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Test R: Too Cold In Vehicle - Passenger Van With Auxiliary HVAC

WARNING: This page is about a different car, the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: For circuit reference, see CONNECTOR IDENTIFICATION  and/or WIRING DIAGRAMS  .
NOTE: Definition: The air temperature can not be adjusted from one or both auxiliary controls or auxiliary cooling is insufficient.
  1. If review of system operation has been performed, go to next step. If review of system operation has not been performed, see DESCRIPTION  and OPERATION  . Review HVAC operation and perform visual inspection of system. See OPERATION . If system inspection and review of operation has been performed, go to next step.
  2. Turn ignition on. Place mode switch in any position except off. Place auxiliary blower switch in each speed position. If auxiliary blower motor operates in any speed position, go to next step. If blower motor does not operate in any speed position, go to TEST I: BLOWER MOTOR INOPERATIVE - AUXILIARY .
  3. If auxiliary blower motor operates correctly in each speed position, go to next step. If auxiliary blower motor does not operate correctly in each speed position, go to TEST J: BLOWER MOTOR MALFUNCTION - AUXILIARY .
  4. Check cooling system for low coolant level, loose or worn accessory drive belt, leaking radiator or heater hoses, kinked radiator or heater hose, missing radiator cap pressure seal, and a leaking radiator cap. If any of these conditions were found, repair as necessary and go to step  37. If none of these conditions were found, go to next step.
  5. Start engine. Place mode switch in OFF, VENT or HEAT position. If A/C compressor operates, go to TEST K: COMPRESSOR CLUTCH DOES NOT DISENGAGE . If A/C compressor does not operate, go to next step.
  6. If the too cold in vehicle condition exists with operation of both front and rear auxiliary control assemblies, go to step  9. If the too cold in vehicle condition does not exist with operation of both front and rear auxiliary control assemblies, go to next step.
  7. If the too cold in vehicle condition exists with front auxiliary control assembly only, go to step  13. If the too cold in vehicle condition does not exist with front auxiliary control assembly only, go to next step.
  8. If the too cold in vehicle condition exists with rear auxiliary control assembly only, go to step  16. If the too cold in vehicle condition does not exist with rear auxiliary control assembly only, go to TEST O: TOO COLD IN VEHICLE .
  9. Turn ignition on. Observe auxiliary air temperature actuator while placing front auxiliary air temperature switch from coldest position to warmest position. If air temperature actuator moves with a smooth transition between COLD and HOT positions, problem is intermittent. Check vacuum hoses, wiring harness, connectors and components for damage or defects which could cause condition, and repair as necessary. If air temperature actuator does not move with a smooth transition between COLD and HOT positions, go to next step.
  10. Disconnect harness connector from auxiliary air temperature actuator. Place blower switch on front auxiliary HVAC control to any position except REAR CNTL or OFF. Using a DVOM, measure voltage of auxiliary air temperature door control circuit (Dark Green wire) at harness connector of auxiliary air temperature actuator, while moving front auxiliary air temperature switch from coldest position to warmest position. If voltage varies zero-12 volts with a smooth transition between COLD and HOT positions, go to next step. If voltage does not vary zero-12 volts with a smooth transition between COLD and HOT positions, go to step  20.
  11. Connect a test light between ignition 3 voltage terminal (Brown wire) and ground terminal (Black wire) at harness connector of auxiliary air temperature actuator. If test light illuminates, go to step  19. If test light does not illuminate, go to next step.
  12. Connect a test light between ignition 3 voltage circuit (Brown wire) at harness connector of auxiliary air temperature actuator and a good ground. See WIRING DIAGRAMS . If test light illuminates, go to step  21. If test light does not illuminate, go to step  22.
  13. Disconnect auxiliary HVAC control processor. Using a DVOM, measure voltage of auxiliary air temperature door control circuit (Dark Green wire) from front auxiliary HVAC control at harness connector of auxiliary HVAC control processor, while moving front auxiliary air temperature switch from coldest position to warmest position. If voltage varies zero-12 volts with a smooth transition between COLD and HOT positions, go to next step. If voltage does not vary zero-12 volts with a smooth transition between COLD and HOT positions, go to step  23.
  14. Place front auxiliary HVAC control blower switch in any position except REAR CNTL or OFF. Connect a test light between ignition 3 voltage circuit (Brown wire) and auxiliary blower switch control circuit (Light Blue wire) to front auxiliary HVAC control assembly at harness connector of auxiliary HVAC control processor. If test light illuminates, go to step  24. If test light does not illuminate, go to next step.
  15. Connect a test light between ignition 3 voltage circuit (Brown wire) at harness connector of auxiliary HVAC control processor and a good ground. See WIRING DIAGRAMS . If test light illuminates, go to step  30. If test light does not illuminate, go to step  25.
  16. Place front auxiliary HVAC control blower switch in REAR CNTL position. Using a DVOM, measure voltage of auxiliary air temperature door control circuit (Dark Green wire) from rear auxiliary HVAC control at harness connector of auxiliary HVAC control processor, while moving rear auxiliary air temperature switch from coldest position to warmest position. If voltage varies zero-12 volts with a smooth transition between COLD and HOT positions, go to next step. If voltage does not vary zero-12 volts with a smooth transition between COLD and HOT positions, go to step  26.
  17. Place front auxiliary HVAC control blower switch in REAR CNTL position. Connect a test light between ignition 3 voltage circuit (Brown wire) at harness connector of rear HVAC control assembly and auxiliary blower switch control circuit (Light Blue wire) to front auxiliary HVAC control assembly. See WIRING DIAGRAMS . If test light illuminates, go to step  25. If test light does not illuminate, go to next step.
  18. Connect a test light between ignition 3 voltage circuit (Brown wire) at harness connector of rear auxiliary control assembly and a good ground. If test light illuminates, go to step  27. If test light does not illuminate, go to step  28.
  19. Check auxiliary air temperature door for misaligned actuator, broken or binding door and/or linkage, obstructions preventing door from operating within its' full range, missing and/or misaligned door seals. If a door condition was found, repair as necessary and go to step  37. If a door condition was not found, go to step  29.
  20. Check auxiliary air temperature door control circuit (Dark Green wire) from front auxiliary HVAC control assembly to auxiliary air temperature actuator for an open, high resistance, a short to ground or a short to voltage. See WIRING DIAGRAMS . If a circuit problem was found, repair as necessary and go to step  37. If a circuit problem was not found, go to step  25.
  21. Check auxiliary air temperature actuator ground circuit (Black wire) for an open or high resistance. See WIRING DIAGRAMS . If an open or high resistance was found, repair as necessary and go to step  37. If an open or high resistance was not found, go to step  29.
  22. Check ignition 3 voltage circuit (Brown wire) of auxiliary air temperature actuator for an open or high resistance. See WIRING DIAGRAMS . If an open or high resistance was found, repair as necessary and go to step  37. If an open or high resistance was not found, go to step  29.
  23. Check auxiliary air temperature door control circuit (Dark Green wire) between front auxiliary HVAC control assembly and auxiliary HVAC control processor for an open, high resistance, a short to ground, or a short to voltage. See WIRING DIAGRAMS . If a circuit problem was found, repair as necessary and go to step  37. If a circuit problem was not found, go to step  30.
  24. Check auxiliary blower switch control circuit (Light Blue wire) for a short to ground. See WIRING DIAGRAMS . If a short to ground was found, repair as necessary and go to step  37. If a short to ground was not found, go to step  30.
  25. Check auxiliary HVAC control processor ignition 3 voltage circuit (Brown wire) for an open or high resistance. See WIRING DIAGRAMS . If an open or high resistance was found, repair as necessary and go to step  37. If an open or high resistance was not found, go to step  32.
  26. Check auxiliary air temperature door control circuit (Dark Green wire) between rear auxiliary HVAC control assembly and auxiliary HVAC control processor for an open, high resistance, a short to ground, or a short to voltage. See WIRING DIAGRAMS . If a circuit problem was found, repair as necessary and go to step  37. If a circuit problem was found, go to step  31.
  27. Check auxiliary blower switch control circuit (Light Blue wire) for an open or high resistance. See WIRING DIAGRAMS . If an open or high resistance was found, repair as necessary and go to step  37. If an open or high resistance was not found, go to step  31.
  28. Check rear auxiliary HVAC control assembly ignition 3 voltage circuit (Brown wire) for an open or high resistance. See WIRING DIAGRAMS . If an open or high resistance was found, repair as necessary and go to step  37. If an open or high resistance was not found, go to step  31.
  29. Check harness connector at auxiliary air temperature actuator for a poor connection. If a poor connection was found, repair as necessary and go to step  37. If a poor connection was not found, go to step  33.
  30. Check harness connector at front auxiliary HVAC control assembly for a poor connection. If a poor connection was found, repair as necessary and go to step  37. If a poor connection was not found, go to step  34.
  31. Check harness connector at rear auxiliary HVAC control assembly for a poor connection. If a poor connection was found, repair as necessary and go to step  37. If a poor connection was not found, go to step  35.
  32. Check harness connector at auxiliary HVAC control processor for a poor connection. If a poor connection was found, repair as necessary and go to step  37. If a poor connection was not found, go to step  36.
  33. Replace auxiliary air temperature actuator. See ACTUATORS  under REMOVAL & INSTALLATION. After repairs are complete, go to step  37.
  34. Replace front auxiliary HVAC control assembly. See FRONT AUXILIARY HVAC CONTROL ASSEMBLY  under REMOVAL & INSTALLATION. After repairs are complete, go to step  37.
  35. Replace rear auxiliary HVAC control assembly. See REAR AUXILIARY HVAC CONTROL ASSEMBLY  under REMOVAL & INSTALLATION. After repairs are complete, go to step  37.
  36. Replace auxiliary HVAC control processor. See AUXILIARY HVAC CONTROL PROCESSOR  under REMOVAL & INSTALLATION. If replacement is complete, go to next step.
  37. Operate system to verify repair. If the condition was corrected, system is okay. If the condition was not corrected, return to step  2.
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