Pinpoint Test E: The Air Conditioning (A/C) Is Inoperative

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

E1 USE THE RECORDED DTCs FROM THE PCM SELF-TEST
- Using the recorded results from the PCM self-test:
- Is DTC P2611, P1459, P1464, P0537, P0538 or P0645 present?
Yes: REFER to INTRODUCTION -- HYBRID ESCAPE & HYBRID MARINER article to continue diagnosis.

No: GO to E2.
E2 CHECK THE REFRIGERANT PRESSURE
- Key in OFF position.
- Connect the manifold set to the service ports.
- Is the pressure 345-1,724 kPa (50-250 psi)?
Yes: GO to E3.

No: CHECK the system for refrigerant leaks. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
E3 CHECK THE A/C CLUTCH RELAY
- Disconnect: A/C Clutch Relay C1008.
- Carry out the A/C clutch relay component test. Refer to COMPONENT TESTING -- ESCAPE HYBRID & MARINER HYBRID for component testing.
- Is the A/C clutch relay OK?
Yes: GO to E4.

No: INSTALL a new A/C clutch relay. TEST the system for normal operation.
E4 CHECK CIRCUIT 1483 (WH/PK) FOR VOLTAGE
- Measure the voltage between A/C compressor clutch relay C1008-3, circuit 1483 (WH/PK), harness side and ground.
  
  Fig 1: Checking Circuit 1483 (WH/PK) For Voltage
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
Yes: GO to E5.

No: INSPECT battery junction box (BJB) fuse 16 (15A) for an open. If OK, REPAIR the circuit. TEST the system for normal operation.
E5 CHECK CIRCUIT 321 (GY/WH) FOR AN OPEN
- Disconnect: A/C Compressor Clutch C100.
- Connect a fused (5A) jumper wire between A/C clutch relay C1008-3, circuit 1483 (WH/PK), harness side and A/C clutch relay C1008-5, circuit 321 (GY/WH), harness side.
  
  Fig 2: Checking Circuit 321 (GY/WH) For Open (1 Of 2)
  Courtesy of FORD MOTOR CO.
- Measure the voltage between A/C compressor C100-1, circuit 321 (GY/WH), harness side and ground.
  
  Fig 3: Checking Circuit 321 (GY/WH) For Open (2 Of 2)
  Courtesy of FORD MOTOR CO.
- Is the voltage greater than 10 volts?
Yes: REMOVE the jumper wire. GO to E6.

No: REPAIR the circuit. TEST the system for normal operation.
E6 CHECK CIRCUIT 57 (BK) FOR AN OPEN
- Measure the resistance between A/C compressor clutch circuit 57 (BK), harness side and ground.
  
  Fig 4: Checking Circuit 57 (BK) For Open
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
Yes: GO to E7.

No: REPAIR the circuit. TEST the system for normal operation.
E7 CHECK THE CLUTCH AIR GAP
- Measure the A/C compressor clutch air gap at 3 equally spaced locations between the clutch hub and the A/C compressor clutch pulley.
- Is the A/C compressor clutch air gap greater than 0.76 mm (0.030 in) ?
Yes: ADJUST the A/C compressor clutch air gap to within specification. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS . TEST the system for normal operation.

No: INSTALL a new A/C compressor clutch coil. REFER to CLIMATE CONTROL . TEST the system for normal operation.