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Test V: Too Hot 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 auxiliary air temperature can not be adjusted from one or both auxiliary controls or auxiliary cooling 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. Start engine. Place blower switch in maximum speed position. Place mode switch in BI-LEVEL position. Place air temperature switch in the coldest position. If A/C compressor operates, go to next step. If A/C compressor does not operate, go to TEST L: COMPRESSOR CLUTCH DOES NOT ENGAGE - 6.5L DIESEL  or TEST M: COMPRESSOR CLUTCH DOES NOT ENGAGE - EXCEPT 6.5L DIESEL  .
  5. Perform A/C system performance test. See A/C PERFORMANCE TEST  under PERFORMANCE TESTS. If system performance test was performed, and a system problem was found and repaired, go to step  37. If a system problem was not found, go to next step.
  6. If too hot in vehicle symptom exists with operation of both front and rear auxiliary HVAC control assemblies, go to step  9. If too hot in vehicle symptom does not exist with operation of both front and rear auxiliary HVAC control assemblies, go to next step.
  7. If too hot in vehicle symptom exists with front auxiliary HVAC control assembly only, go to step  13. If too hot in vehicle symptom does not exist with front auxiliary HVAC control assembly only, go to next step.
  8. If too hot in vehicle symptom exists with defroster on, go to step  16. If too hot in vehicle symptom does not exist with defroster on, go to TEST S: TOO HOT 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 front auxiliary blower switch 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 auxiliary air temperature actuator harness connector terminals No. 7 (Black wire) and 10 (Brown wire). See Figure. If test light illuminates, go to step  19. If test light does not illuminate, go to next step.
  12. Connect a test light between auxiliary air temperature actuator harness connector terminal No. 10 (Brown wire) and a good ground. See Figure. If test light illuminates, go to step  21. If test light does not illuminate, go to step  22.
  13. Disconnect auxiliary HVAC control processor. Place front auxiliary blower switch in any position except REAR CNTL or OFF. Using a DVOM, measure voltage at auxiliary HVAC control processor harness connector terminal No. "A" (Dark Green wire), while moving front auxiliary air temperature switch from coldest position to warmest position. See Fig 1. 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.
    Fig 1: Identifying HVAC Control Processor Terminals
    G00067651Courtesy of GENERAL MOTORS CORP.
  14. Connect a test light between HVAC control processor harness connector terminals No. "J" (Brown wire) and "M" (Light Blue wire). See Fig 1. If test light illuminates, go to step  24. If test light does not illuminate, go to next step.
  15. Connect a test light between HVAC control processor harness connector terminal No. "J" (Brown wire) and a good ground. If test light illuminates, go to step  30. If test light does not illuminate, go to step  25.
  16. Place front auxiliary blower switch in REAR CNTL position. Using a DVOM, measure voltage at auxiliary HVAC control processor harness connector terminal No. "C" (Dark Green wire), while moving rear auxiliary air temperature switch from coldest position to warmest position. See Fig 1. 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 auxiliary HVAC control processor harness connector terminals No. "M" (Light Blue wire) and "J" (Brown wire). See Fig 1. If test light illuminates, go to step  25. If test light does not illuminate, go to next step.
  18. Using a test light connected to ground, probe terminal No. "G" (Brown wire) at rear auxiliary HVAC control assembly. See WIRING DIAGRAMS . 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) between 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 auxiliary air temperature actuator 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  29.
  23. Check auxiliary air temperature door control circuit (Dark Green wire) between front auxiliary HVAC control assembly to 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. If a circuit problem was found, repair as necessary and go to step  37. If a circuit problem was not 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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