit 1001 (WH/YE). TEST the system for normal operation. Is the voltage greater than 10 volts? PINPOINT TEST O: THE BLOWER MOTOR IS INOPERATIVE — EATC Test Step Result / Action to Take O1 CHECK THE BLOWER MOTOR SPEED CONTROL SUPPLY VOLTAGE Ignition OFF.
  • Page 39 2003 Taurus/Sable Workshop Manual Page 39 of 47 Is the resistance less than 5 ohms? O5 CHECK CIRCUIT 371 (PK/WH) FOR AN OPEN Measure the resistance between the blower motor speed control C271a pin 1, circuit 371 (PK/WH) and the blower motor relay socket pin 30, circuit 371 (PK/WH).
  • Page 40 2003 Taurus/Sable Workshop Manual Page 40 of 47 Is the resistance less than 5 ohms? O9 CHECK CIRCUIT 261 (OG/BK) Measure the resistance between the blower motor speed control C271b, circuit 261 (BK) and the blower motor C2006, circuit 261 (BK). GO to O10.
  • Page 41 2003 Taurus/Sable Workshop Manual Page 41 of 47 PINPOINT TEST P: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY — MANUAL CLIMATE CONTROL Test Step Result / Action to Take P1 CHECK THE BLOWER MOTOR SWITCH Ignition OFF. GO to P2. Disconnect: Blower Motor Switch C294a.
  • Page 42 2003 Taurus/Sable Workshop Manual Page 42 of 47 1 and 2 1.4 ohms 2 and 4 1.9 ohms Are the resistances as indicated? PINPOINT TEST Q: THE BLOWER MOTOR OPERATES CONTINUOUSLY IN HIGH SPEED — MANUAL CLIMATE CONTROL Test Step Result / Action to Take Q1 CHECK THE BLOWER MOTOR GROUND Ignition OFF.
  • Page 43 2003 Taurus/Sable Workshop Manual Page 43 of 47 Is the voltage greater than 4.5 volts? R4 CHECK THE BLOWER MOTOR SPEED CONTROL Press the MAX A/C button blower motor speed override control fully down. Without disconnecting the blower motor speed control C271a from the blower motor speed control, use a fused GO to R5.
  • Page 44 2003 Taurus/Sable Workshop Manual Page 44 of 47 Is the resistance less than 5 ohms? PINPOINT TEST T: NO OPERATION IN LOWER SPEEDS — MANUAL CLIMATE CONTROL Test Step Result / Action to Take T1 CHECK CIRCUIT 261 (OG/BK) Ignition OFF. Disconnect: Blower Motor C2004.
  • Page 45 2003 Taurus/Sable Workshop Manual Page 45 of 47 Did the voltage continually decrease without discontinuities? U3 CHECK CIRCUIT 776 (OG/BK) FOR A SHORT TO GROUND Ignition OFF. GO to U4. Disconnect: Blower Motor Speed Control C271a. Measure the resistance between the remote climate control (RCC) module C228 pin 24, circuit 776 (OG/BK) and ground. REPAIR circuit 776 (OG/BK) for a short to ground.
  • Page 46 2003 Taurus/Sable Workshop Manual Page 46 of 47 WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3.
  • Page 47 2003 Taurus/Sable Workshop Manual Page 47 of 47 Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump.

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Sable 2003